Dynabrade 09L1000 User manual

PD09-60R
July, 2018
Supersedes PD09.60R
Alw ys oper te, inspect nd m int in this tool in ccord nce with the S fety Code for port ble ir tools
(ANSI B186.1) nd ny other pplic ble s fety codes nd regul tions. Ple se refer to Dyn br de’s
W rning/S fety Oper ting Instructions for more complete s fety inform tion.
Air Motor and Machine Parts
3" Dynabuffer
M del
57126
156143 3" Pad
251361 Shroud
395630 Snap Ring
457069 Balancer Shaft
595628 Bearing Shield
656053 Bearing Seal
756052 Bearing
857422 Motor Shaft Balancer
956047 Key
10 56046 ock Ring
11 50659 O-Ring
12 57088 Bearing
13 51366 Bearing Plate
14 57113 Rotor/Blade (5/pkg.) Set
15 58358 Cylinder Assembly
(Includes 98462 Pin)
16 98462 Pin
16a 58367 Seal
17 51367 Bearing Plate
18 01206 Bearing
19 95626 Retaining Ring
20 97166 Hang Plate
21 02099 Housing
22 01548 Gasket
23 01461 ock Nut
24 01547 Collar
25 95523 O-Ring
26 01470 Insert Assembly
27 57319 Housing
28 01950 Safety ock ever
29 12132 Pin
30 01449 Valve Stem
31 95558 Retaining Ring
32 95730 O-Ring
33 01024 O-Ring
34 01469 Speed Regulator Assy.
35 01464 Seal
36 01472 Tip Valve
37 01468 Spring
38 01543 Air Control Ring
39 95711 Retaining Ring
40 95438 O-Ring
41 94521 Muffler Base
42 94528 Felt Muffler
43 94522 Muffler Cap
44 95375 O-Ring
45 94526 Spacer
46 94523 Inlet Adapter
47 94519 Muffler Assembly
Index Key
No. Part # Description
Adhesive: A2= Loctite
#263 / #271
A6= Loctite #380
A8= Loctite #567
A10 = Loctite #243
Torque: N•m x 8.85 = In. - lbs.
Grease: Lubriplate 630 AA
Oil: O1= Air Lube
O
A
T
G
KEY
2
3
4
5
6
7
8
9
23 N•m
T
34 N•m
T
11.3 N•m
T
45 N•m
T
A8
O1
G1
A2
A6
A8
O1
A10
A10
A2
59293 – 26 mm open-end51360 – Overmold Grip
10
11
12
13
14
15
1617
18
19
21
20
25
242322
29
27
30
31 35
36
37
38
47
39 40 41 42 43 44 45 46
34
32
33
16a
1
For Seri l No. 09L1000 nd Higher
28
26
Tool Intent: Bu ers are ideal or bu ing/polishing sur aces.
They are designed to be used with appropriate backup pads,
bu ing pads and bu ing compounds.
Always follow adhesive
manufac urers cleaning and
priming recommenda ions.

2
Imp rtant Operating, Maintenance and Safety Instructi ns
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- ubricator to maintain all warranties.
Operating Instructions:
Warning: Eye, face, sound, respiratory, 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.
Caution: This tool is not to be run at free speed for any length of time. The tool is specifically designed to be low in vibration under load. Running the tool at free speed may
cause the buffing pad to become dislodged from the back-up pad.
1. All initial set-up and maintenance to the tool should be done with the air line disconnected from the tool.
2. Install air fitting into inlet bushing of tool. The inlet bushing is a 1/4" NPT, for optimal performance of the tool, directly couple the air line to the tool or use a quick
couple fitting with a large inlet hole such as Dynabrade’s P/N 95675. Important: Secure inlet bushing of tool with a wrench before attempting to install the air fitting to
avoid damaging valve body housing.
3. While there may be other applications suited for this tool it has been specifically designed for the automotive market to be used as the second step of a special two step
operation to remove paint imperfections in the clear coat of automotive finishes. It is imperative that the correct weight mated back-up pad be used with the tool to avoid
excessive vibration. The tool is designed to use a Dynabrade P/N 56142 Pad; this pad has a mass of 27 grams.
4. A waffle pad such as 3M P/N 02648 is required to be attached to the back-up pad, other pads may be available contact a Dynabrade or 3M representative for additional
information. Pre-condition a virgin pad thoroughly with 3M Final Finish Finesse-It Compound 3M P/N 82876 before attaching it to the tool. Once the pad has been
conditioned this process need not be done until a new waffle pad is required either due to wear or the compound has been allowed to set up rendering the pad useless.
5. Apply a small (15mm) dab of Final Finish on the repaired area, and position tool on the repair surface. Apply approximately a 3 pound load on the pad before throttling
the tool on. Adjust the force on the pad as required to feel the “sweet spot” (low vibration). Buffing for approximately 5 seconds with the pad flat on the work surface
should remove the sand scratches of the initial process. Release the throttle lever and then remove the tool from the work piece.
aintenance Instructions:
1. Through use of tool the mufflers may clog, hamper performance and require replacement.
2. Check tool speed regularly with a tachometer. A Magnetic Tachometer such as Dynabrade P/N 96368 is the simplest way to perform this operation. There are two test
conditions to assure that the tool is running properly, these conditions being free speed and under load. The free speed is a simple check to quickly determine if the tool is
out of specification. Checking under load requires additional test equipment but assures the proper operation of the tool. All speed testing must be done with 80 psig of air
at the inlet bushing, a Pressure Gage such as Dynabrade P/N 94315 is required. The tool should run between 9,000 RPM and 11,000 RPM free speed with 80 psig at the
tool inlet bushing. If the tool is running outside these speeds it should be serviced to correct the cause before use. The under load condition can be checked by outfitting
the tool with the proper back-up pad, waffle pad and buffing cream as outlined in the operating instructions. Apparatus is also required to monitor the load applied to the
work surface. Dynabrade offers a oad Cell P/N 80025 that allows the tool to be tested on a bench. First zero out the scale by adjusting the knob on the side of the load
cell to read zero when the tool, back-up pad, and waffle are resting on the wear plate of the load cell while connected to the air line. Apply a 3 pound load to the load cell
and using the digital tachometer check the operating speed of the tool. The tool should be running 5,500 RPM minimum. If the tool is running outside this range it should
be serviced to correct the cause before use.
3. All Dynabrade rotary vane air motors should be lubricated. Dynabrade recommends using Dynabrade Air ube (P/N 95842: 1 pt. 473 ml.) at a rate of 1 drop per minute.
If Dynabrade Air ube is not compatible with paint system it may be substituted with a compatible air tool lubricant with water absorbing properties to prevent internal
components from rusting.
4. It is strongly recommended that all Dynabrade rotary vane air tools be used with a Filter-Regulator- ubricator to minimize the possibility of misuse due to unclean air, wet
air or insufficient lubrication. Dynabrade recommends the following: 10681 Air ine Filter-Regulator- ubricator — Provides accurate air pressure regulation, two-stage
filtration of water contaminants and micro-mist lubrication of pneumatic components.
5. Use only genuine Dynabrade replacement parts. To reorder replacement parts, please specify the odel #, Serial # and RP of your machine.
6. A Motor Tune-Up Kit (P/N 96537) is available which includes assorted parts to help maintain motor in peak operating condition.
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 hydro
carbons or nitro carbons.
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.
LIFETIME WARRANTY
To validate Dynabrade Li etime Warranty, you must register each tool at: www.dynabrade.com. Registration o each tool at website is required.
Dynabrade will not honor Li etime Warranty on unregistered tools. Please view the entire Li etime Warranty Policy at www.dynabrade.com.
DO NOT USE T l f r Anything Other Than Its Intended Applicati ns.
Training: Proper care, maintenance, and storage o your air tool will maximize tool per ormance and reduce chance or accident.
Employer's Responsibility: Provide operators with sa ety instructions and training or sa e use o tools and accessories.
Rep rt t Y ur Supervis r any C nditi n f the T l, Access ries r Operati n y u C nsider Unsafe.
C refully re d nd underst nd the Gener l
nd S nder/Polisher sections found in Tool
S fety & Oper ting Guidelines (PN00001676)
before h ndling or using tool.
•Important: User of tool is responsible for following accepted safety codes such as those published by the American National Standards Institute (ANSI).
•Tool should not be running for extended periods of time free speed as it is not balanced for this condition. Avoid running the tool at free speed with a buffing pad installed
onto the back-up pad as it may dislodge from the tool.
•Always disconnect the air line before changing the back-up pad or making machine adjustments.
•Inspect abrasives/accessories for damage or defects prior to installation on tools.
•Warning: Hand, wrist and arm injury may result from repetitive work, motion and overexposure to vibration.

Motor Dis ssembly:
1. Disconnect the tool from the air supply.
2. Invert the tool and place the 57092 Repair Collar around the 02099 Housing and the 51361 Shroud, above the two handle
bosses so that the back-up pad is facing up.
3. Use the 59293 Wrench (26mm) to remove the back-up pad.
4. Insert the 56058 ock Ring Wrench into the tabs of the 56046 ock Ring and loosen the lock ring from the 02099 Housing by
turning it counterclockwise.
5. Remove the 51361 Shroud from the 02099 Housing by turning it counterclockwise.
6. Pull the motor assembly out of the 02099 Housing and remove the 58357 Cylinder Seal.
7. Use retaining ring pliers to remove the 95626 Retaining Ring.
8. Fasten the 96346 Bearing Separator between the 51367 Bearing Plate and the 58358 Cylinder Assembly.
9. Place the motor assembly with the bearing separator attached, on the table of the 96232 Arbor Press (#2) so that the counter
balance is pointing toward the floor.
10. Use a 3/16" dia. flat end drive punch as a press tool and push the 57422 Motor Shaft Balancer out of the 01206 Bearing.
11. Remove the rotor, vanes, and the 56047 Key from the motor shaft balancer.
12. Remove the 51366 Bearing Plate from the 57088 Bearing.
13. Fasten the bearing separator between the counter balance and the 57088 Bearing and use the arbor press to
remove the bearing.
14. Secure the counter balance portion of the 57422 Motor Shaft Balancer in a vise with aluminum or bronze jaws so that the
26mm hex end of the 57069 Balancer Shaft is accessible and pointing up.
15. Use a small thin screwdriver to pick the notched end of the 95630 Snap Ring out of the motor shaft balancer. Work the
screwdriver under and around the 95630 Snap Ring.
16. Fasten the bearing separator between the 26mm hex end of the 57069 Balancer Shaft and the 95628 Bearing Shield. Place
the separator on the table of the arbor press so that the hex end of the balancer shaft is pointing toward the floor. Use a 5/16"
dia. flat end punch as a press tool and press the 57069 Balancer Shaft out of the 56052 Bearing.
otor Disassembly Complete.
V lve Dis ssembly:
1. Place the 52296 Repair Collar around the 57319 Housing and secure it in a vise so that the air inlet is pointing up.
2. Use two wrenches when removing the air fitting. Place one wrench on the 94523 Inlet Adapter to hold it stationary and use
another wrench to remove the air fitting.
3. Remove the inlet adapter from the valve housing. Note: Refer to the exploded view of the muffler assembly to identify the
parts and their order of assembly.
4. Use needle nose pliers to remove the 01468 Spring and the 01472 Tip Valve. The 01464 Seal can be removed from the
valve housing with a small screwdriver.
5. Use retaining ring pliers to remove the 95558 Retaining Ring and push the 01469 Speed Regulator Assembly along with the
01449 Valve Stem out of the valve housing.
6. Use a 2.5mm dia. drive punch to remove the 12132 Pin and the throttle lever.
Valve Disassembly Complete.
V lve Assembly:
Important: Clean and inspect all parts before assembling.
1. Place the 52296 Repair Collar around the 57319 Housing and secure it in a vise so that the air inlet is pointing up.
2. Install the 01469 Speed Regulator Assembly (includes o-rings) into the valve housing and secure it in place with the
95558 Retaining Ring.
3. Insert the 01449 Valve Stem so that the end with the hole fits into the 01469 Speed Regulator Assembly.
4. Install the 01464 Seal into the inlet so that it is laying flat.
5. Use a needle nose pliers to grasp the white nylon portion of the 01472 Tip Valve and insert the metal pin of the tip valve into
the hole of the 01449 Valve Stem.
6. Install the 01468 Spring so that the smaller end of the spring fits against the center of the tip valve.
7. Place the 01543 Air Control Ring against the air inlet opening of the 57319 Housing.
8. Install the 01468 Spring so that the smaller end of the spring fits against the center of the tip valve.
9. Note: Refer to the exploded view of the muffler assembly to identify the parts and their order of assembly. Apply a small
amount of the octite #567 (or equivalent) to the threads of the inlet adapter and install it into the air inlet of the valve housing.
(Torque to 23 N•m/200 in.-lbs.)
10. Install the throttle lever and secure it in place with the 12132 Pin.
11. Use two wrenches when installing the air fitting. Place one wrench on the 94523 Inlet Adapter to hold it stationary and use
another wrench to install the air fitting.
Motor Assembly:
1. Place the hex end of the 57069 Balancer Shaft on the table of the 96232 Arbor Press (#2).
2. Install the 95628 Bearing Shield onto the balancer shaft so that the concave side is facing up.
3. Install the 56053 Bearing Seal onto the balancer shaft so that it fits down past the step on the balancer shaft.
4. Apply a small amount of the octite #271 (or equivalent) to the bearing surface of the balancer shaft.
5. Position the 56052 Bearing Press Tool to press the bearing down to the step of the 57069 Balancer Shaft.
6. Apply a small amount of octite #609 (or equivalent) to the outer diameter of the 56052 Bearing and install the balancer
bearing assembly into the 57422 Motor Shaft Balancer.
7. Important: To avoid injury it is best to hold the counter balance in a vise when the 95630 Snap Ring is being installed. Use a
small thin screwdriver to install the snap ring. Install the 95630 Snap Ring between the hex end of the balancer shaft and the
95628 Bearing Shield. The snap ring must fit into the groove in the motor shaft balancer.
(continued on next page)
M t r Assembly/Disassembly Instructi ns – 3" Dynabuffer
Important: anufacturer’s warranty is void if tool is disassembled before warranty expires.
Notice: All of the special repair tools referred to in these instructions can be ordered from Dynabrade. The 96525 Tool Repair Kit is available and the items
contained in this kit are shown on the back of this parts page. Please refer to this parts page for proper part identification.
57091
Bearing Press Tool
Balancer Shaft
Assembly
Motor Shaft
Balancer
57088 Bearing
51366
Front Bearing Plate
Drawing 3
57091Bearing
Press Tool
Balancer Shaft
Assembly
Motor Shaft
Balancer
51366 Front
Bearing Plate
(with 57088 Bearing)
51367 Rear Bearing
Plate (with 01206
Bearing)
53858 Cylinder
Assembly.
(w/Rotor and Vanes)
Line-Up Pin
Drawing 4
57091
Bearing Press Tool
Balancer Shaft
Assembly
56052 Bearing
Shaft Step
Bearing Seal and
Bearing Shield
Drawing 1
Balancer Shaft
Assembly
Motor Shaft
Balancer
57088 Bearing
57091
Bearing Press Tool
Drawing 2

M t r Assembly/Disassembly Instructi ns – 3" Dynabuffer (c ntinued)
8. Use the larger end of the 57091 Bearing Press Tool to press the 57088 Bearing down to the top of the counter weight of the 57422 Motor Shaft Balancer. Also install the
51366 Bearing Plate in the same manner.
9. Install the 56047 Key into the 57422 Motor Shaft Balancer.
10. Install the 57113 Rotor/Blade Set (5/pkg.). Apply the 95842 Dynabrade Air ube (10W/NR or equivalent) to the vanes.
11. Position the 58358 Cylinder Assembly so that the short line-up pin side fits against the 51366 Bearing Plate.
12. Install the 51367 Bearing Plate and the 01206 Bearing onto the 57422 Motor Shaft Balancer. Note: The 01206 Bearing is a slip fit into the 51367 Bearing Plate. Use the
smaller end of the 57091 Bearing Press Tool to press the bearing/plate down only until the 51367 Bearing Plate comes in contact with the 58358 Cylinder Assembly. This
should create a snug fit between the bearing plates and the cylinder.
13. Install the 95626 Retaining Ring with retaining ring pliers so that the curve of the ring is arched up. Press the ring down into the groove at the top of the motor shaft balancer.
14. Install the 56046 ock Ring with the 50659 O-Ring over the counter balance of the motor shaft balancer so that the o-ring fits against the 51366 Bearing Plate. Apply a
small amount of the octite #567 (or equivalent) to the threads of the lock ring.
15. Apply the 95842 Dynabrade Air ube (10W/NR or equivalent) to the 58357 Cylinder Seal and install it into the side of the cylinder.
16. Carefully install the motor assembly into the 02099 Housing so that the 98462 Pin fits into the line-up hole on the inside of the housing. Note: Grasp the motor assembly
by the counter balance while applying pressure against the 56046 ock Ring with the tips of your thumb and index finger. Align the 98462 Pin with the hole on the inside of
the 02099 housing and carefully insert the air motor into the housing until the lock ring comes in contact with the internal threads of the 02099 Housing. Using your finger
tips, turn the lock ring clockwise into the housing. If resistance is felt, stop and realign the motor assembly. If the motor assembly is aligned correctly the lock ring and the
motor should advance into the housing easily. Before the lock ring and motor are tightened all the way into the housing. Use the 56058 ock Ring Tool to thread the 56046
ock Ring into the 02099 Housing. Use the 57092 Repair Collar to hold the 02099 Housing in a vise when securing the lock ring. (Torque to 28 N•m/250 in.- lbs.)
17. Add 2-3 drops of octitie #380 (or equivalent) to housing thread. Install 51361 Shroud. (Torque to 11.3 N•m/100 in.- lbs.)
otor Assembly Complete. Tool Assembly Complete.
Throttle Positioning Procedure:
1. Place the 52296 Repair Collar around the valve housing and secure it in a vise so that the 02099 Housing is pointing up.
2. Slip the 01547 Collar down onto the valve housing to expose the 01461 ock Nut.
3. With a firm hold on the 02099 Housing, use a 34mm or an adjustable wrench to turn the 01461 ock Nut counterclockwise to loosen the 02099 Housing from the valve housing.
4. Remove 01461 ock Nut fully from 02099 Motor Housing and 57319 Valve Housing. Clean the threads on both housings and the 01461 ock Nut to remove oil and thread
lock residue.
5. Ensure 95523 O-Ring is still in place on the 01470 Insert Assembly. Apply octite #243 (or equivalent) to the threads on both the valve housing and the motor housing.
Assemble the lock nut onto the valve housing clockwise and then assemble onto the motor housing counterclockwise.
6. Orient the throttle lever to the operators desired grip and positioning. Note: Allow for additional rotation of the 02099 Housing as the 01461 ock Nut is tightened.
7. With a firm hold on the 02099 Housing to reduce its rotation, use a 34mm or an adjustable wrench to tighten the 01461 ock Nut. (Torque to 45 N•m/400 in.- lbs.)
Important: Carefully perform this procedure so as not to entirely separate the 02099 Housing from the valve housing. Loosen the 01461 Lock Nut only enough to
make the desired throttle lever adjustment.
Note: Motor should operate at between 9,000 and 11,000 RPM free speed with 80 PSIG of air at the inlet of the tool. RPM should be checked with a tachometer. Before
operating, we recommend that 2-3 drops of Dynabrade Air ube P/N 95842 (or equivalent be placed directly into the air inlet with throttle lever depressed. Operate the machine
for approximately 30 seconds before application to workpiece to determine if machine is working properly and safely and to allow lubricating oils to properly dispense
through machine. octite®is a registered trademark of the octite Corp.
Disc P d Ch nge:
1. Insert 59293 Wrench on flats of 57069 Balancer Shaft and twist off sanding pad by hand.
2. With wrench still in place, hand tighten new pad on tool.
3. No need to remove shroud.
Opti nal Access ries
96537 otor Tune-Up Kit
•
Includes assorted parts to
help maintain and repair motor.
52296 Repair Collar
•Specially designed collar for use in vise to
prevent damage to valve body during
disassembly/assembly.
57092 Repair Collar
•Specially designed collar for use in vise to
prevent damage to motor housing during
disassembly/assembly.
57091 Bearing Press Tool
•Use with a #2 arbor press to achieve
accurate press of bearings and motor parts.
96525 Tool Repair Kit
•Includes special tools for proper
disassembly/assembly of the tool.
•Includes all above listed tools.
56058 Lock Ring Wrench
•ock Ring Tool has a 3/8 in. square socket
for use with 3/8 in. drive; breaker bar,
ratchet head, or torque wrenches.
80030 Training & aintenance Test Equipment Kit: Includes 80025 Load Cell, 94315 Pressure Gage, 95842 Air Lube and 96368 Tachometer.
odel otor otor Air Inlet aximum Air Flow Air Pressure Spindle Weight Length Height
Number hp (W) RP Thread SCF (LP ) PSIG (Bars) Thread Pound (kg) Inch (mm) Inch (mm)
57126 .2 (149) 10,000 1/4" NPT 23 (651) 80 (5.5) 5/16"-24 female 2.0 (.91) 8-5/16 (211) 3-3/4 (96)
Additional Specifications: Hose I.D. Size 3/8" (10mm) • Visit dynabrade.com for your model’s vibration and sound data.
DYNABRADE, INC. www.dynabrade.c m
8989 Sheridan Drive •Clarence, NY 14031-1419 •Phone: [phone] •Fax: [phone] •International Fax: [phone]
© DYNABRADE, INC., 2018
REFERENCE CONTACT INFORMATION
American Na ional S andards Ins i u e (ANSI) • www.ansi.org
25 West 43 Rd St., 4th Floor • New ork, N 10036 • Tel: [phone]
Compressed Air & Gas Ins i u e (CAGI) • www.cagi.org
1300 Sumner Ave. • Cleveland, OH 44115
Tel: [phone]
European Commi ee for S andards (PNEUROP) • www.pneurop.org
rue de Drapiers 21 • 1050 Brussels, Belgium
In erna ional Organiza ion for S andardiza ion (ISO)
www.iso.org • PO Box 56 • Ch-1211 Geneve 20, Switzerland
U.S. Governmen Publishing Office (GPO) • www.gpo.gov
Superintendent of Documents
732 North Capitol Street NW • Washington, DC 20401
Tel: [phone]