Dynabrade Dynafile II 40501, Dynafile II Operating And Safety Instructions Manual

Parts Page Reorder No. PD95•45

Effective September, 1995

40500 – 120V / 60Hz
40501 – Kit 120V / 60Hz

Models:

Abrasive Belt Machine

Electric Dynafile®II

Always operate, inspect and maintain this tool in accordance with the safety standards established by
OSHA, Underwriters Laboratories, Inc., The Canadian Standards Association and The American National
Standards Institute (ANSI). Dynabrade, Inc. assumes no responsibility for any damage or accidents
resulting from the misuse of this tool, its misapplication or nonadherence to precautionary safety measures.

General Safety Rules

Read and save all instructions before operating this power tool.
Warning:

When using electric tools, basic safety precautions should always be followed
to reduce the risk of a fire, electric shock, and personal injury,
including the following:

1. Keep work area clean. Cluttered areas and benches invite accidents.

2. Consider work area environment. Do not expose tools to rain. Keep

work area well lit. Do not use power tools in damp or wet locations.
Do not use tools in the presence of flammable liquids or gases.

3. Guard against electric shock. Prevent body contact with grounded surfaces.
For example; pipes, radiators, ranges, refrigerator enclosures.

4. Keep children away. Do not let visitors contact tool or extension cord. All
visitors should be kept away from work area.

5. Store idle tools. When not in use, tools should be stored in a dry, or locked
up place - out of the reach of children.

6. Do not force tool. It will do a better and safer job at its intended rate.

7. Use the right tool. Do not force a small tool or attachment to do the job of

a heavy duty tool. Do not use tool for purposes not intended.

8. Dress properly. Do not wear loose fitting clothing or jewelry. They can be
caught in moving parts. Rubber gloves and non-skid footwear are recommended
when working outdoors. Wear protective hair covering to contain long hair.

9. Use safety glasses. Also use face-shield or dust mask if operation area is dusty.

10.Do not abuse cord. Never carry tool by cord or yank it to disconnect from

receptacle. Keep cord from heat, oil and sharp edges.

11.Secure work. Use clamps or a vice to hold workpiece. It’s safer than using
your hand and it frees up both hands to operate tool.

12.Do not overreach. Keep proper footing and balance at all times.

13.Maintain tools with care. Keep tools clean for better use and safer

performance. Follow instructions for lubricating and changing accessories.
Inspect tool cords periodically and if damaged, have repaired by authorized
service facility. Inspect extension cords periodically and replace if
damaged. Keep handles dry, clean and free from oil and grease.

14.Do not leave tool running. Disconnect tools when not in use, before
servicing, when changing belts, contact arms, etc.

15.Remove keys and wrenches. Form a habit of checking to see that all
keys and adjusting wrenches are removed from tool before turning it on.

16.Avoid accidental starting. Do not carry around plugged in tool with finger
on lever. Be sure lever is off when plugging in.

17.Out-door use extension cords. When tool is used outdoors, use only
extension cord suitable for outdoor use. They should be marked with the
suffix W-A(for UL) or W (for CSAin Canada).

18.Stay alert. Watch what you are doing. Use common sense. Do not
operate tool when you are tired.

19.Check damaged parts. Before further use of the tool, a guard or other part
that is damaged should be carefully checked to determine that it will operate
properly and perform its intended function. Check for alignment of moving
parts, breakage of moving parts, binding of moving parts, mounting and any
other conditions that may affect its operation. Aguard or other part that is
damaged should be properly repaired or replaced by an authorized

19.(Cont.) service center unless otherwise indicated elsewhere in this
instruction manual. Have defective switches replaced. Do not use
tool if switch does not turn tool on or off.

20.Avoid gaseous areas. Do not operate portable electric tools in
gaseous or explosive atmospheres. Motors in these tools normally
spark, and the sparks can ignite fumes.

21.Do not alter or misuse tool. This tool is precision built. Any
alteration or modification not specified is misuse and may result in a
dangerous condition. Only these accessories and attachments that
are found in this instruction manual are acceptable for use with this
tool. The use of any other accessoryor attachment might present a risk
to the operator.

22.Replacement parts. When servicing, use only identical replacement
parts. When ordering replacement parts, please specify model and
serial numbers of your machine.

Voltage Warning

Before connecting the tool to a power source (receptacle, outlet, etc.)
be sure the voltage supplied is the same as what is specified on the
nameplate of the tool. Apower source with greater than that specified
for tool can result in serious injury to the user as well as damage to
the tool. Using a power source with voltage less than the nameplate
rating is harmful to the tool’s motor. If in doubt, do not plug in the tool.

Double Insulation

Your Electric Dynafile® II is double-insulated to give you added
safety. This means that the tool is constructed throughout with two
separate “layers” of electrical insulation, or one double thickness of
insulation between you and the tool’s electrical system.

Tools built with this type of insulation system are not intended to be
grounded. As a result, your Electric Dynafile® II is equipped with a two
prong plug whichpermits you to use extension cords without concern for
maintaining a ground connection.

Note: Double-insulation does not take the place of normal safety

precautions when operating this tool. The insulation system is added
for protection against injury resulting from a possible electrical
insulation failure within the tool.

Caution: When servicing double-insulated tools, use onlyidentical

replacement parts. Repair or replace damaged cords.

Extension Cords

Double-insulated tools have two-wire cords, and can be used with
either two-wire or three-wire extension cords. Only round jacketed
extension cords should be used, and we recommend that they be listed
by Underwriters Laboratories (UL) - (CSAin Canada). If the extension
cords will be used outside, the cord must be suitable for outdoor use.
They should be marked with the suffix W-A(for UL) or W (for CSAin
Canada). Any cord marked as an outdoor cord can also be used for
indoor work.

Polarized Plugs: To reduce the risk of electric shock, this equipment has

a polarized plug (one blade is wider than the other). This plug will fit in
a polarized outlet only one way. If the plug does not fit in the outlet,
reverse the plug. If it still does not fit, contact a qualified electrician to
install the proper outlet. Do not change the plug in any way.

Warning: Keep extension away from the immediate working area.

!

WARNING

Important Operating 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.

Operating Instructions:

Warning: Eye, face 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. Connect power source to tool. Be careful not to depress paddle switch in the process.

3. Hold tool by the motor housing only. One or two hands may be used. Do Nothold tool by head/housing assembly. Keep hands away from all
grinding/sanding edges and moving parts. Aside handle is included for two hand operation of tool. (See “Installing Side Handle” instructions.)

4. Depress paddle switch (trigger) and hold to start tool. Release switch to stop tool.

5. While tool is running, Adjust belt tracking by tuning 95218 Rough Adjustment Knob to the left or right accordingly, so as abrasive belt rides

evenly over contact arm.

6. Always work off the return-side of the abrasive belt. This will ensure superior tracking and reduce downtime of tool

Housing Angle Adjustment:

To pivot housing, loosen 95311Screw on housing with the supplied 9/64" hex wrench (P/N – 95134). Pivot housing to desired angle and
retighten 95311Screw.

Installing Side Handle:

The side handle may be installed on either side of the rotor housing for right or left hand operation. Position the side handle on the side offering the
best comfort and control of the tool. To install, thread side handle into side handle socket on desired side of motor housing and tighten securely.

Safety Instructions:

• Warning:Eye, face 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.

• 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 30 seconds before application to workpiece to determine if machine is working properly and safely before work begins.

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

• Inspect abrasives and 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.

2

Full 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.

Abrasive Belt/Contact Arm Change
Instructions:

To Change Belt:

1. Disconnect power source.

2. Remove 40365 Belt Guard by pulling backwards and

upwards over the 40314 Button Latch Assembly.

3 Pull back on tension arm assembly.

4. Remove and replace abrasive belt and Belt Guard.

5. Connect power source.

5. Remove contact arm and replace with desired arm, making sure

6. Adjust belt tracking by turning 95218 Rough Adjustment Knob.

to the left or right accordingly while machine is running.

Abrasive Belt/Contact Arm Change
Instructions:

To Change Contact Arm Assembly:

1. Disconnect power source.

2. Remove 40365 Belt Guard by pulling backwards and

upwards over the 40314 Button Latch Assembly.

3. Pull back on tension arm assembly and remove abrasive belt.

4. Remove 95218 Rough Adjustment Knob.

5. Remove contact arm and replace with desired arm, making sure

that the tab on the end of the arm is facing downward

6. Replace 95218 Knob.

7. Install abrasive belt and replace Belt Guard.

8. Connect power source and adjust belt tracking by turning
95218 Knob.

Extension Cords

Grounded tools require a three wire extension cord. Double insulated tools can use either a two or three wire extension cord. As the distance from the supply
outlet increases, you must use a heavier gauge extension cord. Using extension cords with inadequately sized wire causes a serious drop in voltage resulting
in loss of power and possible tool damage. Refer to the table below to determine the required minimum wire size.

The smaller the gauge number of the wire the greater the capacity of the cord. For example a 14 gauge cord can carry a higher current than a 16 gauge cord.
When using more than one extension cord to make up the total length, be sure each cord contains at least the minimum wire size required. If you are using
one extension cord for more than one tool, add the nameplate amperes and use the sum to determine the required minimum wire size.

Guidelines For Using Extension Cords

• If you are using an extension cord outdoors, be sure it is marked with the suffix“W-A” (“W” in Canada) to indicate that it is acceptable for outdoor use.

• Be sure your extension cord is properly wired and in good electrical condition. Always replace a damaged extension cord or have it repaired by a qualified
person before using it.

• Protect your extension cords sharp objects, excessive heat and damp or wet areas.

READ AND SAVE ALLINSTRUCTIONS FOR FUTURE REFERENCE

3

Head / Housing Assembly

40365 Belt Guard

(Incl. 40371 Gasket)

40371 Gasket

40360 Housing

95311 Screw
40029 Motor Lock

40520 Electric Motor only (See page 4 for Electric Motor Parts Breakdown)
40518 Electric Motor Assembly (Includes 40511 Drive Wheel, 40513 and
96110 Set Screws.)

*40511 Drive Wheel

*96110 Set Screws

Note: Shaded parts represent 40014 Housing Assembly.

95218 Knob

40361 Tension Arm

Contact Arm Assembly

For more information on Contact
Arm Assembly please refer to
chart on page 6.

95426 Spring

40367 Dust Cover

40362 Support Rod

11040 Spring

95217 Screw

40314 Button Latch Assy.

95425 Screw
40025 Button

95042 Washer

11535 Side Handle

Nameplate Extension Cord Length
Amperes 25' 50' 75' 100' 150' 200'

0-5 16 16 16 14 12 12

5.1-8 16 16 14 12 10 –

8.1-12 14 14 12 10 – –

12.1-15 12 12 10 10 – –

15.1-20 10 10 10 – – –

*Based on limiting the line voltage
drop to live volts at 150% of the
rated amperes

40366 Guide
95427 Screw

*40513 Adapter