Dynabrade 40595 Guide

Parts Page Reorder No. PD05•42
Effective October, 2005
Electric Right Angle Grinder
Tool Manual – Safety, Operation and Maintenance
Models:
40595 – 120 V / 60 Hz
Accepts 4-1/2" Type 27 Grinding Wheels
with 7/8" Arbor Hole
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
G
WARNING
Read and understand tool manual before
work starts to reduce risk of injury to
operator, visitors, and tool.
WARNING
Eye protection must be worn at all times,
eye protection to conform to ANSI Z87.1.
WARNING
Respiratory protection to be used when exposed to
contaminants that exceed the applicable threshold
limit values required by law.
WARNING
Practice safety requirements. Work alert,
have proper attire, and do not operate tools under
the influence of alcohol or drugs.
WARNING
Ear protection to be worn when exposure to sound,
exceeds the limits of applicable Federal, State or
local statues, ordinances and/or regulations.
WARNING
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, Safety Requirements and applicable State and Local Regulations.
WARNING
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.
Caution: Hand, wrist and arm injury may result from repetitive work, motion and overexposure to vibration.
Tool Intent: Dynabrade Electric Right Angle Grinders are used to grind; metal, wood, stone, fiberglass or plastic surfaces.
CUS

Electrical Safety (Continued)
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 in a high, dry place, locked up 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.
9. Use the right tool. Do not force small tools or attachments to do the job of a heavy duty 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. Always use proper guard with grinding wheel. A guard protects operator from broken wheel fragments.
2. Accessories must be rated for at least the speed recommended on the tool warning label. Wheels and other accessories running over rated speed can fly
apart and cause injury.
3. Hold tool by insulated gripping surfaces when performing an operation where the tool may contact hidden wiring or its own cord. Contact with a “live”
wire will make exposed metal parts of the tool “live” and shock the operator.
4. Be aware of the acceptable processing of the material you are grinding. Certain material can create an explosive environment.
(See Definitions of label symbols on pg. 3)
TOOL DESCRIPTION
4-1/2" Sander Grinder – Is a right angle electric hand tool with a 5/8"-11 spindle which includes: an on/off switch, side handle, a guard, and is equipped
with a 8 ft. cord set.
ASSEMBLY and OPERATION INSTRUCTIONS
1. With power source disconnected from tool, securely fasten abrasive/accessory on tool with the wrench provided and the spindle lock on the gear case. The rated RPM
of the accessory must be equal to or greater than the rated RPM of the tool.
2. To adjust the guard loosen the pinch screw P/N 89357 and position the guard between the operator and the wheel. Securely tighten the pinch screw.
3. Check to make sure the switch is in the off position and connect power source to tool.
4. Hold tool by the motor housing and the side handle. Do Not hold tool by head/housing assembly. Keep hands away from all grinding/sanding
edges and moving parts.
5. Push, slide switch forward to start tool. Depress rear of slide switch to disengage 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 RPM of your tool.
Routine Preventative Maintenance:
• Mineral spirits are recommended when cleaning the angle head. 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. Compressed air may be used to remove dirt from electrical components.
• DO NOT clean or maintain tools with chemicals that have a low flash point (example: WD-40®).
• Tool label must be kept legible at all times, if not, reorder Tool Specification Label and replace. User is responsible for maintaining specification information i.e.:
Model #, S/N, and RPM. (See Assembly Breakdown)
• Visually inspect plugs and cords for frays, visible damage and signs of deterioration. Damaged or worn components must be replaced by qualified service personnel.
• Brush Changing – Unplug tool, cut both Dynabrade logo labels along housing joint, remove 89343 Screw and remove rear cover. Bend brass tab on brush holders up
and remove brushes. Install new brushes, bend tabs down and replace rear cover. Brush changing – Change brushes every 100 hrs. to ensure proper tool function. After
changing brushes, it is recommended to replace the right angle gear grease with 95542 Grease.
• After maintenance is performed on tool check for excessive tool vibration.
• Check for excessive current leakage at 550 volts with a current leakage checker 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. Bench mounts are NOT to be used.
• DO NOT carry tool by cord.
• Protect abrasive accessories from exposure to water, solvents, high humidity, freezing temperature and extreme temperature changes.
• Store accessories in protective racks or compartments to prevent damage.

Complete Assembly
3
32
31
30
29
28
27
26
22
21
35
36
37
34
52
56
40
41
49
42
53 54
55
48
47
46
45
44
39
51
50
33
25
24
22
23
20
19 18
17
16 15
14 13
12 11
10
9
8
7
189310 Flange
289356 Flange
389357 Screw
489307 Screw (3)
589358 Tension Washer
689359 Guard
789300 Screw (4)
889360 Gear Case Cover
989350 Shim
10 89303 Woodruff Key
11 89302 Retaining Ring
12 89361 Spindle (5/8"-11)
13 50677 Bearing
14 89306 Bearing Retainer
15 89307 Screw (3)
16 89308 Gear Spacer
17 89309 Spiral Bevel Gear
18 01015 Bearing
19 89311 Shaft Lock Pin
20 89314 GearBox Housing
21 89351 Side Handle
22 89312 Plug (2)
23 89313 Screw (4)
24 89315 Spring
25 89316 Button
26 89317 Nut
27 89318 Spiral Bevel Pinion
28 89319 Bearing
29 89320 Bearing Retainer
30 89321 Screw (2)
31 89322 Armature Assembly
32 89323 Washer
33 89324 Bearing
34 89325 Bearing Holder
35 89327 Screw (2)
36 89328 Fan Baffle
37 89329 Field
38 89330 Motor Housing
39 89331 Switch
40 89332 Screw (2)
41 89339 Wire - Black
42 89340 Wire - Red (2)
43 89335 Pin
44 89342 Brush (2)
45 89334 Brush Holder (2)
46 89336 On/Off Switch
47 89337 Drawbar
48 89338 Drawbar
49 89341 Wire - White
50 89346 Cord Protector
51 89348 Rear Cover
52 89343 Screw
53 89344 Cord Clamp
54 89349 Screw
55 89345 Power Cord
56 40403 Label
57 89305 Wrench
58 40402 Label (2)
Index Key
No. Part # Description
To order replacement parts, specify model number and serial number of your machine.
Boxed index numbers represent 89326 Motor Housing Assembly.
38 43
3
4
5
6
2
57
58
A . . . . . . . . . . . . . . . . . . . . .amperes
Hz . . . . . . . . . . . . . . . . . . . . . . . .hertz
. . . . . . . . . . .Class II Construction
no. . . . . . . . . . . . . . . .no load speed
.../min . . . . . . . . .revolutions per min.
Definitions of Label Symbols
Symbol Description
1

Outer Flange Nut
1/8"
DYNABRADE
®
DYNABRADE, INC., 8989 Sheridan Drive • Clarence, NY 14031-1490 • Phone: [phone] • Fax: [phone] • International Fax: [phone]
DYNABRADE EUROPE S.àr.l., Zone Artisanale • L-5485 Wormeldange—Haut, Luxembourg • Telephone: [phone] • Fax: [phone]
© DYNABRADE, INC., 2005 PRINTED IN USA
Visit Our Web Site: www.dynabrade.com Email: Customer[email protected]
1. CSA International
8501 East Pleasant Valley Road
Cleveland, Ohio 4431-5575
Tel: [phone]
Fax: [phone]
2. Government Printing Office – GPO
Superintendent of Documents
Attn. New Orders
P.O. Box 371954
Pittsburgh, PA 15250-7954
Tel: [phone]
Reference Contact Information
Machine Specifications
Wiring Diagram Optional Accessories
Wheel Mounting Instructions
AC 120V ~ 60Hz
Stator
Switch
Rotor
FIND THE MOST CURRENT OFFERING OF ACCESSORIES AND
SUPPORT DOCUMENTS @ WWW.DYNABRADE.COM
95542 Grease 10 oz.
• High film strength; excellent
resistance to water, steam, etc.
• Workable range 0˚ F to 300˚ F.
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 con-
tingent 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, brushes, gears, etc.,
are not covered under this warranty.
Model Motor Pad Diameter Weight Length Height
Number RPM Inch (mm) Voltage Current Phase Frequency Pound (kg) Inch (mm) Inch (mm)
40595 11,600 4-1/2 (114) 120 V (AC) 6.7 Amps 1 60 Hz 4 (1.8) 10-3/4 (274) 3-3/8 (86)
Type 27 Flanged Wheel (7/8" Dia. Arbor Hole)
1. With power source disconnected from the tool.
2. Clean spindle and flange mounting surfaces. Inspect for nicks, cuts and sharp edges.
3. Install drive flange with raised boss facing outward. Engage bottom flange slot and spindle flats.
4. Check for flange flatness and runout by rotating spindle and drive flange together.
5. Install Type 27 grinding wheel over spindle thread and over raised boss on flange.
6. With 1/4" thick wheels & greater, install outer flange nut with raised boss facing toward abrasive wheel,
engage spindle lock and secure flange firmly against wheel. (See fig. 1)
7. With 1/8" thick wheels & less, install outer flange nut with raised boss facing away from abrasive wheel,
engage spindle lock and secure flange firmly against wheel. (See fig. 2)
8. Check for wheel firmness by holding the spindle and pulling on the edge of the wheel in the
tightening direction.
Caution: Over tightening the outer flange nut can cause damage to the wheel and/or flanges.
• Use only Dynabrade flanges: 89310 & 89356 Flanges.
Right Angle Housing
Side View
Fig. 1
Fig. 3
Fig. 2
Driving Flange
Outer Flange Nut
Spindle
Safety Guard
1/4"
Outer Flange Nut
Wheel
Right Angle Housing
Bend of Lip
Face of Wheel must be behind bend of lip.
Side View
Safety Guard
Wheel
Type 27 Hubbed Wheel (5/8"-11 Internal Affixed Flange)
1. With power source disconnected from the tool.
2. Some TYPE 27 grinding wheels come equipped with a disposable flange affixed to them. For use of this
type wheel store both the driving flange and the outer flange nut provided with the tool for future use.
3. Engage spindle lock and thread grinding wheel to tool securely.
4. Visually inspect the grinding surface face relationship to the bend of the lip on the guard.
55..ONLYUSE grinding wheel whose face of the wheel is behind bend of lip on guard. (See fig. 3)