Dynabrade Electric Dynafile II 40501, Electric Dynafile II 40500 Safety, Operation And Maintenance Manual

Parts Page Reorder No. PD04•17

Effective March, 2004
Supersedes PD02•42

Electric Dynafile®II

Tool Manual – Safety, Operation and Maintenance

Models:

40500 – 120 V / 60 Hz
40501 – Versatility Kit

G

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 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 Electric Motor
Operated Tools – Safety Requirements and applicable State and Local Regulations.

SAVE THIS DOCUMENT, EDUCATE ALL PERSONNEL

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)

SAFETY LEGEND

WARNIN

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

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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 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.

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

(See Definitions for label symbols on pg. 4)

TOOL DESCRIPTION

Dynafile II – Is an electric hand tool with a moving sanding belt, tool includes: an on/off switch, side handle, Dynafile II Belt Sanding Head Assembly, and is equipped

with a 8 ft. cord set.

ASSEMBLY and OPERATION INSTRUCTIONS

1. With power source disconnected from tool rotate head to desired position and tighten set screw with hex wrench provided to clamp.

2. Connect power source to tool. Be careful not to depress switch in the process.

3. Hold tool by the motor housing only. One or two hands may be used. Do Not hold tool by head/housing assembly. Keep hands away from all grinding/sanding edges

and moving parts. A side handle is included for two hand operation of tool. (See "Installing Side Handle" Instructions.)

4. Slide and rock slide switch forward to start tool. Touch rear of slide switch to release.

5. While tool is running, adjust belt tracking by turning 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.

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 SFPM of your tool.

Routine Preventative Maintenance:

• Mineral spirits are recommended when cleaning the Dynafile II Assembly. 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, send tool in for relabeling. User is responsible for maintaining specification information i.e.:

Model #, S/N, and SFPM. (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 – When the brushes wear down to a predetermined length, the tool is automatically shut off to prevent damage to the armature. Unplug tool and

remove brush caps (item #23) and replace brushes (item #22). Replace brush caps.

After maintenance is performed on tool check for excessive tool vibration. Check for excessive current leakage at 550 volts with a current leakage tester 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.

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, 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.

One Y ear 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, brushes, gears, etc., are not covered under this warranty.

3

Abrasive Impregnated Non-Woven Nylon

A non-woven synthetic fiber and an abrasive mineral are bonded together to
form a tough, open web that is chemically resistant and long-lasting. This web
design allows controlled conformable contact to workpiece contours, corners
and edges. The product wears away slowly, exposing new abrasive leaving a
uniform, consistent surface. It also conditions surfaces without removing or
damaging the base material and is excellent for deburring, cleaning, blending
and final finishing of metal, wood and plastics. It is available in many forms such
as belts, discs and wheels. Various mineral grades are available
ranging from very coarse to ultra-fine.

Cloth Polishing Belts

Used on power tools in conjunction with Dynuba®polishing compounds. The
result is brilliant cut, color and luster on metals such as stainless steel,
aluminum, copper and brass.

Coated Aluminum Oxide

The most widely used abrasive grain. This tough durable synthetic is used for
grinding and deburring high carbon steels, general metalworking and for
sanding certain hardwoods.

Ceramic Coated Aluminum Oxide

Synthetic grain two-to-three times tougher than conventional aluminum oxide.

Coated Silicon Carbide

Excellent for sanding primer and sealer. This sharp, fast-penetrating grain is
used for sanding soft materials such as plastics and fibrous wood.

Coated Alumina Zirconia

Effective for coarse stock removal of metal and wood. This synthetic grain has
self-sharpening characteristics and provides continuous new cutting edges for
longer life and greater efficiency.

Abrasive Types and Cloth Polishing Belts

All abrasive accessories may be found in the most current Dynabrade®Catalog and abrasive literature.

Abrasive Belt/Contact Arm Change Instructions

To Change Belt: To Change Contact Arm Assembly:

1. Disconnect power source. 1. Disconnect power source.

2. Remove 15312 Belt Guard by unscrewing 15329 Screw. 2. Remove 15312 Belt Guard by unscrewing 15329 Screw.

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

4. Remove and replace abrasive belt and belt guard. 4. Remove 95218 Rough Adjustment Knob.

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

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

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

to the left or right accordingly while machine is running. 6. Replace 95218 Knob.

7. Install abrasive belt and replace belt guard.

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

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

Installing Side Handle: The side handle may be installed on either side of the gear case 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 gear case and tighten securely.