Dynabrade 58501, 58505, 58502, 58503, 58504 Safety, Operation And Maintenance

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Dynabug

Random Orbital Sander

Safety, Operation and Maintenance – Save This Document and Educate All Personnel

Parts Page Reorder No. PD11•21

Effective May, 2011

Supersedes PD10•01

WARNING

Read and understand this tool manual before operating your air tool. Follow all safety rules for the protection of operating personnel as well as adjacent areas. Always operate, inspect and maintain this tool in accordance with the American National Standards Institute (ANSI) Safety Code for Portable Air Tools – B186.1. For additional safety information, refer to Safety Requirements for the Use, Care and Protection of Abrasive Wheels – ANSI B7.1, Code of Federal Regulation – CFR 29 Part 1910, European Committee for Standards (EN) Hand Held Non-Electric Power Tools – Safety Requirements and applicable State and Local Regulations.

Find The Most Current Offering of Support Documents and Accessories at www.Dynabrade.com

Read and understand tool manual before work starts to reduce risk of injury to operator, visitors, and tool.

Ear protection to be worn when exposure to sound, exceeds the limits of applicable Federal, State or local statues, ordinances and/or regulations.

Practice safety requirements. Work alert, have proper attire, and do not operate tools under the influence of alcohol or drugs.

Air line hazard, pressurized supply lines and flexible hoses can cause serious injury. Do not use damaged, frayed or deteriorated air hoses and fittings.

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.

Some dust created by sanding, 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.

DO NOT USE Tool for Anything Other Than Its Intended Applications.

Training: Proper care, maintenance, and storage of your air tool will maximize tools performance and reduce chance for accident. Employer's Responsibility: Provide operators with safety instructions and training for safe use of tools and accessories.

Report to Your Supervisor any Condition of the Tool, Accessories or Operation you Consider Unsafe.

Tool Intent: Dynabug®II is used for sanding and finishing a variety of materials including; wood, metal, plastic,

fiberglass, solid surfaces, composites, rubber, glass and stone.

SAFETY and OPERATING INSTRUCTIONS

Carefully Read and Understand the General and Sander/Polisher sections found in Tool Safety and Operating Guidelines (PN00001676) Before Handling or Using Tool.

Carefully Read all instructions before operating or servicing any Dynabrade®Abrasive Power Tool. Products offered by Dynabrade are not to be modified, converted or otherwise altered from the original design.

For Serial No. 10A1000 and Higher

Models: Hook-Face Pad

58500 -

Non-Vacuum (74 mm x 109 mm)

58501 -

Self-Generated Vacuum (74 mm x 109 mm)

58502 -

Central Vacuum (74 mm x 109 mm)

58503 -

Non-Vacuum (80 mm x 130 mm)

58504 -

Self-Generated Vacuum (80 mm x 130 mm)

58505 -

Central Vacuum (80 mm x 130 mm)

58506 -

Central Vacuum (99 mm x 143 mm, delta-style)

Models: Vinyl-Face Pad

58507 -

Non-Vacuum (68 mm x 175 mm, with Clips)

58509 -

Non-Vacuum (74 mm x 109 mm)

Model 58500

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MAINTENANCE INSTRUCTIONS

Important: To keep tool safe, a Preventative Maintenance Program is recommended. The program should included inspection of the tool and all related accessories and consumables, including air lines, pressure regulators, filters, oilers, etc. refer to ANSI B186.1 for additional maintenance information. If accessory or tool breakage occurs, investigate failure to determine the cause and correct before issuing tool for work. Use the following schedule as a starting point in developing a Preventative Maintenance Program. If tool does not operate properly (RPM, Vibration, Start/Stop) after these scheduled checks or at any time, the tool must be repaired and corrected before returning tool to use.

INSTALLATION

• To ensure long life and dependable service, use a Closed Loop Air System and Filter-Regulator-Lubricator as diagramed below.

• Each tool should have its own dedicated hose connected to an air supply manifold. Quick disconnects should be installed at the manifold in an effort to reduce contamination into the tool.

• It is strongly recommended that all Dynabrade rotary vane air tools be used with a Filter-Regulator-Lubricator to minimize the possibility of misuse due to unclean air, wet air or insufficient lubrication. Dynabrade recommends the following: 10681 Air Line Filter-Regulator-Lubricator — Provides accurate air pressure regulation, two-stage filtration of water contaminants and micro-mist lubrication of pneumatic components.

• Dynabrade recommends one drop of air lube per minute for each 20 SCFM (example: if the tool specification states 40 SCFM, set the drip rate on the filter-lubricator to 2 drops per minute) Dynabrade Air Lube (P/N 95842: 1pt/473ml) is recommended.

MAINTENANCE SCHEDULE

Daily (every 8 hours):

• Inspect tool and accessories for damage or broken parts. Replace items as necessary to ensure proper operation and safety.

• Lubricate motor as recommended. Use Dynabrade Air Lube (P/N 95842: 1pt/473ml) 10W/NR. (1 Drop per minute of air lube per 20 SCFM.)

• Check air line pressure with a gage. (MAX. 90 PSIG or 6.2 Bar operating pressure at the air inlet of the tool.)

• Right angled gear and wick system through gear case grease fitting with 3 plunges of gear oil (P/N 95848) and grease gun (P/N 95541). (Prime grease gun prior to greasing.)

• Check tool for proper operation: If operating improperly or demonstrates unusual vibration, the tool must be serviced and problem corrected before further use.

Every 20 Hours or Once a Week Which Ever Comes First:

• Check free speed of tool without the abrasive accessory mounted. Measure RPM (speed) with tachometer and with air pressure set at 90 PSIG while the tool is running. If a governed tool is operating at a higher speed than the RPM marked on the tool housing, the tool must be serviced and corrected before use. A non-governed tool may exceed the RPM marked on the tool by 10% when operated at free speed with no accessories.

• If tool is running fast look for worn, damaged or missing governors, air control rings and silencers. Special care must be taken when servicing

governors and speed control devices. Injection molded governor assemblies are non-serviceable and must be replaced.

• If tool is running slow look for clogged inlet screen, air stream, silencer(s) or a malfunctioning governor (see concerns for servicing governors). Service as required.

Every 50 Hours:

• Lubricate planetary gears through gear case grease fitting with 3 plunges of grease (P/N 95542) and grease gun (P/N 95541). (Prime grease gun prior to greasing.)

REPAIR

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

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

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

• A Motor Tune-Up Kit is available which includes high wear and medium wear motor parts.

• Air tool markings must be kept legible at all times, if not, reorder housing and replace. User is responsible for maintaining specification information.

• After maintenance is performed on tool, add a few drops of Dynabrade Air Lube (P/N 95842) to the tool inlet and start the tool a few times to lubricate air motor. Verify RPM (per 20 hr maintenance schedule), vibration and operation.

HANDLING & STORAGE

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

• Protect tool inlet from debris (see Notice).

• DO NOT carry tool by air hose or near the tool throttle lever.

• Store accessories in protective racks or compartments to prevent damage.

• Follow the handling instructions outlined in the operating instructions when carrying the tool and when changing accessories.

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

END OF USE/ DISPOSAL

When tool has reached its end of useful service, disassemble tool into its primary components (i.e. steel, aluminum and plastic part) and recycle or discard per local, state and/or federal regulations as to not harm the environment.

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.

Filter

Regulator

Lubricator

90 PSIG

(6.2 Bar)

To Tool Station

Ball

Valve

Ball

Valve

Filter

Regulator

Lubricator

Air Flow

Drain Valve

Air Tool

Air Compressor

and Receiver

Drain Valve

Air Hose

90 PSIG MAX

(6.2 Bar)

Air Flow

Refrigerated

Air Dryer

• Dynabrade Air Power Tools are designed to operate at 90 PSIG (6.2 Bar) maximum air pressure at the tool inlet, when the tool is running. Use recommended regulator to control air pressure.

• Ideally the air supply should be free from moisture. To facilitate removing moisture from air supply, the installation of a refrigerated air dryer after the compressor and the use of drain valves at each tool station is recommended.

➤

AIR SYSTEM

Closed Loop Pipe System, Sloped in Direction of Air Flow

1 DROP/MIN.

20 SCFM

LUBRICATOR SETTING

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Dynabug

Complete Assembly

Models

58500, 58501, 58502 58503

58504, 58505

58506

58507, 58509

1 Screw (4)

96539 Models: 58500-06, 09 96080 Model: 58507

2 96538 Lock Washer (8) 3 Pad: See Charts (lower rt.) 4 95344 Screw 5 95935 Washer 6 54552 Bearing 7 57895 Pad Base (Standard)

57875 Pad Base (w/Clips) 8 57896 Felt Seal 9 94590 Pin (2)

10 57899 Spring (2) 11 57834 Rubber Grip (2) 12 57898 Clip (2) 13 Shaft Balancer

57892 Models: 58500-06, 09

57894 Model: 58507

14 56047 Key 15 56046 Lock Ring 16 59057 Front Bearing Seal 17 59083 Felt Washer 18 58368 Bearing (2) 19 57893 Front Bearing Plate 20 57113 Blade (5)/Rotor Set 21 59051 Cylinder

(Incl. 01024 O-Ring) 22 01024 O-Ring 23 57891 Rear Bearing Plate 24 98463 Retaining Ring 25 57890 Isolator Post (4) 26 Housing: See Chart (upper rt.) 27 96539 Screw (4) 28 57888 Throttle Lever 29

94590 Pin 30 98459 O-Ring 31 58363 Valve Stem 32 59075 Speed Regulator 33 01025 O-Ring (2) 34 95697 Retaining Ring 35 01464 Seal 36 58365 Tip Valve 37 01468 Spring 38 01494 Inlet Bushing 39 57897 Vacuum Tube 40 96540 Vacuum Port Cover 41 57041 Comfort Platform

Index Key

No. Part # Description

Adhesive: A

= Loctite #271

A8= Loctite #567

A10= Loctite #243

Torque: N•m x 8.85 = In. - lbs.

Oil: O

= Air Lube

KEY

5 N•m

17 N•m

Internal Threads

2.5 N•m

23 N•m

Exhaust & vacuum configuration

displays on page 8

SANDING PADS– HOOK-FACE

Model No. Pad No.

58500 ................ 56315

58501 ................ 56316

58502 ................ 56316

58503 ................ 56317

58504 ................ 56319

58505 ................ 56319

58506 ................ 56323

SANDING PADS– VINYL-FACE

Model No. Pad No.

58507 ................ 56354

58509 ................ 56355

HOUSING MODEL

ASSEMBLY # NUMBER

58064 58500 58065 58501 58066 58502 58067 58503 58068 58504 58069 58505 58062 58506 58061 58507 58071 58509

Note: Orientation of Vacuum Pad

Note: 57867 Complete

Clipped Pad Base Assembly available, includes items; #6, 7, 9, 10, 11 and 12.

DO NOT REMOVE

WARNING

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DYNABRADE, INC. www.dynabrade.com

8989 Sheridan Drive •Clarence, NY 14031-1419 •Phone: (716) 631-0100 •Fax: 716-631-2073 •International Fax: 716-631-2524

1. American National Standards Institute – ANSI

1899 L Street, NW 11th Floor Washington, DC 20036 Tel: 1 (212) 642-4900

3. Power Tool Institute, Inc.

P.O. Box 818 Yachata, Oregon 97498-0818 Tel: 1 (503) 547-3185

2. Government Printing Office – GPO

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

MACHINE SPECIFICATIONS

REFERENCE CONTACT INFORMATION

LIFETIME WARRANTY

To validate Dynabrade Lifetime Warranty, you must register each tool at: www.dynabrade.com. Registration of each tool at website is required. Dynabrade will not honor Lifetime Warranty on unregistered tools. Please view the entire Lifetime Warranty Policy at : www.dynabrade.com.

4. European Committee for Standardization

Rue de Stassart 36 B - 1050 Brussels, Belgium

Model Speed Power Sound Air Consumption Air Pressure Weight Length Height

58500 10,000 RPM .15 hp (112 W) 81 db(A) 13 SCFM 368 (LPM) 90 PSIG (6.2 Bars) 1.8 lb. (.8 kg) 5-3/4" (147 mm) 3.5" (91 mm)

58501 10,000 RPM .15 hp (112 W) 78 db(A) 13 SCFM 368 (LPM) 90 PSIG (6.2 Bars) 1.9 lb. (.85 kg) 8-1/4" (212 mm) 3.5" (91 mm)

58502 10,000 RPM .15 hp (112 W) 83 db(A) 13 SCFM 368 (LPM) 90 PSIG (6.2 Bars) 1.8 lb. (.8 kg) 7" (147 mm) 3.5" (91 mm)

58503 10,000 RPM .15 hp (112 W) 81 db(A) 13 SCFM 368 (LPM) 90 PSIG (6.2 Bars) 1.8 lb. (.8 kg) 6-1/4" (157 mm) 3.5" (91 mm)

58504 10,000 RPM .15 hp (112 W) 78 db(A) 13 SCFM 368 (LPM) 90 PSIG (6.2 Bars) 1.9 lb. (.85 kg) 8-3/4" (222 mm) 3.5" (91 mm)

58505 10,000 RPM .15 hp (112 W) 83 db(A) 13 SCFM 368 (LPM) 90 PSIG (6.2 Bars) 1.8 lb. (.8 kg) 7-1/2" (190 mm) 3.5" (91 mm)

58506 10,000 RPM .15 hp (112 W) 83 db(A) 13 SCFM 368 (LPM) 90 PSIG (6.2 Bars) 1.8 lb. (.8 kg) 8-3/4" (222 mm) 3.5" (91 mm)

58507 10,000 RPM .15 hp (112 W) 82 db(A) 13 SCFM 368 (LPM) 90 PSIG (6.2 Bars) 2.1 lb. (.8 kg) 7-1/16" (179 mm) 3.75" (95 mm)

58509 10,000 RPM .15 hp (112 W) 81 db(A) 13 SCFM 368 (LPM) 90 PSIG (6.2 Bars) 1.8 lb. (.95 kg) 5-3/4" (147 mm) 3.5" (91 mm)

Additional Specifications: Air Inlet Thread 1/4" NPT • Hose I.D. 1/4" (6 mm) Sound Level is the pressure measurement according to the method outlined in ISO regulation ISO-15744

OPTIONAL ACCESSORIES

MACHINE EXHAUST ASSEMBLIES

98222 Motor Tune-Up Kit

•

Includes assorted parts to help maintain and repair motor.

59469 Drop-In Motor Note: Not for use with model 58507

•

Allows quick and easy replacement. No motor adjustments needed.

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: 1 gal. (3.8 L)

Vacuum-Ready

Self-Generated Vacuum

Non-Vacuum

3 9 10

9 10

Index Key

No. Part # Description

1 57083 Vacuum Adapter 2 96197 Dowel Pin 3 57065 Cone Muffler 4 57066 Muffler Body 5 95526 O-Ring 6 57068 Vac Nozzle 7 57067 Vac Tube 8 57093 Vacuum Adapter

9 56027 Muffler Insert (2) 10 69359 Muffler Cap 11 69274 Muffler Assembly