Dynabrade 53435 Important Operating, Maintenance And Safety Instructions

Page 1

Always operate, inspect and maintain this tool in accordance with the Safety Code for portable air tools (ANSI B186.1) and any other applicable safety codes and regulations. Please refer to Dynabrade

’s

Warning/Safety Operating Instructions for more complete safety information.

Air Motor and Machine Parts

Parts Page Reorder No. PD01•101

Effective December, 2001

.4 Hp/Right-Angle/Planetary Geared/Rear Exhaust

Drill

Index Key

No. Part # Description

1 02034 1/4"-28 Spindle

2 02035 Lock Nut

3 01486 Felt Silencer (5)

4 54520 Bearing (2)

5 97116 Shim

6 97117 Shim

7 97118 Shim

8 02599 Gear - 20,000 RPM

9 02044 Wick - Bottom

10 02045 Wick - Top

11 02031 Housing (includes: Gear

oil fitting, plate and needle bearing)

12 02033 Needle Bearing

13 02041 Gear Oil Plate

14 01041 Gear Oil Fitting

15 02600 Pinion - 20,000 RPM

16 50019 Lock Nut

17 02649 Bearing (2)

18 50022 Spacer

19 06213 Gear (2)

20 54472 Gear Shaft (2)

21 50023 Planetary Carrier

22 54468 Ring Gear

23 50024 Gear Case

24 01041 Grease Fitting

25 50784 Set Screw

26 54543 Shim

27 54544 Shim

28 54551 Shim

29 01478 Bearing Plate

30 50767 Pin (2)

31 01479 Spacer

32 54553 Rotor

33 01480 Blades (4)

34 01476 Cylinder

35 02676 Bearing Plate

36 02696 Bearing

37 02679 Shield

38 01547 Collar

39 53437 Housing - 53435

40 12132 Pin

41 01449 Valve Stem

42 01448 Throttle Lever

01462 Safety Lock Lever

43 95558 Retaining Ring

44 95730 O-Ring

45 01024 O-Ring

46 01469 Speed Regulator Assy.

47 01464 Seal

48 01472 Tip Valve

49 01468 Spring

50 01564 Air Control Ring

51 95711 Retaining Ring

52 01578 Inlet Adapter

53 01379 Bronze Muffler

54 96065 O-Ring

55 01446 Air Deflector

56 95620 Retaining Ring

57 94535 Muffler Assembly

Models:

53435 – Drill – 3,200 RPM

23 N•m

34 N•m

23 N•m

Adhesive: A4= Loctite #680

= Loctite #567

Torque: N•m x 8.85 = In. - lbs.

Oil: O

= Air Lube

Wicking: W

= Gear Oil

Grease: G

= Lubriplate 630 AA

KEY

Right Hand

Threads

Left Hand

Threads

26 28

17 N•m

WARNING

Page 2

Important Operating, Maintenance and Safety Instructions

Carefully read all instructions before operating or servicing any Dynabrade®Abrasive Power Tool. Warning: Hand, wrist and arm injury may result from repetitive work motion and overexposure to vibration. Important: All Dynabrade Rotary Vane air tools must be used with a Filter-Regulator-Lubricator to maintain all warranties.

Operating Instructions:

Warning: Eye, face, respiratory, sound, and body protection must be worn while operating power tools. Failure to do so may result in serious injury or death. Follow safety

procedures posted in workplace.

1. With power source disconnected from tool, securely fasten abrasive/ accessory on tool.

2. Install air fitting into inlet bushing of tool. Important: Secure inlet bushing of tool with a wrench before attempting to install the air fitting to avoid damaging valve body housing.

3. Connect power source to tool. Be careful not to depress throttle lever in the process.

4. Check tool speed with tachometer. If tool is operating at a higher speed than the RPM marked on the tool or operating improperly, the tool should be

serviced to correct the cause before use.

Maintenance Instructions:

1. Check tool speed regularly with a tachometer. If tool is operating at a higher speed than the RPM marked on the tool, the tool should be serviced to correct the cause before use.

2. Some silencers on air tools may clog with use. Clean and replace as required.

3. All Dynabrade Rotary Vane air motors should be lubricated. Dynabrade recommends one drop of air lube per minute for each 10 SCFM (example: if the tool specifications state 40 SCFM, set the drip rate of your filter-lubricator at 4 drops per minute). Dynabrade Air Lube (P/N 95842: 1 pt. 473 ml.) is recommended.

4. An Air line Filter-Regulator-Lubricator must be used with this air tool to maintain all warranties. Dynabrade recommends the following: 11405 Air Line Filter-Regulator-

Lubricator — Provides accurate air pressure regulation, two-stage filtration of water contaminant's and micro-mist lubrication of pneumatic components. Operates up to 40 SCFM @ 100 PSIG has 3/8" NPT female ports.

5. Lubricate wick system through the angle gear head gear oil fitting with 2-3 plunges for every 8 hours of use, to achieve maximum gear life. Important: Use only the recommended angle gear oil for the wick system. Do not contaminate the wick with any other oil or grease product (order 95848 Gear Oil and 95541 Gun).

6. Lubricate planetary gears through the gear casing grease fitting with 2-3 plunges for every 50 hours of use, to achieve maximum gear life (order 95542 Grease and 95541 Gun).

7. Use only genuine Dynabrade replacement parts. To reorder replacement parts, specify the model #, Serial #, and RPM of your machine.

8. A Motor Tune-Up Kit (P/N 96179) is available which includes assorted parts to help maintain motor in peek operating condition. Please refer to Dynabrade’s Preventative

Maintenance Schedule for a guide to expectant life of component parts.

9. Mineral spirits are recommended when cleaning the tool and parts. Do not clean tool or parts with any solvents or oils containing acids, esters, keytones, chlorinated hydrocarbons or nitro carbons.

• Important: User of tool is responsible for following accepted safety codes such as those published by the American National Standards Institute (ANSI).

• Operate machine for one minute before application to workpiece to determine if machine is working properly and safely before work begins.

• Always disconnect power supply before changing abrasive/accessory or making machine adjustments.

• Inspect abrasives/accessories for damage or defects prior to installation on tools.

• Please refer to Dynabrade’s Warning/Safety Operating Instructions Tag (Reorder No. 95903) for more complete safety information.

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

Notice

All Dynabrade motors use the highest quality parts and metals available and are machined to exacting tolerances. The failure of quality pneumatic motors can most often be traced to an unclean air supply or the lack of lubrication. Air pressure easily forces dirt or water contained in the air supply into motor bearings causing early failure. It often scores the cylinder walls and the rotor blades resulting in limited efficiency and power. Our warranty obligation is contingent upon proper use of our tools and cannot apply to equipment which has been subjected to misuse such as unclean air, wet air or a lack of lubrication during the use of this tool.

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, contact wheels, rotor blades, etc., are not covered under this warranty.

Safety Instructions:

Products offered by Dynabrade should not be converted or otherwise altered from original design without expressed written consent from Dynabrade, Inc.

Model Motor Motor Sound Maximum Air Flow Air Pressure Spindle Weight Length Height

Number HP (W) RPM Level CFM/SCFM (LPM) PSIG (Bars) Thread Pound (kg) Inch (mm) Inch (mm)

53435 .4 (298) 3,200 84 dB(A) 3/21 (595) 90 (6.2) 1/4-28 female 1.3 (.61) 7 (177) 2.2 (56)

Additional Specifications: Air Inlet Thread 1/4" NPT • Hose I.D. Size 1/4" (8 mm)

Disassembly/Assembly Instructions - Right-Angle Tools

Important: Manufacturer’s warranty is void if tool is disassembled before warranty expires. Please refer to parts breakdown for part identification. Special repair tools are mentioned in these instructions. These can be ordered from Dynabrade

through your Dynabrade®Distributor.

Motor Disassembly:

1. Disconnect the tool from the air supply. Important: Hold the air inlet adapter securely with a wrench before removing any air fitting to prevent damage to the composite housing.

2. Secure the motor housing in a vise using 52296 Repair Collar or padded jaws to provide protection for the housing. Position the tool so that the angle-head is pointing up.

3. Use a 34 mm or adjustable wrench to remove the 50024 Gear Case, turning it counter clockwise.

4. Pull motor assembly out of the motor housing.

5. Fasten a 2 in. bearing separator around the portion of the 01476 Cylinder nearest the 02676 Rear Bearing Plate.

6. Place the bearing separator on the table of the arbor press so that the sun gear end of the rotor is pointing toward the floor.

(continued on next page)

Page 3

Disassembly/Assembly Instructions - (continued)

7. Use a 3/16 in. dia. drive punch as a press tool and position it on the rear rotor shaft. Press the rotor out of the 02696 Bearing. The 02696 Bearing can be removed from the 02676 Bearing plate with a 96210 Bearing Removal tool and arbor press.

8. Place the flat side of the 01478 Front Bearing Plate on an arbor press tool plate or bearing separator and press the sun gear end of the 54553 Rotor from the front

bearing/plate assembly.

9. Push 02649 Bearing out of the front bearing plate and remove shims. Slip 01479 Spacer off rotor.

Motor Disassembly Complete.

Valve Body Disassembly:

1. Use 52296 Repair Collar to securely hold the motor housing in a vise so that the inlet adapter is pointing up.

2. Remove the 94535 Muffler Assembly by loosening the 01578 Inlet Adapter. Also remove 01468 Spring, 01472 Tip Valve, and 01464 Seal. Note: Refer to the parts breakdown for parts identification and order of assembly of the 94535 Muffler

3. Reposition the motor housing in the vise so that the throttle lever, and 12132 Pin are accessible. Remove the pin and lever by using a 2.5 mm dia. drive punch.

4. Use retaining ring pliers to remove the 95558 Retaining Ring and push the 01469 Speed regulator Assembly out of the motor housing.

Valve Body Disassembly Complete.

Planetary Gear Disassembly:

1. Separate the 50024 Gear Case from the 50019 Lock Nut. (Use two 34 mm or adjustable wrenches.)

2. Remove the 50784 Set Screw and pull the planetary gear assembly out of the gear case.

3. Fasten a bearing separator between the 54520 Bearing and the 54468 Ring Gear. Place the separator on

the table of the arbor press so that the pinion gear is pointing toward the floor. Use a 3/8 in. dia. drive punch as a press tool to push the carrier from the 54520 Bearing.

4. Carefully hold the 50023 Planetary Carrier in a vise with aluminum or bronze jaws. Note: Do not crush the gears.

5. Use a 14 mm wrench to remove the 02600 Pinion turning it counter clockwise.

6. Press the front 54520 Bearing from the planetary carrier.

7. Use a 3/32 in. dia. drive punch to remove the 54472 Shafts and 06213 Gears.

Planetary Gear Disassembly Complete.

Angle-Head Disassembly:

1. Secure the 02031 Housing in a vise using 52296 Repair Collar to provide protection for the housing. Position the housing so that the 02035 Lock Nut is facing up.

2. Use 50971 Lock Ring Tool to remove the 02035 Lock Nut, turning it counter-clockwise.

3. Grasp the 02034 Spindle and pull the spindle along with 54520 Bearing, 02599 Gear and shims out of the housing.

4. The bearing and gear can be pressed off the spindle with an arbor press.

5. If necessary the 02033 Needle Bearing can be removed by using a 5/16 in. dia. drive punch to push the 02041 Gear Oil Plate, and 01041 Gear Oil Fitting out of the 02031 Housing.

Angle-Head Disassembly Complete.

Valve Body Assembly:

1. Install 01469 Speed Regulator Assembly into the motor housing, and secure it in place with 95558 Retaining Ring.

2. Use 52296 Repair Collar to securely hold the motor housing in a vise so that the air inlet is pointing up.

3. Insert the 01449 Valve Stem into the speed regulator assembly so that the hole in the valve stem aligns with the air inlet hole in the motor housing.

4. Install 01464 Seal so that it lays flat. Use a needle nose pliers to grasp the nylon portion of the 01472 tip Valve and install it so that the metal pin fits into the hole of the 01449 Valve Stem.

5. Install the 01468 Spring so that the smaller end fits over the back of the tip valve.

6. Install the 94535 Muffler Assembly by applying a small amount of Loctite®#567 or equivalent to the male threads of the 01578 Inlet Adapter and tighten.

(Torque to 23 N•m/200 in. lbs.)

Valve Body Assembly Complete.

Motor Assembly:

Important: Clean and inspect parts for wear or damage before assembling.

1. Hold the body of the 54553 Rotor in a vise with aluminum or bronze jaws so that the sun gear is pointing up.

2. Slip 01479 Spacer onto 54553 Rotor.

3. Place a .002 thick shim into the 01478 Front Bearing Plate as an initial spacing and then install 02649 Bearing into the front bearing plate.

4. Use the 96240 Bearing Press Tool so that it pushes against the inner race of the 02469 Bearing and with an arbor press, install the bearing and plate assembly onto the rotor.

5. Check the clarence between the rotor and the bearing plate with a .001" thick feeler gage. Clarence should be .001" to .0015". If it is necessary, readjust clarence by

repeating steps 3-5 with a different thickness shim.

6. Once the proper rotor/plate clarence is achieved, apply air motor lubricant (Dynabrade Air Lube; 10W/NR or equivalent) to the (4) 01480 Blades and install them into the door.

7. Use the 96216 Bearing Press Tool so that it pushes against the outer race of the 02696 Bearing and install it into the 02676 Rear Bearing Plate with an arbor press.

8. Install the 01476 Cylinder so that it rests against the 01478 Bearing Plate. Note: Make sure that the air inlet passage of the cylinder is properly aligned with the air inlet passage in the 02676 Bearing Plate.

9. Use the 96216 Bearing Press Tool so that it pushes against the inner race of the 02696 Bearing and install the rear bearing/plate assembly onto the motor assembly with an

arbor press. Important: Carefully press the rear bearing/plate assembly onto the rotor until it touches the 01476 Cylinder. A "snug" fit should exist between the bearing plates and cylinder. If it is too tight the rotor will not turn freely and will cause damage to the bearings. If it is too loose the proper bearing preload will not be achieved.

10. Apply a small amount of grease to the seal of the 02696 Rear Bearing and place the 02679 Shield against the seal of the bearing.

11. Install the motor assembly into the housing so that the air passage node of the rear bearing plate aligns with the air passage notch inside the housing.

12. Apply a small amount of Loctite®#567 (or equivalent) to the threads of the motor housing and use a 34 mm (or an adjustable wrench) to connect the gear case assembly

to the motor housing. (Torque to 34 N•m/300 in. lbs.)

Motor Assembly Complete.

Planetary Gear Assembly:

1. Place front face (end with threaded male spindle) of 50023 Planetary Carrier against a block so that the carrier is sitting flat.

2. Start (2) 54472 Shafts by hand with a hammer into the two holes in the rear face of the carrier. (Be careful not to set the shafts too deep.)

3. Apply some of grease (Lubriplate #630 AA or equivalent) to the (2) 06213 Gears and position gear into the 50023 Planetary Carrier. Use an arbor press and carefully press the 54472 Shafts through the 06213 Gears so that the end of the shaft is flush with the top of the carriers rear face.

4. Place the flat side of 50022 Spacer against the front face of the carrier. Slide the 02649 Bearing onto the threaded shaft of the carrier and secure it with the 02600 Pinion. (Torque to 17 N•m/150 in. lbs.)

5. Install the 54468 Ring Gear onto the planetary carrier assembly so that the two notches face away from the threaded shaft.

(continued on next page)

02031 Housing

02033 Needle Bearing

02041 Gear Oil Plate

2 Drops of Loctite

01041 Gear Oil Fitting

Page 4

Disassembly/Assembly Instructions - (continued)

6. Position the 96240 Bearing Press Tool against the inner race of the 54520 Bearing and carefully press the bearing onto the planetary carrier until the outer race touches the ring gear. This should achieve a snug fit between the carrier bearings and the ring gear establishing the proper preload on the bearings.

7. Slide the planetary carrier assembly into the 50024 Gear Case aligning the notches of the ring gear with the set screw and grease fitting access holes. Apply a small amount of Loctite®#567 to the 50784 Set Screw and install.

8. Lubricate the planetary gears through the gear case grease fitting with 2-3 plunges every 50 hours of use to achieve maximum gear life. Order and use 95542 Grease and 95541 Grease Gun.

Planetary Gear Assembly Complete.

Angle-Head Assembly:

Important: This assembly procedure should be preformed once the motor and planetary gear assemblies have been completed and tested for operation. Clean and

inspect parts for wear or damage before assembling.

1. Press 01041 Gear Oil Fitting into 02041 Gear Oil Plate.

2. Carefully apply two drops of Loctite®#680 or equivalent to the recessed area of the 02031 Housing and press the gear oil plate along with gear oil fitting into the housing.

(Allow 30 minutes for the adhesive to cure.)

3. Press 02033 Needle Bearing into the housing.

4. Place the 96239 Bearing Press Tool so that it rests against the inner race of the 54520 Bearing and press it onto the spindle.

5. Align the hex shaped area of the 02599 Gear with that of the spindle and press the gear into place.

6. Apply a small amount of Loctite®#567 or equivalent to the matting threads of the 02031 Housing, the 50024 Gear Case, and the 50019 Lock Nut.

7. Connect these parts while being aware of the right and left hand threads.

8. Place the 52296 Repair Collar around the motor housing and position the tool in a vise so that the angle housing end of the tool is pointing up.

9. Use a 34 mm or an adjustable wrench on the 50019 Lock Nut while holding the angle housing stationary with the other hand. Note: The throttle lever can be positioned in

360˚ to the desired location. Allow for additional rotation when applying torque. (Torque to 23 N•m/200 in. lbs.)

10. Reposition the tool assembly in the vise so that the angle housings lock ring opening is facing up.

11. Soak the wicks in 95848 Gear Oil before installing into 02031 Housing. Install 02045 Top Wick first followed by 02044 Bottom Wick. Position truncated side of the

wicks against the end of the pinion gear.

12. Install the 02034 Spindle into the angle housing. Apply a slight amount of pressure down on the spindle while rotating it back and forth checking for proper backlash or fit

between the gears. A slight amount of backlash or clearance should exist between the bevel and pinion gears. If a tight fit exist then shim as needed placing the required thickness of shims between the outer race of 54520 Bearing and the bearing seat in the housing.

13. Place (1) 01486 Felt Silencer into the 02035 Lock Ring, and apply a small amount of Loctite®#567 or equivalent to the threads of the 02035 Lock Ring. Use 50971 Lock Ring Wrench to install the lock ring onto the 02031 Housing. (Torque to 23 N•m/200 in. lbs.)

Tool Assembly Complete. Please allow 30 minutes for adhesives to cure before operating tool.

Important: Before operating, place 2-3 drops of Dynabrade Air Lube (P /N 95842) directly into air inlet with throttle lever depressed. Operate tool for

30 seconds to determine if tool is operating properly and to allow lubricating oils to properly penetrate motor. Motor should now be tested for proper operation at 90 PSIG. If motor does not operate properly or operates at a higher RPM than marked on the tool, the tool should be serviced to correct the cause before use.

Loctite®is a registered trademark of Loctite Corp.

DYNABRADE

DYNABRADE, INC., 8989 Sheridan Drive • Clarence, NY 14031-1490 • Phone: (716) 631-0100 • Fax: 716-631-2073 • International Fax: 716-631-2524 DYNABRADE EUROPE S.àr.l., Zone Artisanale • L-5485 Wormeldange—Haut, Luxembourg • Telephone: 352 76 84 94 1 • Fax: 352 76 84 95 1

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

Optional Accessories

96179 Motor Tune-Up Kit

• Includes assorted parts to help

maintain and repair motor.

Dynabrade Angle Gear Oil

• Specifically formulated to saturate wick system in right

angle gear head.

• Easy to apply using Dynabrade P/N 95541 Oil Gun.

Apply 3 plunges every 8 hours of operation into tools lubrication fitting.

95848: 2 oz. tube

95849: 10 oz. tube

52296 Repair Collar

• Specially designed collar for use in vise to prevent damage

to valve body of tool during disassembly/assembly.

Open-End Wrenches

95262 – 14 mm open-end.

Dynaswivel

• Swivels 360° at two locations which allows an

air hose to drop straight to the floor, no matter how the tool is held.

94300 1/4" NPT.

Apply 3 plunges

into lubrication

fitting every

8 hours of operation.

Expect a gear life of 500 hours minimum, with proper lubrication.

Dynabrade Air Lube

• Formulated for pneumatic equipment.

• Absorbs up to 10% of its weight in water.

• Prevents rust and formation of sludge.

• Keeps pneumatic tools operating longer

with greater power and less down time.

95842: 1pt. (473 ml)

95843: 1gal. (3.8 L)

95542 Grease 10 oz.

• Multi-purpose grease for all types of

bearings, cams, gears.

• High film strength; excellent resistance to

water, steam, etc.

• Workable range 0˚ F to 300˚ F.

95541 Push-type Grease Gun

• One-hand operation.

96216 Bearing Press Tool 96240 Bearing Press Tool

• This tool is designed to safely press a

bearing into a bearing plate and onto a shaft.

96210 Bearing Removal Tool

• This tool is designed to pass through the

I.D. of the bearing plate and push against the I.D. of the bearing.

50971 Lock Ring Tool

• Lock Ring Tool has a 3/8" square socket

for use with 3/8" driver; breaker bar, ratchet head, or torque wrenches.