Dynabrade 51612, 51613, 51611 Safety, Operation And Maintenance

Page 1

GENERAL SAFETY RULES

WARNING! Read and understand all instructions. Failure to follow all instructions listed below, may result in electric shock, fire and /or serious personal injury.

SAVE THESE INSTRUCTIONS

Work Area

1. Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents.

2. Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Power tools create sparks which ignite

the dust or fumes.

3. Keep bystanders, children, and visitors away while operating a power tool. Distractions can cause you to lose control.

Electrical Safety

1. Double Insulated tools are equipped with a polarized plug (one blade is wider than the other.) This plug will fit in polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized outlet. Do not change the plug in any way. Double Insulation eliminates the need for the three wire grounded power cord and grounded power supply system.

2. Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is grounded.

3. Don't expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.

4. Do not abuse the cord. Never use the cord to carry the tools or pull the plug from an outlet. Keep cord away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately. Damaged cords increase the risk of electric shock.

(continued on next page)

Parts Page Reorder No. PD05•28

Effective July, 2005

Supersedes PD05•08

Tool Manual – Safety, Operation and Maintenance

SAFETY LEGEND

Read and understand tool manual before

work starts to reduce risk of injury to

operator, visitors, and tool.

Eye protection must be worn at all times, eye protection to conform to ANSI Z87.1.

Respiratory protection to be used when exposed to

contaminants that exceed the applicable threshold

limit values required by law.

Practice safety requirements. Work alert,

have proper attire, and do not operate tools under

the influence of alcohol or drugs.

Ear protection to be worn when exposure to sound,

exceeds the limits of applicable Federal, State or

local statues, ordinances and/or regulations.

Electric shock hazard. Avoid bodily contact with

grounded objects, bodies of water.

Do not damage cord set.

Read and understand this tool manual before operating your tool. Follow all safety rules for the protection of operating personnel as well as adjacent areas. For safety information, refer to Code of Federal Regulation – CFR 29 Part 1910, European Committee for Standards (EN) Hand Held Electric Motor Operated Tools – Safety Requirements and applicable State and Local Regulations.

SAVE THIS DOCUMENT, EDUCATE ALL PERSONNEL

Some dust created by grinding, drilling, and other construction activities contain chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

• Lead from lead-based paints

• Crystalline silica from bricks and cement and other masonry products

• Arsenic and chromium from chemically treated lumber

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

Caution: Hand, wrist and arm injury may result from repetitive work, motion and overexposure to vibration.

Tool Intent: Dynabrade Random Orbital Sander for sanding, leveling solid surfaces, fillers, etc.

11" Random Orbital Sanders

Electronic Variable Speed

Models:

51612 - Non-Vac

- 0-3,000 RPM Dial

- Variable Speed On/Off Switch

- 120V

51613 - Central-Vac (1-1/4" Port)

- 0-3,000 RPM Dial

- Variable Speed On/Off Switch

- 120V

CUS

WARNIN

WARNING

Page 2

Electrical Safety (Continued)

5. When operating a power tool outside, use an outdoor extension cord marked “W-A” or “W.” These cords are rated for outdoor use and reduce the

risk of electric shock.

Personal Safety

1. Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use tool while tired or under the influence of drugs,

alcohol, or medication. A moment of inattention while operating power tools may result in serious personal injury.

2. Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing, and gloves away from moving parts. Loose clothes,

jewelry, or long hair can be caught in moving parts.

3. Avoid accidental starting. Be sure switch is off before plugging in. Carrying tools with your finger on the switch or plugging in tools that have the switch on invites accidents.

4. Remove adjusting keys or switches before turning the tool on. A wrench or a key that is left attached to a rotating part of the tool may result in personal injury.

5. Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the tool in unexpected situations.

6. Use safety equipment. Always wear eye protection. Dust mask, non-skid safety shoes, hard hat, or hearing protection must be used for appropriate conditions.

Tool Use and Care

1. Use clamps or other practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable and may

lead to loss of control.

2. Do not force tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed.

3. Do not use tool if switch does not turn it on or off. Any tool that cannot be controlled with the switch is dangerous and must be repaired.

4. Disconnect the plug from the power source before making any adjustments, changing accessories, or storing the tool. Such preventative safety measures

reduce the risk of starting the tool accidentally.

5. Store idle tools in a high, dry place, locked up out of reach of children and other untrained persons. Tools are dangerous in the hands of untrained users.

6. Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools, with sharp cutting edges are less likely to bind and are easier to control.

7. Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tools operation. If damaged, have the tool serviced before using. Many accidents are caused by poorly maintained tools.

8. Use only accessories that are recommended by the manufacturer for your model. Accessories that may be suitable for one tool, may become hazardous

when used on another tool.

9. Use the right tool. Do not force small tools or attachments to do the job of a heavy duty tool.

Service

1. Tool service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury.

2. When servicing a tool, use only identical replacement parts. Follow instructions in the Maintenance section of this manual. Use of unauthorized parts or failure

to follow Maintenance Instructions may create a risk of electric shock or injury.

SPECIFIC SAFETY RULES

1. Accessories must be rated for at least the speed recommended on the tool warning label. Wheels and other accessories running over rated speed can fly apart and cause injury.

2. Hold tool by insulated gripping surfaces when performing an operation where the tool may contact hidden wiring or its own cord. Contact with a “live” wire will make exposed metal parts of the tool “live” and shock the operator.

(See Definitions for label symbols on pg. 3)

TOOL DESCRIPTION

Random Orbital Sander – Is a random orbital electric hand tool which includes: a variable speed on/off switch; side handle; a RPM Dial which maintains desired RPM, when

under load; and is equipped with an 8 ft. cord set.

ASSEMBLY and OPERATION INSTRUCTIONS

1. With power source disconnected from tool, securely fasten abrasive/accessory on tool by depressing spindle locking button located on the right angle head. The rated RPM of the accessory must be equal to or greater than the rated RPM of the tool.

2. Hold tool by the motor housing and the side handle. Do Not hold tool by head/housing assembly. Keep hands away from all sanding edges and moving parts.

3. Tool has variable RPM dial on top side of rear handle. Dial desired maximum RPM (see label B) and then proceed to follow step 4.

4. Squeeze variable speed on/off switch on rear handle to run tool. Tool's on/off switch maybe used as a throttle to fluctuate RPM. To lock tool in “on” position continue

to squeeze on/off switch and depress side button. Electronic module maintains specified speed even under load. To disengage tool when locked in “on” position push on/off switch inward.

MAINTENANCE and ACCESSORY CARE INSTRUCTIONS

Important: A preventative maintenance program is recommended whenever portable power tools are used.

•

Use only genuine Dynabrade replacement parts to insure quality. To order replacement parts, specify Model #, Serial # and RPM of your tool.

Routine Preventative Maintenance:

•

Mineral spirits are recommended when cleaning the sanding heads. Do not use on electrical components or clean tool or parts with any solvents or oils containing acids, esters, ketones, chlorinated hydrocarbons or nitro carbons. Blow the dirt from electrical components with air.

•

DO NOT clean or maintain tools with chemicals that have a low flash point (example: WD-40

•

Tool labels must be kept legible at all times, if not, reorder label(s) and replace. User is responsible for maintaining specification information i.e.: Model #, S/N, and RPM. (See Assembly Breakdown)

•

Visually inspect plugs and cords for frays, visible damage and signs of deterioration. Replace damaged or worn components.

•

Refer to Dynabrade's Warning/Safety Operating Instructions Tag (Reorder No. 95903) for safety information.

•

Brush Changing – Unplug tool and remove brush caps and replace brushes. Replace brush caps. Brush changing – Change brushes every 225 hrs. to ensure proper tool function. After changing brushes, caps etc. it is recommended to replace the right angle gear grease with 95542 Grease.

•

After maintenance is performed on tool check for excessive tool vibration.

•

Check for excessive current leakage at 550 volts with a current leakage checker on all screws and the gear case, if the electrical components have been disturbed during repair.

Handling and Storage of Tool and Accessories:

•

Use of tool rests, hangers and/or balancers is recommended.

•

DO NOT carry tool by cord.

•

Protect abrasive accessories from exposure to water, solvents, high humidity, freezing temperature and extreme temperature changes.

•

Store accessories in protective racks or compartments to prevent damage.

Page 3

Vacuum Shroud Assembly

Complete 11" Random Orbital Sander Assembly

1 89254 Shaft 2 89252 Key 3 89259 C-Ring (2) 4 89261 Screw (4) 5 89251 Dust Cap 6 89253 Gear Box 7 89255 Bearing 8 89256 Bearing Plate 9 89257 Screw (3)

10 89258 Gear

11 89260 Washer 12 89264 Screw (2) 13 89262 Screw (4) 14 89263 Shaft Lock Pin 15 89267 Spring 16 89268 Button 17 89265 Needle Bearing 18 89266 Gear Box 19 89270 Bearing 20 89271 Bearing Plate 21 89276 Brush Holder (2) 22 89275 Terminal (2) 23 89274 Brush (2)

24 89273 Brush Cap (2) 25 89272 Brush Set Assembly (2) 26 89277 Speed Control 27 89279 Screw 28 89278 Switch 29 89282 Strain Relief 30 89283 Screw (2) 31 89281 Cord Guard 32 89280 Power Cord 33 89292 Armature Assembly 34 97592 Washer 35 02649 Bearing 36 89293 Bearing Holder 37 97589 Screw (5) 38 51728 Rear Housing, Left 39 51719 Rear Housing, Right 40 89294 Plate 41 97596 Screw 42 89295 Field 43 51718 Housing 44 89297 Field/Housing Assembly 45 89296 Magnet 46 97599 E-Ring

47 61366 Mounting Collar 48 01791 Washer 49 01790 Screw 50 61368 Vac. Shroud Assembly 51 95886 Washer (11) 52 96425 Screw (6) 53 61362 1-1/4" Vac Adapter 54 61361 Lip Seal 55 61356 Guard Assembly 56 97547 Spacer 57 95344 Screw (3) 58 61351 Adapter 59 61354 Spacer (2) 60 61352 Counterweight 61 96557 Screw (2) 62 94914 Spacer 63 54520 Bearing (2) 64 96118 Screw (3) 65 61353 Mount Plate 66 61355 Bearing Shaft 67 56231 Hook-Face Backing Pad 68 95178 Screw (5) 69 18553 Side Handle

Index Key

No. Part # Description

Brush Set Assembly

Field/Housing Assembly

45 46

A 89289 Rating Label - 51612

89290 Rating Label - 51613

B 89284 RPM Label C 89286 Warning Label D 89287 Logo

Label Key

Item Part # Description

A . . . . . . . . . . . . . . . . . . . . .amperes

Hz . . . . . . . . . . . . . . . . . . . . . . . .hertz

. . . . . . . . . .Class II Construction

Definitions of Label Symbols

Symbol Description

To order replacement parts, specify model number and serial number of your machine.

Country of Origin of Electric Motor: Made in Taiwan

Adhesive:

A3= Loctite #242 A8= Loctite #567

Torque: N•m x 8.85 = In. - lbs.

KEY

20 N•m

3 N•m

5.7 N•m

LEFT HAND

THREADS

48 49

95134 Hex Key Wrench (9/64 in.)

Page 4

One Year Warranty

Following the reasonable assumption that any inherent defect which might prevail in a product will become apparent to the user within one year from the date of purchase, all equipment of our manufacture is warranted against defects in workmanship and materials under normal use and service. We shall repair or replace at our factory, any equipment or part thereof which shall, within one year after delivery to the original purchaser, indicate upon our examination to have been defective. Our obligation is contingent upon proper use of Dynabrade tools in accordance with factory recommendations, instructions and safety practices. It shall not apply to equipment which has been subject to misuse, negligence, accident or tampering in any way so as to affect its normal performance. Normally wearable parts such as bearings, brushes, gears, etc., are not covered under this warranty.

Machine Specifications

DYNABRADE, INC.,

8989 Sheridan Drive •Clarence, NY 14031-1490 •Phone: (716) 631-0100 •Fax: 716-631-2073 •International Fax: 716-631-2524

Visit Our Web Site: www.dynabrade.com Email: Customer.Service@Dynabrade.com

1. American National Safety Institute – ANSI

25 West 43

Street Fourth Floor New York, NY 10036 Tel: 1 (212) 642-4900 Fax: 1 (212) 398-0023

3. European Committee for Standardization

Rue de Stassart 36 B - 1050 Brussels, Belgium

2. Government Printing Office – GPO

Superintendent of Documents Attn. New Orders P.O. Box 371954 Pittsburgh, PA 15250-7954 Tel: 1 (202) 512-1803

Reference Contact Information

Optional Accessories

Model Motor Motor Weight Length Height

Number RPM hp (w) Voltage Current Phase Frequency Pound (kg) Inch (mm) Inch (mm)

51612 0 - 3,000 1.1 (835) 120 V (AC) 9 Amp 1 60 Hz 11.3 (5.1) 21 (533) 7-1/4 (186)

51613 0 - 3,000 1.1 (835) 120 V (AC) 9 Amp 1 60 Hz 12.5 (5.7) 21-1/2 (546) 7-1/4 (186)

95542 Grease 10 oz.

•

High film strength; excellent resistance to water, steam, etc.

•

Workable range 0˚ F to 300˚ F.

Accessories are available for sanding. Check our website and literature to review all items.

FIND THE MOST CURRENT OFFERING OF ACCESSORIES AND SUPPORT DOCUMENTS @ WWW.DYNABRADE.COM

Wiring Diagram

AC 120V ~ 60Hz

6 Speed

Variable

Control

Trigger

Switch

Stator

Rotor

DYNABRADE