Dura Gold DUR P9521 Maintenance and service guide

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POWERFUL VARIABLE SPEED ROTARY
POLISHER AND SANDER
Approximate Speed Settings on LED Display Screen
Setting Speed Usage
3: 1050 RPM
450 RPM
750 RPM
Polishing & Cleaning
4: 1350 RPM Polishing & Cleaning
5: 1650 RPM Removing Paint Defects & Oxidation
6: 1950 RPM Removing Paint Defects & Oxidation
ROTATING CIRCULAR MOTION
SAFETY & OPERATING
INSTRUCTION MANUAL
DUR P9521
With LED Screen for RPM Display and Operation Controls

2
WARNING: indicates a potentially hazardous situation which may result in death or serious injury
and/or property damage.
CAUTION: Indicates a potentially hazardous situation which may result in minor or moderate
injury and/or property damage.
NOTICE: Indicates a potentially hazardous situation, which may result in minor or moderate
injury and/or property damage.
GENERALPOWER TOOLSAFETY WARNINGS
WARNING: Read all safety warnings and instructions. Failure to follow the warnings and
SAVE ALL WARNINGS AND INSTRUCTIONS FORFUTURE REFERENCE
The term power tool in the warnings refers to your mains-operated (corded) power tool or battery-operated
(cordIess) power tool.
a) Keep work area clean and well lit. Cluttered or
dark areas invite accidents.
b) Do not operate power tools in explosive atmo-
a) Power tool plugs must match the outlet. Never
modify the plug in any way. Do not use any
adapter plugs with earthed (grounded) power
will reduce risk of electric shock.
b) Avoid body contact with earthed or grounded
surfaces such as pipes, radiators, ranges
and refrigerators. There is an increased risk
of electric shock if your body is earthed or
grounded.
c) Do not expose power tools to rain or wet
conditions. Water entering a power tool will
increase the risk of electric shock.
a) Stay alert, watch what you are doing and
use common sense when operating a power
tool. Do not use a power tool while you are
or medication. A moment of inattention while
operating power tools may result in serious
personal injury.
b) Use personal protective equipment. Always
wear eye protection. Protective equipment
such as dust mask non-skid safety shoes hard
hat, or hearing protection used for appropriate
conditions will reduce personal injuries.
liquids, gases or dust. Power tools create
sparks which may ignite the dust or fumes.
c) Keep children and bystanders away while oper-
ating a power tool. Distractions can cause you
to lose control.
d) Do not abuse the cord. Never use the cord for
carrying, pulling or unplugging the power tool.
Keep cord away from heat, oil, sharp edges
or moving parts. Damaged or entangled cords
increase the risk of electric shock.
e) When operating a power tool outdoors, use an
extension cord suitable for outdoor use. Use
of an extension cord suitable for outdoor use
reduces the risk of electric shock.
f) If operating a power tool in a damp location
is unavoidable, use a residual current device
(RCD) protected supply. Use of an RCD reduces
the risk of electric shock.
c) Prevent unintentional starting. Ensure the
power source and/or battery pack, picking up,
or carrying the tool. Carrying power tools with
tools that have the switch on invites accidents.
d) Remove any adjusting key or wrench before
turning the power tool on. A wrench or a key left
attached to a rotating part of the power tool may
result in personal injury.
1) WORK AREA SAFETY
2) ELECTRICAL SAFETY
3) PERSONAL SAFETY

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a) Do not force the power tool. Use the correct
power tool for your application. The correct
power tool will do the job better and safer at the
rate for which it was designed.
b) Do not use the power tool if the switch does not
be controlled with the switch is dangerous and
must be repaired.
c) Disconnect the plug from the power source
and/or the battery pack from the power tool
before making any adjustments, changing
accessories, or storing power tools. Such
preventive safety measures reduce the risk of
starting the power tool accidentally.
d) Store idle power tools out of the reach of children
and do not allow persons unfamiliar with the
power tool or these instructions to operate the
power tool. Power tools are dangerous in the
hands of untrained users.
e) Maintain power tools. Check for misalignment or
binding of moving parts, breakage of parts and
tool’s operation. If damaged, have the power
tool repaired before use. Many accidents are
caused by poorly maintained power tools.
f) Keep cutting tools sharp and clean. Properly
maintained cutting tools with sharp cutting
edges are less likely to bind and are easier to
control.
g) Use the power tool, accessories and tool bits
in accordance with these instructions, taking
into account the working conditions and the
work to be performed. Use of the power tool for
result in a hazardous situation.
4) POWER TOOL USE AND CARE
e) Do not overreach. Keep proper footing and
balance at all times. This enables better control
of the power tool in unexpected situations.
f) Dress properly. Do not wear loose clothing or
jewelry. Keep your hair, clothing and gloves
away from moving parts. Loose clothes, jewelry
or long hair can get caught in moving parts
g) lf devices are provided for the connection of dust
extraction and collection facilities, ensure these
are connected and properly used. Use of dust
collection can reduce dust-related hazards.
ensure that the safety of the power tool is maintained.
5) SERVICE
This tool is designed to be used as a
polisher . Read all the
warnings, instructions and indications
provided on drawings and
to comply
with all the instructions provided
injuries.
This tool is not intended to be used for metal
brushing and cutting operations. The use of
this tool for unintended applications may cause
hazards and injuries to people.
The tool must be used with accessories that have
tool does not guarantee a safe operation; read
the following additional instructions.
The rated speed of the accessories must be
at least equivalent to the maximum speed
speeds above the rated one, may cause them to
break or be projected into the air.
5. The external diameter and thickness of the
the tooI. Accessories with incorrect dimensions
cannot be adequately protected or controlled.
the tooI. The use of accessories that cannot
imbalance, excessive vibrations and loss of
control of the tool.
7. Do not use damaged accessories. Before
use, inspect all the accessories. Inspect the
supporting pads and verify there are no cracks,
tears or excessive wear. If the tool or accessory
ADDITIONAL SAFETY INSTRUCTIONS

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KICKBACK AND RELATED WARNINGS
Kickback is a sudden reaction to a pinched or
snagged rotating wheel, backing pad, brush or
any other accessory. Pinching or snagging causes
rapid stalling of the rotating accessory which in turn
causes the uncontrolled power tool to be forced in
the direction opposite of the accessory’s rotation at
the point of the binding.
For example, if a polishing
is snagged or pinched by the workpiece, the
edge of the that is entering into the
pinch point can dig into the material causing the
to climb out or kick out. The
may either jump toward or away from the
operator depending on direction of the ’s
movement at the point of pinching. Polishing
may also break under these
conditions.
Kickback is the result of tool misuse and/or
incorrect operating procedures or conditions and
can be avoided by taking proper precautions as
given below:
position your body and arm to allow you to
resist kickback forces. Always use auxiliary
handle, if provided, for maximum control over
kickback or torque reaction during start up. The
operator can control torque reaction or kickback
forces, if proper precautions are taken.
Never place your hand near the rotating
accessory. Accessory may kickback over your
hand.
Do not position your body in the area where
power tool will move if kickback occurs.
Kickback will propel the tool in direction
opposite to the wheel’s movement at the point
of snagging.
Use special care when working corners and
sharp edges. Avoid bouncing and snagging the
accessory. Corners, sharp edges or bouncing
have a tendency to snag the rotating accessory
and cause loss of control or kickback.
Do not attach a saw chain, woodcarving blade
or toothed saw blade. Such blades create
frequent kickback and loss of control.
FURTHER SAFETY INSTRUCTIONS FOR ALL OPERATIONS
has fallen, verify that they are not damaged
or install a new accessory. After inspecting or
installing an accessory, test the operation of
the tool at maximum speed and without load for
one minute, keeping at a safety distance. If the
accessories are damaged, they will break during
this test
.
8. Wear personal protective equipment. Depending
on application, use face shield, safety goggles
or safety glasses. As appropriate, wear dust
mask, hearing protectors, gloves and workshop
apron capable of stopping small abrasive or
workpiece fragments. The eye protection must
by various operations. The dust mask or
generated by your operation. Prolonged
exposure to high intensity noise may cause
hearing loss.
9. Keep bystanders a safe distance away from work
area. Anyone entering the work area must wear
personal protective equipment. Frag merits of
away and cause injury beyond immediate area
of operation.
10. Hold power tool by insulated surfaces only
when performing an operation where the
cutting accessory may contact hidden wiring
or its own cord. Cutting accessory contacting
a “live” wire may make exposed metal parts of
the power tool “live” and shock the operator.
11. Position the cord clear of the spinning
accessory. If you lose control, the cord may be
cut or snagged and your hand or arm may be
pulled into the spinning accessory.
12. Never lay the power tool down until the
accessory has come to a complete stop. The
spinning accessory may grab the surface and
pull the power tool out of your control.
13. Do not run the power tool while carrying it at
your side. Accidental contact with the spinning
accessory could snag your clothing, pulling
the accessory into your body.
14. Regularly clean the power tool’s air vents.
The motor’s fan will draw the dust inside
the housing and excessive accumulation of
powdered metal may cause electrical hazards.
materials. Sparks could ignite these materials.
16. Do not use accessories that require liquid
coolants. Using water or other liquid coolants
may result in electrocution or shock.

• Always use eye protection. All user and
bystanders must wear eye protection that
conforms to Z87.1.
• Clean out your tool often, especially after heavy
use. Dust and grit containing metal particles
often accumulate on interior surfaces and
could create an electric shock hazard.
• Do not operate this tool for long periods of time.
Vibration caused by the operating action of this
hands and arms. Use gloves to provide extra
cushion, take frequent rest periods and limit
daily time of use.
• Air vents often cover moving parts and should
be avoided. Loose clothes, jewelry or long hair
can be caught in moving parts.
• An extension cord must have adequate wire
size (AWG or American Wire Gauge) for
safety. The smaller the gauge number of the
wire, he greater the capacity of the cable,
that is 16 gauge has more capacity than 18
gauge. An undersized cord will cause a drop
ADDITIONAL SPECIFIC SAFETY INSTRUCTIONS FOR POLISHER S
in line voltage resulting in loss of power and
overheating. When using more than one
extension to make up the total length, be sure
each individual extension contains at least
the minimum wire size. The following table
shows the correct size to use depending on
cord length and nameplate ampere rating. If in
doubt, use the next heavier gauge. The smaller
the gauge number, the heavier the cord.
Minimum Gauge for Cord Sets
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
• Avoid prolonged contact with dust from
polishing. Wear protective clothing and
wash exposed areas with soap and water.
Allowing dust to get into your mouth, eyes,
or lay on the skin may promote absorption
of harmful chemicals
WARNING: ALWAYS use safety glasses. Everyday eyeglasses are NOT safety glasses. Also use
face or dust mask if cutting operation is dusty.
ALWAYS WEAR CERTIFIED SAFETY EQUIPMENT:
WARNING: Always wear proper personal hearing protection that conforms to ABSI S12.6 (S3.19)
during use. Under some conditions and duration of use, noise from this product may contribute to
hearing loss.
WARNING: Some dust created by polishing contains chemicals known to the state of California to
cause cancer birth defects or other reproductive harm. Some examples of these chemicals are:
WARNING: Use of this tool can generate and/or disperse dust, which may cause serious and
permanent respiratory or other injury. Always use NIOSH/OSHA approved respiratory protection
appropriate for the dust exposure. Direct particles away from face and body.
CAUTION: Use extra care when working into a comer because a sudden, sharp movement of the
polisher may be experienced when the polishing pad or other accessory contacts a secondary
surface or a surface edge.
• ANSI Z87.1 eye protection (CAN/CSA Z94.3)
• ANSI S12.6(S3.19) hearing protection,
• NIOSH/OSHA/MSHA respiratory protection.
•Lead from lead-based paints,
•Crystalline silica,
•Arsenic and chromium from chemically-treated lumber.
CAUTION: Should your tool fail to start, check to make sure the prongs on the cord plug are making
good contact in the outlet. Also check for blown fuses or open circuit breakers in the line.
FAILURE TO START
5

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MODEL
7” (180 mm) and 6” (150 mm)
7” (180 mm) and 6” (150 mm)
POWER W 1200
RPM 450-1950
WEIGHT kgs 2.7
SPEED CONTROL
PROTECTION CLASS II
OPERATING VOLTAGE V- 0HZ
WARNING: Before mounting or replacing application tools or accessories, pull the power plug. This
preventive safety measure rules out the danger of injuries through accidental starting of the power tool.
MOUNTING THE AUXILIARY SIDE HANDLE, AND D-HANDLE
Screw the auxiliary side handle tightly onto the left or right side of the power tool, depending on the
working method. Mount the gear housing cover onto the gear case, put on the D-handle and tighten
with screws.
WARNING: Before mounting or replacing application tools or accessories, pull the power plug. This
preventive safety measure rules out the danger of injuries through accidental starting of the power tool.
SWITCHING ON and OFF
WARNING: First check that the power cord and plug are not damaged. CAUTION: Always hold the
power tool firmly, otherwise, you could lose control over the power tool.
SWITCHING ON
To start the polisher, squeeze the ON/OFF trigger switch to power it ON. The motor will start and take a
few moments to reach full operating speed. This is the soft-start function that allows you to spread the
polish on the surface to be polished slowly before the polisher reaches full operating speed.
OPERATING THE LOCK-ON FUNCTION
If you want to operate the polisher in the LOCKED-ON position, press the lock button whilst squeezing
the ON/OFF trigger switch, thus locking the switch in the ON position.
SWITCHING OFF
To turn the polisher OFF, release the ON/OFF trigger switch. If the ON/OFF trigger switch is in the
LOCKED-ON position, squeeze the trigger switch to release the lock button, then release the trigger to
stop the machine. WARNING: Always wait until the machine has come to a complete standstill
before putting it down.
ASSEMBLY INSTRUCTIONS
REPLACING THE POLISHING PAD OR SANDING DISC
OPERATING INSTRUCTIONS
CAUTION: Pull the used polishing pad or sanding disc off and apply the new one pressing it onto
the backing plate.
CAUTION: Accessories must be rated for at least the speed recommended on the tool warning
label. Accessories running over rated speed can fly apart and causes injury. Accessory ratings must
always be above tool speed as shown on tool name plate
P9521

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LED CONTROL PANEL DISPLAY SCREEN
SPEED LEVEL DISPLAY
Push the "+" and "-" buttons to increase or decrease speed increments between
450, 750, 1050, 1350, 1650 to 1950 RPM (revolutions per minute)
SETTING THE SPEED
The speed can be variably adjusted by pushing the "+" and "-" buttons to increase or decrease
speed increments between 450, 750, 1050, 1350, 1650 to 1950 RPM (revolutions per minute),
which is displayed on the center of the display screen. The polishing usage chart for each RPM
speed increment setting is listed on this manual's first page.
CARBON BRUSH INDICATOR LIGHT
When the indicator light on the top left side of the power tool display screen is green, it indicates
that the power is on and the power tool can work properly. When the indicator light is red, it will not
work properly. It indicates that the carbon brush has been consumed or the carbon brush is
damaged. At this time, the carbon brushes need to be replaced.
POLISHER WORKING HOURS
The indicator light on the bottom left side of the power tool display screen shows how many
working hours the polisher has been in use. This enables you to see the run time and assess
power tool servicing. The total working hours can be reset to 0 by pressing down the "-" button and
holding it for 3-4 seconds.
SERVICE INDICATOR LIGHT
When the indicator light on the top right side of the power tool display screen turns red, it indicates
that the polisher has been used for 80 working hours, and it is time to be serviced. A service and
maintenance check of carbon brushes, grease for the gear, switch, air vents, backing plate, etc.
The service light will go back to blue again when you press down the "+" and "-" buttons and hold
them for a few seconds.
CURRENT RUNNING TIME
The indicator light on the bottom right side of the power tool display screen shows how long the
polisher has been in continuous operation. This enables you to see the run time and assess the
power tool’s operation, as the power tool can overheat if it is left running too long or has been
running with an excessive load placed on it.
SERVICE INDICATOR LIGHT
Red Light – 80 Hours of polisher use
CURRENT RUNNING TIME
How long the polisher has been in
continuous operation
CARBON BRUSH INDICATOR LIGHT
Green Light – Ready for use
Red Light – Replace carbon brushes
POLISHER WORKING HOURS
How many hours the polisher has
been in use

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MAINTENANCE
WARNING: To reduce the risk of injury, turn unit off and disconnect it form power source before
installing and removing accessories, before adjusting or when making repairs. Be sure the
switch is in the “OFF” position. An accidental start-up can cause injury.
WARNING: Blow dirt and dust out of all air vents with clean, dry air at least once a week. To
minimize the risk of eye injury always wear ANSI Z87.1 performing this.
WARNING: Never use solvents or other harsh chemicals for cleaning the non-metallic parts for
the tool. These chemicals may weaken the plastic materials used in these parts. Use a cloth
dampened only with water and mild soap. Never let any liquid get inside the tool never immerse
any part of the tool into a liquid.
CLEANING
Maintenance and cleaning of the inner parts like brushes, ball bearings, gears or others,
must be carried out only by an authorized customer service workshop.

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We make every effort to assure that its products meet high quality and durability standards,
and warrants to the original purchaser that this product is free from defects in materials and
workmanship for the period of one year from the date of purchase. This warranty will not apply
to damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs or
alterations outside our facilities, criminal activity, improper installation, normal wear and tear,
or to lack of maintenance. We shall in no event be liable for death, injuries to persons or
property, or for incidental, and contingent, special or consequential damages arising from the
use of our product. Some states do not allow the exclusion or limitation of incidental or
consequential damages, so the above limitation of exclusion may not apply to you.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.
To take advantage of this warranty, the product or part must be returned to us with transporta-
tion charges prepaid. Proof of purchase date and an explanation of the complaint must
accompany the merchandise. The polisher’s serial number must also be intact. If our
inspection verifies the defect, we will either repair or replace the product at our election or we
may elect to refund the purchase price if we cannot readily and quickly provide you with a
replacement. We will return repaired products at our expense. If we determine there is no
defect, or that the defect resulted from causes not within the scope of our warranty, then you
must bear the cost of returning the product. This warranty gives you specific legal rights and
you may also have other right which varies from state to state.
DuraGold Customer Service contact:
[phone], [email protected]
www.TCPGlobal.com
www.Dura-Gold.com
DuraGold is a division of TCP Global Corp.
WARRANTY

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DUR P9521

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PS9521X Part List
No. NAME QTY No. NAME QTY
1 Packing pad 1 30 Bearing 6000-2RS 1
21 31 Bearing shroud 1
3 Output shaft 1 32 Elastic collar 1
4 Cross pan screw 8 33 Cross pan screw 2
5 Front cover 2 34 Stator 1
6 Bearing 6001-
2RS
1 35 Body housing 1
7 Elastic collar 1 36 Name plate 1
8 Output shaft gear 1 37 Right brush holder
cover
1
9 Bearing 696 2 38 Sping coil 2
10 Elastic collar 1 39 Brush holder 2
11 10 tooth shaft 1 40 Carbon brush 2
12 Middle cover 1 41 Left brush holder
cover
1
13 Bearing 6000-
2RS
1 42 Cross pan screw 4
14 Elastic collar 1 43 Left rear handle 1
15 Lager gear 1 44 Cable shroud 1
16 Elastic collar 1 45 Cable 1
17 Elastic collar 2 46 Cable plate 1
18 Cross pan screw 4 47 Cross pan screw 2
19 Gear box shroud 1 48 Capacitance 1
20 Plastic screw 2 49 Switch 1
21 Gear box shroud
label
1 50 Cross pan screw 1
22 Self-lock pin 1 51 Breadboard 1
23 Self-lock pin coil 1 52 LED screen frame 1
24 Elastic collar 1 53 Detector 1
25 Gear housing 1 54 Speed control button 1
26 Bearing plate 1 55 LED screen frame 1
27 Cross pan screw 3 56 LED screen cover 1
28 Rotor 1 57 right rear handle 1
29 Magnetic ring 1 58 Cross pan screw 5
59 Sponge Pad 1

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