Dynabrade 51602 User manual

29
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.
Air Motor and Machine Parts
Metric Wet Sander/Polisher
Index Key
No. Part Description
2 50963 Retainer
3 50899 Shaft Seal
4 07181 Spindle Assy.
5 50887 Bearing
6 50997 Bevel Gear - 2,000 RPM
50996 Bevel Gear - 3,100 RPM
7 96306 Shim (as req.)
8 96307 Shim (as req.)
9 02048 Wick
10 96325 Shell Bearing
11 53163 Handle Assy.
12 50981 Head Assy.
13 96324 Shaft Seal
14 50988 Inlet Block
15 50989 Spindle Cover
16 95759 Close Nipple
17 95760 Coupling
18 95761 Needle Valve
19 95841 Ferrule (Inc. 95761 Valve)
20 95939 Retaining Ring
21 52158 Bevel-Pinion-2,000 RPM
52124 Bevel-Pinion-3,100 RPM
22 01266 Bearing
23 50435 Key
24 50985 Pinion Shaft
25 07154 Shim (as req.)
26 07155 Shim (as req.)
27 50986 Spacer
28 53551 Coupling Nut
29 50951 Coupler
30 50956 Adapter
31 50987 Lock Ring
32 50970 Gear Casing Assy.
33 04014 Screw
34 02552 Bearing
35 53191 Ring Gear
36 53180 Planetary Carrier
37 53193 Gear
38 53182 Gear Shaft
39 01007 Bearing
40 01121 Shim Pack (as req.)
41 53183 Front Bearing Plate
42 01010 Spacer
43 04017 Rotor
44 01185 Blades (4)
45 01028 Cylinder
46 50767 Pin
47 01721 Rear Bearing Plate
48 02649 Bearing
49 53175 Collar
50 51618 Housing - 51602
51619 Housing - 51603
51620 Housing - 51604
51621 Housing - 51605
51 01477 Valve Stem
52 01089 Throttle Lever
53 01017 Spring Pin
54 95558 Retaining Ring
55 95730 O-Ring
56 01247 Speed Regulator
57 01024 O-Ring
58 01464 Seal
59 01472 Tip Valve
60 01468 Spring
Models:
51602 – 2,000 RPM Basic
51603 – 3,100 RPM Basic
51604 – 2,000 RPM Deluxe
51605 – 3,100 RPM Deluxe
L
T
O
Loctite/Hernon:
L2= Loctite #567 L4= Loctite #567
Torque: N•m x 8.85 = In. - lbs. T2= 17 N•m, T3= 23 N•m,
T4= 28 N•m, T5= 34 N•m, T6= 45 N•m
G
Oil 95542 Grease W94848 Gear Oil
O
L4
T3
KEY
2
3
4
5
7
89
10
12
14
6
15
16 17 18 19
11
20
21
22
24
23
25
26 27 22
28
13
30
31
32
33
35
36
38 34
39
41
40
42
43
44
45
47
46
48
49
50
52
53
51
54
55 56
57
58
59
60
61
62
63
64 65
66
67
69
68
71
Index Key
No. Part Description
61 01564 AIr Control Ring
62 95438 O-Ring
63 95711 Retaining Ring
64 94521 Muffler Base
65 94528 Muffler
66 94522 Muffler Cap
67 95375 O-Ring
68 94526 Spacer
69 94523 Inlet Adapter
70 94519 Muffler Assy.
71 96323 Air Line Assy.
72 95884 Hose Clamp
73 96302 Exhaust Hose Assy.
74 96303 Basic Wet Assy.
75 95955 Hose
76 95962 Quick Coupler
77 95963 Female Connector
78 95965 Valve Assy.
79 95964 Hose Bib Assy.
80 96298 Deluxe Water Line Assy.
81 95579 Waterline Assy.
82 95430 Fitting
Deluxe Models incl. #74 and #80
83 04026 Bearing (4)
70
80
T5L4
W
L4
L2T2
L4 L4
L2
T2
T6
L4
L4
T4
G
L4
O
72
73
74
75 76 77 78
79
81
37
83
34
PD17.06
January, 2017
Supercedes PD99.12

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 air tools must be used with a Filter-Regulator-Lubricator to maintain all warranties.
Operating Instructions:
Warning: Eye, face 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.
4. Check tool speed with tachometer. If tool is operating at a higher speed than the RPM marked on the tool or operating improperly, the tool should be
serviced to correct the cause before use.
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 air motors should be lubricated. Dynabrade recommends one drop of air lube per minute for each 10 SCFM (example : if the tool
specification state 40 SCFM, set the drip rate of your filter-lubricator at 4 drops per minute). Dynabrade Air Lube (P/N 95842: 1pt. 473ml.) is recommended.
4. An air line filter-regulator-lubricator must be used with this air tool to maintain all warranties. Dynabrade recommends the following: 11411 Air Line Filter-
Regulator-Lubricator — Provides accurate air pressure regulation, two-stage filtration of water contaminants and micro-mist lubrication of pneumatic
components. Operates up to 100 CFM @ 100 PSI has 1/2" NPT female ports.
5. Lubricate planetary gears through 50970 Gear Casing grease fitting ever 50 hours of use for maximum gear life.
6. Lubricate 02048 Wick System through angle gear head grease fitting ever 8 hours of use for maximum gear life. Important: Use recommended
angle gear oil only for wick system. Do not contaminate wick with any other oil or grease product (Order 95848 Gear Oil and 95541 Gun).
7. Use only genuine Dynabrade replacement parts. To reorder replacement parts, specify the Model #, Serial # and RPM of your machine.
8. A motor tune-up kit (P/N 96178) 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.
9. A lubrication accessory kit (P/N 50790) is available which contains Dynabrade's 95542 Grease, 95541 Lubrication Gun (2) and 95848 Gear Oil.
10. 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.
• Important: User of tool is responsible for following accepted safety codes such as those published by the American National Standards Institute (ANSI).
• Operate machine for one minute before application to workpiece to determine if machine is working properly and safely before work begins.
• 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.
• Warning: Hand, wrist and arm injury may result from repetitive work, motion and overexposure to vibration.
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.
2
Model Length Height Weight Air Flow Rate Sound Motor Motor Air Pressure
Number Inch (mm) Inch (mm) Pound (N) SCFM (LPM) Level HP (W) RPM PSI (BArs)
51602 13.0" (330) 4"(102) 5.4 (24) 43 (1218) 82 dBA .7 (522) 2,000 90 (6.2)
51603 13.0" (330) 4"(102) 5.4 (24) 43 (1218) 80 dBA .73 (522) 3,100 90 (6.2)
51604 13.0" (330) 4.6"(117) 7.9 (35) 43 (1218) 79 dBA .7 (522) 2,000 90 (6.2)
51605 13.0" (330) 4.6"(117) 7.9 (35) 43 (1218) 79 dBA .73 (522) 3,100 90 (6.2)
Additional specifications: Air Inlet Thread 1/4" (6 mm) NPT • Hose Size 3/8" (9 mm)

Disassembly/Assembly Instructions - Sander / Polisher
Important: Manufacturer’s warranty is void if tool is disassembled before warranty expires.
Please refer to parts breakdown for part identification.
Motor and Gear Casing Disassembly:
1. Important: inlet adapter must be secured before attempting to remove air fitting to avoid damaging composite motor housing.
2. Disconnect tool from power source, and secure motor housing, using the two molded flats, in a padded vise.
3. Remove 50970 Gear Casing Assembly using 40mm wrench flats provided.
4. Remove 04014 Set Screw from gear casing.
5. Push 50956 Hex Adapter through 50970 Gear Casing Assembly.
6. Remove 02552 Bearing from planetary assembly (opposite end from hex adapter).
7. Remove 53191 Ring Gear and spur gears from 53180 Planetary Carrier.
8. Secure planetary carrier in vise and remove 50956 Hex Adapter. Press carrier through 02552 Bearing.
9. Grab onto pinion gear and pull 53169 Motor Assembly from motor housing.
10. Secure 01028 Cylinder and press 04017 Rotor through 01721 Rear Bearing Plate.
11. Press 04017 Rotor through 53183 Front Bearing Plate and remove 01010 Spacer, 01007 Bearing and shims.
Motor Disassembly complete.
Motor Housing Disassembly:
1. Secure motor housing, using the two molded flats in a padded vise, with the air inlet facing upwards.
2. Remove 94519 Muffler assembly from motor housing.
3. Remove 01564 Air Control Ring, 01468 Spring, 01472 Tip Valve and 01464 Seal from motor housing.
4. Using a 2.5mm drift pin, tap 01017 Spring from housing and remove 01089 Throttle Lever and 01477 Valve Stem.
5. Remove 95558 Retaining Ring. Push 01247 Speed Regulator Assembly from housing.
Motor housing disassembly complete.
Right-Angle Housing and Spindle Disassembly:
1. Secure housing in a padded vise, and remove 50987 Lock Ring (left-hand thread) using 44mm wrench flats.
2. Remove 50951 Coupler and pull 53351 Coupling Nut and pinion assembly from housing.
3. Secure pinion in a padded vise and remove 53551 Coupling Nut, remove 01266 Bearing, 50986 Spacer and shims.
4. Secure 01266 Bearing and push 50985 Pinion Shaft through pinion and bearing, remove 50435 Key.
5. Secure housing in a padded vise with spindle facing upwards.
6. Remove 50963 Retainer using an adjustable pin wrench (left-hand thread).
7. Pull spindle assembly from angle-housing. Remove shims and 02048 Wick from housing.
8. Secure 50887 Bearing and push spindle through bevel gear and bearing.
9. Remove 96325 Shell Bearing using 57099 Bearing Puller.
Angle-Housing disassembly complete.
Motor and Gear Casing Reassembly:
Important: Be sure parts are clean and in good repair before reassembly. Follow all grease, oil, and torque specifications.
1. Place 04017 Rotor in padded vise with threaded spindle facing upwards.
2. Slip 01010 Spacer onto 04017 Rotor.
3. Place a .002" shim into 53183 Front Bearing Plate as an initial spacing and slip 01007 Bearing into plate. Note: 01121 Shim Pak contains .001"
and .002" shims.
4. Press bearing/bearing plate assembly onto rotor.
5. Check clearance between rotor and bearing plate by using a .001" feeler gauge. Clearance should be at .001" to .0015". Adjust clearance by repeating
steps 2-4 with different shim if necessary.
6. Once proper rotor gap clearance is achieved, install well lubricated 01185 Blades (4) into rotor slots. Dynabrade recommends using their 95842 Air Lube.
7. Install cylinder over rotor/pinion. Be sure air inlet holes of cylinder face away from 53183 Front Bearing Plate.
8. Press 02649 Rear Bearing into 01721 Rear Bearing Plate. Press bearing/bearing plate assembly onto rotor. Be sure that pin and air inlet holes line up
with pin slot and air inlet holes in cylinder.
Important: Fit must be snug between bearing plates and cylinder. If too tight, rotor will not turn freely. Rotor must then be lightly tapped at press fit end so
it will turn freely while still maintaining a snug fit. A loose fit will not achieve the proper preload of motor bearings.
10. Secure motor housing in padded vise so motor cavity faces upwards. Install motor assembly into housing. Be sure motor inlet is facing the handle and it
drops all the way into housing
11. Press front 02552 Bearing onto front end of 53180 Planetary Carrier.
12. Apply #271 Loctite® to 50956 Hex Adapter and install onto 53180 Planetary Carrier (torque 17.0 N•m/150 in. - lbs.).
13. Install 53193 Gears, 04026 Bearings and 53182 Gear Shafts onto planetary carrier.
14. Slip 53191 Ring Gear over gears and press rear 02552 Bearing onto planetary carrier.
15. Install planetary carrier assembly into 50970 Gear Casing by aligning the slot in 53191 Ring Gear with set screw hole.
16. Apply #567 Loctite (or equivalent) to 04014 Set Screw and install into 50970 Gear Casing.
17. Apply two drops of #271 Loctite adhesive to motor housing threads.
18. Install gear casing sub-assembly onto motor housing to secure motor, torque 28 N•m/250 in-lbs.
3

Disassembly/Assembly Instructions - Sander / Polisher (continued)
Motor Housing Reassembly:
1. Insert 01247 Regulator with o-rings and valve stem, place into motor housing. Secure with 95558 Retaining Ring.
2. Secure valve body in padded vise with inlet facing upwards. Insert 01464 Seal.
3. Line up hole in valve stem with hole in housing (looking past brass bushing). Insert 01472 Tip Valve so that the metal pin passes through the hole in the
valve stem. Install 01468 Spring (small end towards tip valve).
4. Assemble felt muffler and place in 94522 Muffler Cap. Install 94521 Muffler Base onto muffler cap.
5. Install 94538 O-Ring into groove on muffler base. Place 95375 O-Ring and 94526 Spacer into recessed area of muffler cap.
6. Slip 94523 Inlet Adapter through muffler assembly and install 95711 Retainer Ring into groove on inlet adapter.
7. Install 01564 Air Control Ring into valve body housing.
8. Apply #567 Loctite Pipe Sealant to threads of 94523 Inlet Adapter and install entire muffler assembly onto valve body (torque 23.0 N•m/200 in-lbs.).
9. Replace air fitting. Secure inlet adapter with a wrench before tightening air fitting. Install throttle lever and 01017 Pin.
Right-Angle Housing and Spindle Reassembly:
1. Secure 50985 Pinion Shaft in padded vise with key slot end up. Install 02552 Bearing onto pinion shaft.
2. Press pinion gear onto pinion shaft with 50435 Key in key slot. replace 95939 Retaining Ring.
3. Secure pinion in padded vise and install 50986 Spacer, 01266 Bearing and 53551 Coupling Nut.
4. The 50986 Spacer must fit snug between the two 01266 Bearings (shim required to achieve a snug fit).
5. Apply #271 Loctite adhesive to spindle thread and install 53551 Coupling Nut (torque 17 N•m/150 in-lbs.).
6. Install 96235 Shell Bearing into angle housing and insert pinion/shaft assembly.
7. Apply #567 Loctite to angle housing and install 50987 Lock Ring (left-hand thread, 44mm wrench flats).
8. Insert 50951 Coupling over 53551 Coupling Nut.
9. Install 50987 Lock Ring and angle housing sub-assembly onto 50970 Gear Casing. Take care in the aligning of the two male hex adapters to the 50951
Coupling (torque 45 N•m/400 in-lbs.).
10. Press 50887 Bearing and bevel gear onto spindle assembly.
11. Secure angle housing with drive spindle cavity facing upward and install well lubricated 02048 Wick (wick must be completely saturated with 95848 Gear
Oil before installation). Note: Do not contaminate wick with any other oil or grease product.
12. Insert spindle assembly and check for gear alignment and backlash. Install shims as required (Minimum backlash is recommended for maximum gear life.
Make sure there is clearance throughout 360° revolution.).
13. Install 50963 Retainer with 50899 Shaft seal in place (left-hand thread), torque 34 N•m/300 in-lbs.
Tool Assembly is complete. Please allow 30 minutes for adhesives to cure before operating tool.
Important: Motor should now be tested for proper operation at 90 PSI. If motor does not operate properly or operates at a higher RPM than marked on the
tool, the tool should be serviced to correct the cause before use. Before operating, place 2-3 drops of Dynabrade Air Lube (P/N 95842) directly into air inlet
with throttle lever depressed. Operate tool for 30 seconds to determine if tool is operating properly and to allow lubricating oils to properly penetrate motor
Loctite® is a registered trademark of Loctite Corp.
Accessories
96178 Motor Tune-Up Kit
• Includes assorted parts to help
maintain motor in tip-top shape.
50984 Top Handle Assy.
Dynabrade Air Lube (10W/NR)
• Formulated for pneumatic equipment.
• Absorbs up to 10% of its weight in water.
• Prevents rust and formation of gum/sludge for longer tool
operation with greater power and less downtime.
95821: 4 oz. (118 ml). 95842: 1 pt. (473 ml).
95843: 1 gal. (3.8 l).
Dynabrade Angle Gear Oil
• Specifically formulated for to saturate wick system in right
angle gear head.
95848: 2 oz. tube
95849: 10 oz. tube
50790 Dynabrade Lubrication Accessory Kit
• Includes: 95848: Gear Oil 2 oz. tube,
95842: Grease 1 pt. (473 ml).
95541: Lubricant Gun (2)
50679 - 26mm Wrench 57099 Bearing Puller
Grease
• Multi-purpose grease for all types of bearings, cams, gears.
• High film strength; excellent resistance to water, steam, etc.
• Workable range 0° F to 300° F.
95541: Push-type Grease Gun (one-hand operation).
95542: 10 oz. (283.5 g) tube.
DYNABRADE
®
DYNABRADE, INC., 8989 Sheridan Drive • Clarence, NY 14031-1490 • Phone: [phone] • Fax: [phone] • International Fax: [phone]
© DYNABRADE, INC., 2017 PRINTED IN USA
Visit our new Web Site at http://www.dynabrade.com