Dynorbital 57201, 57200, 57202, 57203, 57204 Operating, Maintenance And Safety Instructions

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6" Non-Vac/Central Vac 5" Non-Vac/Central Vac

6" Non-Vac

6" Vac-Ready

5" Non-Vac

5" Vac-Ready

Models:

57200 – 5" Non-Vacuum 57201 – 5" Vac-Ready 57202 – 5" Basic Vac 57203 – 5" Deluxe Vac 57204 – 5" Central Vac-Ready 57210 – 6" Non-Vacuum 57211 – 6" Vac-Ready 57212 – 6" Basic Vac 57213 – 6" Deluxe Vac 57214 – 6" Central Vac-Ready

Air Powered, Random Orbital Sander, 12,000 RPM

Parts Page Reorder No. PD00•26

Effective March, 2000 Supersedes PD99•07

5" & 6" Two Hand

Dynorbital

Sander

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.

WARNING

1 56104 5" Vac Sanding Pad

56105 6" Vac Sanding Pad 56106 5" Non-Vac Sanding Pad 56107 6" Non-Vac Sanding Pad

2 95858 Spacer 2

A 95859 Spacer

3 95886 Washer (4) (CVR) 4 96425 Screw (4) (CVR) 5 57737 6" Vacuum Shroud 6 57369 Lip Seal Shroud 7 96166 Set Screw 8 57332 Lock Ring

9 57069 Balancer Shaft 10 95630 Snap Ring 11 95628 Bearing Shield 12 56053 Bearing Seal 13 56052 Balancer Bearing 14 57364 5" Motor Shaft Balancer

57365 6" Motor Shaft Balancer 15 54673 Rotor Key 16 02695 Bearing 17 54630 Front Bearing Plate 18 54705 Rotor/Blade Set 19 54631 Cylinder Assy. (incl. #20) 20 95865 Line-Up Pin 21 54629 Rear Bearing Plate 22 01206 Bearing 23 95626 Retaining Ring 24 57382 Gasket (5", 6" Non-Vac

6" Central Vac)

57383 Gasket (5", 6" Vac-Ready

5" Central Vac)

25 57205 Housing - 57200

57206 Housing - 57201, 02, 03

57207 Housing - 57204

57208 Housing - 57210

57209 Housing - 57211, 12, 13

57218 Housing - 57214

26 95523 O-Ring (2) 27 56671 Handle 28 96123 Screw (2) 29 57396 Valve Stem 30 95886 Flat Washer (4) 31 01211 Split Lock Washer (6) 32 97010 Screw (4) 33 01464 Seal (2) 34 01472 Tip Valve 35 01468 Conical Spring 36 56673 Gasket 37 96328 O-Ring 38 98597 Retaining Ring 39 56672 Adapter Assembly 40 01024 O-Ring (2) 41 57343 Speed Regulator 42 54199 Muffler Seat 43 54195 Muffler (3) 44 54194 Muffler Cap 45 57344 Throttle Lever 46 01017 Pin 47 96421 Flat Washer (2) 48 01788 Screw (2) 49 01494 Inlet Bushing

30 31

33 34 35

36 37 38 39 40

47 31

33 49

41 42 43 44

23 N•m

3.38 N•m

34 N•m

Adhesive:

= Loctite #271

A3= Loctite #242

Torque: N•m x 8.85 = In. - lbs.

KEY

Index Key

No. Part # Description

For Serial No. 9L1437 and Higher

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(PD00•26)

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.

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

• 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.

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.

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.

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. It is strongly recommended that all Dynabrade rotary vane air tools be used with a Filter-Regulator-Lubricator to minimize the possibly of misuse due to unclean air, wet air or insufficient lubrication. Dynabrade recommends the following: 11405 Air Line Filter-Regulator-Lubricator — Provides accurate air pressure regulation, two-stage filtration of water contaminants and micro-mist lubrication of pneumatic components. Operates 40 SCFM @ 100 PSIG has 3/8" NPT female ports.

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

6. A Motor Tune-Up Kit (P/N 96122) 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.

7. 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.

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 Pad Dia. Sound Air Flow Rate Air Pressure Weight Length Height

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

57200 .4 (298) 12,000 5 (127) 78 dB(A) 4/27 (765) 90 (6.2) 2.7 (1.2) 10-1/4 (260) 4-1/2 (114)

57201-03 .4 (298) 12,000 5 (127) 82 dB(A) 4/27 (765) 90 (6.2) 2.7 (1.2) 10-1/4 (260) 4-1/2 (114)

57204 .4 (298) 12,000 5 (127) 86 dB(A) 4/27 (765) 90 (6.2) 2.7 (1.2) 10-1/4 (260) 4-1/2 (114)

57210 .4 (298) 12,000 6 (152) 82 dB(A) 4/27 (765) 90 (6.2) 4.5 (2.0) 10-1/2 (267) 4-1/2 (114)

57211-13 .4 (298) 12,000 6 (152) 88 dB(A) 4/27 (765) 90 (6.2) 4.5 (2.0) 10-1/2 (267) 4-1/2 (114)

57214 .4 (298) 12,000 6 (152) 84 dB(A) 4/27 (765) 90 (6.2) 4.5 (2.0) 10-1/2 (267) 4-1/2 (114)

Additional Specifications: Orbit Diameter 3/16" (5mm) • Spindle Thread 5/16"-24 Female • Air Inlet Thread 1/4" NPT • Hose Size 1/4" (6mm)

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Motor Assembly/Disassembly Instructions

Important: Manufacturer’s warranty is void if tool is disassembled before warranty expires. These instructions are for use in conjunction with Part Number 57260 Repair Kit, which includes special tools for proper disassembly/assembly of tool. A complete Tune-Up Kit, Part Number 96122 is available which includes assorted parts to help maintain and repair motor.

To Disassemble:

1. Invert machine and secure in vise, using 57092 Collar (supplied in 57260 Repair Kit) or padded jaws.

2. Remove sanding pad with 50679 Open-End Wrench (supplied with sander).

3. Using a 2mm hex key remove the 96166 Set Screw.

4. Insert 56058 Lock Ring Wrench (supplied in 57260 Repair Kit) into corresponding tabs of lock ring and unscrew. Motor may now be lifted out for service. Important: Do not remove the rubber seals from the motor housing.

5. Remove 95626 Retainer Ring. Motor may now be disassembled.

6. Remove the rear plate assembly by securing the 54631 Cylinder in a standard 2 inch bearing separator or use a standard bearing puller gripped on the

cylinder inlet/exhaust area. Push the motor shaft balancer through the bearing. Remove cylinder, rotor, vanes and key.

7. Remove 54630 Front Plate and press off 02695 Front Motor Bearing, using a 2 inch bearing separator and a #2 arbor press.

8. Remove 01206 Bearing from the 54629 Rear Bearing Plate.

9. Disassemble the balancer assembly as follows:

a.) Remove 95630 Snap Ring. Screw the threaded portion of the 56056 Bearing Puller (supplied in 57260 Repair Kit) into the 57069 Balancer Shaft. Note: Heat the outside of the motor shaft balancer to approximately 200° F. Now, using the slider weight, pull the assembly out.

b.) Press off 56052 Bearing and remove loose parts.

10. If during step 8, the 56052 Bearing remains in the motor shaft balancer, it can be removed by heating the shaft balancer again and using the 56081 Bearing Chuck, 56080 Bearing Puller Stud, 95334 Hex Nut connected to the 56056 Balancer Bearing Puller Assembly. Remove the bearing.

To Assemble:

Important: Be certain parts are clean and in good repair before assembling.

1. Assemble the balancer assembly as follows:

a.) Install 95630 Snap Ring onto 57069 Balancer Shaft. Install 95628 Shield with convex face toward hex

of balancer shaft.

b.) Install 56053 Bearing Seal. Note: Be certain seal is pressed completely over shaft step.

c.) Apply a slight amount of #271 Loctite

(or equivalent) to inside diameter of the 56052 Bearing and the

outside diameter of the 57069 Balancer Shaft.

d.) Press 56052 Bearing, with seal side toward hex of balancer shaft, up to shaft step using 57091 Bearing

Press Tool (supplied in 57260 Repair Kit) (Drawing 1).

2. Place the motor shaft balancer in a soft jaw vise with large end up.

3. Apply a slight amount of #271 Loctite

(or equivalent) on the outside diameter of the 56052 Bearing and slide the balancer shaft assembly into the motor shaft balancer until 56052 Bearing is firmly seated at bottom. Squeeze 95630 Snap Ring into groove in motor shaft balancer to complete the assembly. Remove from vise.

4. Press 02695 Bearing onto the motor shaft balancer down to the shoulder using 57091 Bearing Press

Tool (Drawing 2).

5. Install 54630 Front Bearing Plate onto 02695 Bearing and check for smooth rotation (Drawing 3).

6. Place 54673 Rotor Key, 54671 Rotor, and 54674 Blades onto shaft. Note: Be certain rotor “floats” easily on the shaft. Because the design of this

motor uses a “floating rotor”, there is no need to set or adjust gap between the rotor and the end plates.

7. Place 54631 Cylinder over rotor. The “short” line-up pin goes toward the 54630 Front Bearing Plate.

8. Install 01206 Bearing into 54629 Rear Bearing Plate. Place bearing and bearing plate over shaft and “long” end of line-up pin and press fit

in place (Drawing 4).

9. Install 95626 Retaining Ring concave side toward motor. Note: Be certain that retaining ring is completely pressed down onto its groove on the shaft.

10. Grease the rubber seals inside the housing using a small amount of multi purpose grease or petroleum jelly. Note: Be certain that rubber seals in housing have not pulled out of their seat during disassembly. If this has happened re-seat seals by pushing them

until they are flush with inside diameter.

(continued on next page)

Balancer Shaft

Shaft Step

Bearing Seal and

Bearing Shield

Drawing 1

Balancer Shaft

Assembly

Motor Shaft

Balancer

02695 Bearing

57091

Bearing Press Tool

Drawing 2

57091

Bearing Press Tool

Balancer Shaft

Assembly

Motor Shaft

Balancer

02695 Bearing

Front Bearing Plate

Drawing 3

57091

Bearing Press Tool

Front Bearing Plate

(with 02695 Bearing)

54629 Rear Bearing Plate

(with 01206 Bearing)

Cylinder Assembly

(w/ rotor and vanes)

Line-Up Pin

Drawing 4

56052 Bearing

57091

Bearing Press Tool

Motor Shaft Balancer

Balancer Shaft

Assembly

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Accessories

Self-Contained Dust Collection Systems

Service Kits

54290 “Bag-in-Box” System

• 95361 Air Line 5' long.

• 50682 Flex-Hose 1" dia. x 6' long.

• 95362 Rubber Connectors (5).

• 95575 Durable Box Receptacle.

• Sample paper bag included.

Paper bag reorder:

50692 (400/ case) or

50693 (24 per package.)

96122 Motor Tune-Up Kit:

•

Includes assorted parts to help maintain and repair

motor.

57260 Motor Repair Kit:

• Contains special tools for

disassembly/assembly of machine.

50617, 56303 – 6' Long Flex-Hose Systems

• 50617: Has 50683 Standard Reusable Felt Bag

with hook ’n loop end for easy emptying.

• 56303: Has 56304 Zipper-Lock Bag.

Both systems include 6' long 50682 Flex-Hose. Shown with optional 95361 Air Line (1/4").

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 Sit: www.dynabrade.com Email: Customer.Service@Dynabrade.com

Motor Disassembly/Assembly Instructions

(continued)

11. Secure motor housing in vise, using 57092 Collar or padded jaws. Slide motor assembly into secured housing. Note: With handle pointing toward you while looking into motor bore, be certain line-up pin enters slot to right side of center.

12. Tighten 57332 Lock Ring with 56058 Lock Ring Tool to 34 N•m/300 on. - lbs. Attach shroud and weight-mated sanding pad.

13. Apply one drop of #242 Loctite

(or equivalent) to threads of 96166 Set Screw and reinstall into 57332 Lock Ring. Do not over tighten.

To Disassemble Valve And Speed Regulator Assemblies:

1. Invert tool and place in soft jaw vise or use 57092 Repair Collar.

2. Loosen and remove 01788 Screws (2), 01211 Lock Washers (2) and 96421 Flat Washers from 56672 Adapter.

3. Carefully remove 56672 Adapter making sure no parts fall to the ground. On non-vacuum and central vacuum models: pry off 54194 Muffler Cap and remove 54195 Muffler (3).

4. Remove 57343 Speed Regulator by detaching 98597 Retaining Ring with a pair of snap ring pliers. Remove 01024 O-Rings with a small screwdriver.

5. Remove tip valve assembly from housing.

To Assemble Valve And Speed Regulator Assemblies:

1. Lightly lubricate 01024 O-Rings and slide them on 57343 Speed Regulator. Install through regulator hole on 56672 Adapter. Place 98597 Retaining Ring on groove of speed regulator using a pair of retaining ring pliers.

2. Line up hole in valve stem with inlet hole in handle. Place 01464 Seal in handle. Insert 01472 Tip Valve so that metal pin goes through the valve stem. Place 01468 Spring into the housing, small end first. Install 56673 Gasket and 96328 O-Ring.

3. Gently line up 56672 Adapter onto handle so no parts shift when tightening. Replace and tighten 01788 Screws (2), 01211 Lock Washers (2), and 96421 Flat Washers (2).

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

Important: Motor should operate at 12,000 RPM at 6.2 bar (90 PSIG). RPM should be checked with a tachometer. Before operating, we recommend

that 3-4 drops of pneumatic tool oil be placed directly into the air inlet with throttle lever depressed. Operate tool for 30 seconds to determine if machine is operating properly and to allow lubricating oils to properly dispense through machine.

Loctite®is a registered trademark of the Loctite Corp.

01089 Safety Lock Lever

• A 57375 Valve Stem must be used in

conjunction with this lever to function properly.

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Dynorbital 57201, 57200, 57202, 57203, 57204 Operating, Maintenance And Safety Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual