Dynabrade Dynalocke 52760 Guide

SAFETY INSTRUCTIONS
Carefully Read all instructions before operating or servicing any Dynabrade®Abrasive Power Tool.
Products offered by Dynabrade are not to be modified, converted or otherwise altered from the original design.
Tool Intent: 5" & 6" Dynalocke®Head Sanders are ideal for material removal and surface preparation using abrasive discs with appropriate back-up pads.
Do Not Use Tool For Anything Other Than Its Intended Applications.
This power tool is not intended for use in potentially explosive atmospheres and is not insulated against contact with electrical power.
Training: Proper care, maintenance, and storage of your air tools will maximize their performance.
• Employer's Responsibility – Provide 5" & 6" Dynalocke®Head Sanders operators with safety instructions and training for safe use of tools and accessories.
Accessory Selection:
•Warning: DO NOT use cut-off wheels, saw blades, grinding wheels or flap discs. See tool intent for recommended accessory.
• Follow tool specifications before choosing size and type of accessory.
• Back-up Pad/Abrasive RPM (speed) rating MUST be approved for AT LEAST the tool RPM rating.
• Only use recommended fittings and air line sizes. Air supply hoses and air hose accessories must have a minimum working pressure of 150 PSIG (10 Bars, g) or 150 percent of the maximum
pressure produced in the system, whichever is higher. (See Machine Specifications table on back cover.)
(continued on next page)
Parts Page Reorder No. PD10•06
Effective January, 2010
1.3 hp, 5" & 6" Dynalocke
®
Head Sanders
Air Tool Manual – Safety, Operation and Maintenance
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
Air line hazard, pressurized supply lines and flexible
hoses can cause serious injury. Do not use damaged,
frayed or deteriorated air hoses and fittings.
SAVE THIS DOCUMENT, EDUCATE ALL PERSONNEL
SAFETY LEGEND
WARNING
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.
Read and understand this tool manual before operating your air tool. Follow all safety rules for the protection of operating personnel
as well as adjacent areas. Always operate, inspect and maintain this tool in accordance with the American National Standards
Institute (ANSI) Safety Code for Portable Air Tools – B186.1. For additional 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, European Committee for
Standards (EN) Hand Held Non-Electric Power Tools – Safety Requirements and applicable State and Local Regulations.
WARNING
Some dust created by grinding, sanding, 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.
FIND THE MOST CURRENT OFFERING OF SUPPORT DOCUMENTS AND ACCESSORIES @ WWW.DYNABRADE.COM
Model 52760
Shown
Model RPM Pad Size Pad Style Spindle
52760 12,000 5" Hook-Face 5/8"-11
52761 12,000 6" Hook-Face M14 x 2
52762 12,000 6" Hook-Face 5/8"-11

To Tool Station
Closed Loop Pipe System
(Sloped in the direction of air flow)
Ball
Valve
Ball
Valve
Filter
Regulator
Lubricator
Air Flow
Drain
Valve
Drain
Valve
Air Compressor
and Receiver
Drain Valve
Air Hose
Air Flow
Refrigerated
Air Dryer
2
OPERATING INSTRUCTIONS
Warning: Always wear eye protection. Operator of tool is responsible for following: accepted eye, face, respiratory, hearing and body protection.
Caution: Hand, wrist and arm injury may result from repetitive work, motion and overexposure to vibration. Vibration level was established using ISO 8662-8.
5" Models: Vibration level (m/s^2): 3.38 with a 100 gram back-up pad attached. 6" Models: Vibration level (m/s^2): 3.55 with a 125 gram back-up pad attached.
Warning: Be sure that any loose clothing, hair and all jewelry is properly restrained.
• Keep hand and clothing away from working end of the air tool which has a potential hazard of cutting and severing.
• Secure inlet bushing on air tool with a wrench before attempting to install the air fitting to avoid damaging housing assembly.
• BEFORE MOUNTING DYNALOCKE®SANDING HEAD ASSEMBLY, after all tool repairs and whenever a sander is issued for use, check tool RPM (speed) with tachometer with air pressure set at 90
PSIG while the tool is running. If tool is operating at a higher speed than the RPM marked on the tool housing, or operating improperly, the tool must be serviced and corrected before use.
Warning: Back-up pad speed rating must be approved for at least the tool RPM rating. Check accessory manufacturer for details on maximum operating speed or special mounting instructions.
• Connect tool to air source. Be careful NOT to depress throttle lever in the process. Do not expose air tool to inlet pressure above 90 PSIG or (6.2 Bars).
Warning: After installing the back-up pad/abrasive, make sure that no one is in the unguarded plane before starting the sander. IN A PROTECTED AREA, test run the sander at a reduced speed to
check for good balance. Gradually increase tool speed. DO NOT USE if tool vibration is excessive. Correct cause, and retest to insure safe operation. Test sander at its free speed (RPM) in a protected
area for at least one minute before use.
Warning: Use only appropriately sized abrasive sanding discs properly secured and centered to the backing pads provided with the air sander.
• Release throttle lever when air supply is interrupted.
• DO NOT engage spindle lock while spindle is rotating.
• Make sure that work area is uncluttered, and visitors are at a safe range from the tools and debris.
• Air tools are not intended for use in explosive atmospheres and are not insulated for contact with electric power sources.
• Use a vise or clamping device to hold work piece firmly in place.
• Do not apply excessive force on tool or apply "rough" treatment to it.
• Always work with a firm footing, posture and proper lighting.
• Ensure that sparks and debris resulting from work does not create a hazard.
• Always be aware of bystanders in work areas.
• This tool has side exhaust, rotate muffler cover by hand to desired exhaust direction. Exhaust may contain lubricants, vane material, bearing grease, and other materials flushed through the tool.
Warning: Sanding certain materials can create explosive dust. It is the employers responsibility to notify the user of acceptable dust levels.
• Always use dust extraction or suppression systems and personal protective equipment which are suitable for the materials being processed.
• Sanding can cause sparks which can cause fires or explosions. It is the users responsibility to make sure the work area is free of flammable materials.
• Use side handle provided to best control tool during sanding.
Report to your supervisor any condition of the tool, accessories, or operation you consider unsafe.
Air System
1DROP/MIN.
20 SCFM
LUBRICATOR SETTING
• Check all connections and air hoses for good condition
and proper installation.
• Dynabrade Air Power Tools are designed to operate at
90 PSIG (6.2 Bar/620 kPa) maximum air pressure at the
tool inlet, when the tool is running. Use recommended
regulator to control air pressure.
• Ideally the air supply should be free from moisture.
To facilitate removing moisture from air supply, the
installation of a refrigerated air dryer after the
compressor and the use of drain valves at each
tool station.
➤➤
➤
➤
➤
➤
Back-Up Pad/Abrasive Mounting
• Disconnect air source from the tool.
• Clean Stud Washer and Dynalocke®Sanding Head mounting surfaces. Inspect for
nicks, cuts, sharp edges, and thread wear.
• Install back-up pad onto Dynalocke Sanding head with stud secured. Stud should be
fully threaded into Dynalocke®Sanding Head.
• Tighten stud of pad onto Dynalocke®Sanding Head.
• Check mounting by rotating spindle, make certain abrasive disc is concentrically
mounted and back-up pad is not excessively warped.
Side View
90 PSIG MAX
(6.2 Bar)
Air Tool
Tool Spindle
Abrasive Disc Stud
Dynalocke®Sanding Head
1/8" MAX. Overhang
of Abrasive Disc
Back-Up Pad

Maintenance Instructions
Important: To keep tools safe a Preventative Maintenance Program is required whenever portable power tools are used. The program shall include
inspection of air supply lines, air line pressure, proper lubrication and repair of tools. Refer to ANSI B186.1 and EN 792 for additional maintenance information.
• Use only genuine Dynabrade replacement parts to insure quality. To order replacement parts, specify Model#, Serial# and RPM of your air tool.
• It is strongly recommended that all Dynabrade rotary vane air tools be used with a Filter-Regulator-Lubricator to minimize the possibility of misuse due
to unclean air, wet air or insufficient lubrication. Dynabrade recommends the following: 10681 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 55 SCFM @ 100
PSIG has 1/2" NPT female ports.
• Lubricate wick system through the angle gear oil fitting with 2-3 plunges for every 24 hours of use, to achieve maximum gear life.
Important: Use only the recommended angle gear oil for the wick system. Do not contaminate the wick with any other oil or grease product.
(Order 95848 Gear Oil and 95541 Gun) Always prime pump to ensure good flow before lubricating gears.
• Dynabrade recommends one drop of air lube per minute for each 20 SCFM (example: if the tool specification states 40 SCFM, set the drip rate on the
filter-lubricator to 2 drops per minute). Dynabrade Air Lube (P/N 95842: 1 pt 473 ml) is recommended.
Routine Preventative Maintenance:
• Check free speed of tool using a tachometer without Dynalocke®Sanding Head Assembly attached with 90 PSIG at inlet while tool is running. This
governor controlled tool should be speed checked every 20 hours of use or weekly, whichever occurs more frequently. Always check tool speed after any
maintenance or repair.
• Take special care when performing any maintenance to the governor, the governor is preset at the factory to maintain the maximum rated speed for the
tool, if any inconsistency is found in the operating speed the tool must not be used and must be further tested.
• Inspect pad backing for excessive wear, nicks, cracks and cuts at the pad edges. Do not use pads that show excessive wear.
Check pad backing for concentricity.
• Visually inspect abrasive discs for nicks, cuts, tears at the edges. Abrasive disc with a curved shape indicates improper storage. Do not use abrasives that
show these characteristics.
• Mineral spirits are recommended when cleaning the tool and parts. Do not clean tool or parts with any solvents or oils containing acids, esters,
ketones, chlorinated hydrocarbons or nitro carbons.
• DO NOT clean or maintain tools with chemicals that have a low flash point (example: WD-40®).
• A Motor Tune-Up Kit (P/N 96100) is available which includes high wear and medium wear motor parts.
• Air tool labels must be kept legible at all times, if not, reorder label(s) and replace. User is responsible for maintaining specification information i.e.:
Model #, S/N, and RPM. (See Assembly Breakdown)
• Blow air supply hose out prior to initial use.
• Visually inspect air hoses and fittings for frays, visible damage and signs of deterioration. Replace damaged or worn components.
• Refer to Dynabrade's Warning/Safety Operating Instructions Tag (Reorder No. 95903) for safety information.
After maintenance is performed on tool, add a few drops of Dynabrade Air Lube (P/N 95842) to the air line and start the tool a few times to lubricate air motor.
Check for tool vibration before mounting abrasive wheel accessory.
Handling and Storage:
• Use of tool rests, hangers and/or balancers is recommended.
• Protect tool inlet from debris (see Notice below).
• DO NOT carry tool by air hose. When carrying tool keep hands away from throttle lever to avoid accidental startup.
• Protect abrasives accessories from exposure to water, solvents, high humidity, freezing temperature and extreme temperature changes.
• Store abrasive discs prior to use at 40-50% relative humidity and 60-80˚ F (15-27˚ C) to reduce curling.
• Store accessories in protective racks or compartments to prevent damage.
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
All Dynabrade portable pneumatic power tools are rigorously inspected and performance tested in our factory before shipping to our customers. If
a Dynabrade tool develops a performance problem and an inherent defect is found during normal use and service, Dynabrade will warrant this
tool against defects in workmanship and materials for the lifetime of the tool. Upon examination and review at our factory, Dynabrade shall confirm
that the tool qualifies for warranty status, and will repair or replace the tool at no charge to the customer. Normally wearable parts and products
are NOT covered under this warranty. Uncovered items include bearings, contact wheels, rotor blades, regulators, valve stems, levers, shrouds,
guards, O-rings, seals, gaskets and other wearable parts. Dynabrade’s warranty policy is contingent upon proper use of our tools in accordance
with factory recommendations, instructions and safety practices. It shall not apply to equipment that has been subjected to misuse, negligence,
accident or tampering in any way so as to affect its normal performance. To activate lifetime warranty, customer must register each tool at
www.dynabrade.com. Dynabrade will not honor lifetime warranty on unregistered tools. A one-year warranty will be honored on all unregistered
portable pneumatic power tools. Lifetime warranty applies only to portable pneumatic tools manufactured by Dynabrade, Inc. in the USA. Lifetime
warranty applies only to the original tool owner; warranty is non-transferable.
3

Index Key
No. Part # Description
125265 Retainer
253609 Felt Seal
325271 Spindle - 5/8" - 11
25269 Spindle - M14 x 2
401036 Bearing
598288 Shim (as required)
698287 Shim (as required)
725230 Bevel Gear Set
825264 Wick
902057 Bearing
10 98243 Wave Spring
11 25273 Plunger Assembly
(Incld 97156 Ring)
12 98285 Spring
13 Housing Assembly
(Includes: 01041 Gear Oil Fitting,
25275 Bushing)
25260 Model - 52760
25323 Model - 52761
25324 Model - 52762
14 25283 Silencer
15 25217 Muffler Assembly
16 98282 O-Ring (2mm)
17 98281 O-Ring (2.4mm)
18 25282 Silencer
19 25278 Muffler Cover
20 25281 Muffler Stem Assembly
21 53134 Vibration Dampening
Handle
22 01007 Bearing
23 01294 Shim (as required)
24 01293 Shim (as required)
25 98242 O-Ring
26 25236 Front Bearing Plate
27 01010 Spacer
28 25233 Rotor
29 25234 Vane (4/Pkg.)
30 25235 Cylinder
31 96441 Pin
32 25237 Rear Bearing Plate
33 01206 Bearing
34 98279 Pin (2)
35 25290 Governor Cage
36 25291 Governor Weight (2)
37 25293 Governor Valve
38 25294 Governor Spring
39 25298 Shim (.25 mm Thk.) (as Req.)
40 25299 Shim (.13 mm Thk.) (as Req.)
41 25292 Governor Spindle
42 25295 Pin
43 66435 O-Ring
44 25256 Governor Housing
45 25257 Cup Nut
46 12132 Pin
47 01462 Safety-Lock Lever
48 25247 Valve Stem Assembly
(Incld 96443 O-Ring)
49 25245 Throttle Handle
(Incld 25246 Bushing)
50 51945 Valve Seat
51 25249 Tip Valve
52 25250 Spring
53 96442 O-Ring
54 51940 Spacer
55 25213 Inlet Bushing
(Incld 51938 Screen (2)
56 25253 Insulating Cover
57 61326 Bolt
58 61325 Rotary Switch
59 96027 Screw - 5" Models (2)
97099 Screw - 6" Models (2)
60 61322 Housing - Model 52760
61266 Housing - Model 52761
61323 Housing - Model 52762
61 61328 Counterweight - 5 in.
61338 Counterweight - 6 in.
62 61329 Screw
63 61396 Pin
64 61397 Spring
65 61393 Pin
66 61395 Spring
67 61398 Locking Pin Bushing
68 61327 Counterweight - 5 in.
61337 Counterweight - 6 in.
69 56052 Bearing
70 59084 V-Seal
71 61324 Balancer Shaft
72 54325 5 in. Pad - Hook-Face
54327 6 in. Pad - Hook-Face
7 N•m
T
17 N•m
T
23 N•m
T
5.7 N•m
T
9 N•m
T
Adhesive: A1= Loctite #609
A3= Loctite #242
A6= Loctite #380
A8= Loctite #567
A10 = Loctite #243
Torque: N•m x 8.85 = In. - lbs.
Oil: O1= Air Lube
WWicking: W1= Gear Oil
O
A
T
KEY
A10
A10
A8
A10 A8
A6
A8
W1
Right Angle Dynalocke
®
Head Sander
Complete Assembly
4
21
14
15
8
10
6
4
5
3
1
5.7 N•m
T
5.7 N•m
T
2
7
9
7
29
27
28
30 47
46
48
49
45
44
43
50
51
52
53
54
56
41 42
39
38
37
36
34
40
31
32
33
12
11
22
24 25
26
23
16 18
17
19
25217 Muffler Assembly
Left Hand
Threads
See Label Key
Apply to
both sides
34 N•m
T
30 N•m
T
35 N•m
T
20
55
A8
25285 S/N, RPM Label
25287 Sanding Label
Label Key
Part # Description
13
35
68
60
58
61
66
Left Hand
Threads
A3
A3
A3
57
62
59
A1
72
71
69
63
64
65
A1
A867
70
Open-End Wrench
95823 – 21mm

Disassembly/Assembly Instructions - Right Angle Sanders
Important: The Manufacturing Warranty is void if the tool is disassembled before the warranty expires by anyone other than a Dynabrade®Approved Repair Technician.
Notice: A 96100 Motor Tune-Up Kit is available. Also, the special repair tooling referred to in these instructions can be ordered through your Dynabrade®
Distributor. Please refer to this tool manual for correct part number identification.
Important: Always follow these steps before servicing any part of this air tool.
1. Shut off the air supply, and depress throttle lever to dissipate the remaining air. Carefully disconnect the tool from the air supply hose.
Note: Use a wrench to hold the air tool inlet bushing stationary when removing the air supply connection.
2. Remove any abrasive product, flanging, guard, and side handle.
Motor Disassembly:
1. Use a 3mm drive punch to remove the throttle lever.
2. Roll back front edge of 25253 Insulating Cover just enough to expose wrench flats on 25257 Cup Nut.
3. Place padding around the housing and carefully hold the housing stationary in a vise. Use an adjustable wrench or 98283 Open End Wrench (sold separately) to loosen the
25257 Cup Nut. Turn counterclockwise. Note: Applying heat to cup nut will help loosen adhesive.
4. Carefully pull motor assembly out of the housing.
5. Hold pinion gear in a vise with aluminum or bronze jaws. Use an adjustable wrench or 95281 Open End Wrench (sold separately) to remove the governor
assembly. LEFT HAND THREAD Turn clockwise.
6. Fasten 96346 2" Bearing Separator around the portion of 25235 Cylinder that is closest to 25237 Rear Bearing Plate. Place the bearing separator motor on the table
of the 96232 #2 Arbor Press with pinion gear pointing downward. Use a 3/16" or 4mm diameter flat end drive punch push rotor out of the 01206 Bearing.
7. Remove the vanes from rotor and 01206 Bearing from bearing plate.
8. Fasten the vane slot portion of rotor in a vise with aluminum or bronze jaws so that the pinion gear is pointing up.
9. Use a hook/pin spanner wrench unthread pinion gear from rotor. Turn counterclockwise.
10. Remove the front bearing plate, shims and 01010 Spacer.
Motor Disassembly Complete.
Spindle/Gear Disassembly:
1. Place padding around the housing and carefully hold the housing stationary in a vise with the spindle pointing up. Use the 97782 Pin Wrench (sold separately) or an
adjustable pin wrench to remove 25265 Retainer. LEFT HAND THREAD Turn clockwise.
2. Remove 53609 Felt Seal from spindle or retainer.
3. Pull spindle and gear assembly out of the housing.
4. Fasten the 96346 2" Bearing Separator under 02057 Bearing and press spindle through bearing. Remove 25264 Wick. Remove 98243 Wave Spring from the right angle housing.
5. Fasten the 96346 2" Bearing Separator between 01036 Bearing and spiral bevel gear. Place the bearing separator along with the spiral bevel gear assembly on the table of the
96232 #2 Arbor Press so that the spindle thread is pointing down. Push the gear off the spindle.
6. Remove the 01036 Bearing the same way.
7. Remove the housing from vise.
Spindle Disassembly Complete.
Spindle Lock Disassembly:
1. Apply a small amount of the Dynabrade Air Lube 10W/NR (P/N 95842 or equivalent) around the 25273 Plunger Assembly.
2. Place padding around the housing and carefully hold the housing stationary in a vise with the plunger assembly facing up.
3. Use two flat blade screwdrivers to pry the plunger assembly out of the 25275 Spindle Lock Bushing.
4. Remove the 98285 Spring and the 97156 Ring from the plunger.
Spindle Lock Disassembly Complete.
Valve Disassembly:
1. Secure 25245 Throttle Handle in a vise using wrench flats so that the 25213 Inlet Bushing pointing upward.
2. Use an adjustable wrench, unthread 25213 Inlet Bushing. Turn counterclockwise.
3. Use needle nose pliers, pull 25249 Tip Valve from handle.
4. Use a small screwdriver to remove the 96443 O-Ring from the valve stem and remove the valve stem.
5. Position 25245 Throttle Handle in the vise with 25257 Cup Nut and 25256 Governor Housing pointing up. Use a 10 mm hex key to remove the 25256 and
25257. Turn counterclockwise. Note: Applying heat to throttle handle will help loosen adhesive bond.
6. Push the 51945 Valve Seat out of the 25245 Throttle Handle.
Valve Body Disassembly Complete.
Locking Random Orbital Sanding Head Disassembly:
1. Lock Head Assembly in Orbital mode.
2. Secure flats on Head Assembly with 95823 21mm Open End Wrench.
3. Rotate pad counter-clockwise, removing pad from Head Assembly.
4. Engage Plunger on tool to lock spindle.
5. Turn wrench counter-clockwise to remove Head Assembly from tool.
6. Disassemble the balancer assembly as follows:
a. Screw the threaded portion of the 56056 Bearing Puller into the 61324 Balancer Shaft and heat the outside of the motor shaft balancer to approximately 200˚ F/93˚ C
(approximately 10 seconds with a propane torch). Now, using the slider weight, pull the assembly out.
b. Place 96345 15/16" Bearing Separator between 56052 Bearing and 61324 Balancer Shaft.
c. Using 96214 Bearing Removal Tool and 96232 Arbor Press, press Balancer Shaft from Bearing and discard 59084 V-Seal.
7. If during step 6, the 56052 Bearing remains on the motor shaft balancer, it can be removed by heating the shaft balancer again and using either an inside bearing puller or a
blind hole bearing puller.
8. Use 95252 2.5mm Hex Key to remove 61326 Shoulder Bolt and 61325 Rotary Switch.
9. Remove 61396 Locking Pin Insert and 61397 Spring.
10. Use a HOT AIR GUN to apply heat to 61398 Locking Pin Bushing.
11. Use 96364 Large Slotted Screwdriver to remove 61398 Locking Pin Bushing.
12. Remove 61395 Switch Spring and 61393 Pin.
Locking Random Orbital Sanding Head Disassembly is complete.
Important: Clean and inspect all parts for wear before assembling. Note: Follow all lubricant, adhesive, and torque specifications.
Valve Assembly:
1. Install 96443 O-Ring onto 25247 Valve Stem. Apply Dynabrade Air Lube to 96443 O-Ring and carefully install the valve stem and o-ring assembly into the
throttle handle. Note: Rotating the valve stem while inserting prevents damage to the o-ring
2. Apply several drops of the Dynabrade Air Lube 10W/NR (P/N 95842 or equivalent) to valve seat pocket wall on the inside of the 25245 Throttle Handle before inserting the
51945 Valve Seat. Install the 51945 Valve Seat by aligning the 3 male prongs of the valve seat with three slots of the valve seat pocket in the throttle handle. Note: Use an
arbor press and the 96241 Bearing Press Tool to support the valve seat and press it into the valve seat pocket. Make certain that the valve seat lays flat.
(continued on next page)

3. Use needle nose pliers install 25249 Tip Valve into the throttle handle.
4. Install 51940 Spacer onto 25213 Inlet Bushing, followed by the 96442 O-Ring. Install the larger end of the 25250 Spring into the inlet bushing. The smaller end of the
spring fits against the back of the tip valve.
5. Apply a small amount of the Loctite®#243 (or equivalent) to the external threads of the 25213 Inlet Bushing and install it onto the throttle handle. Secure throttle handle in a
vise using wrench flats. (Torque to 35N·m/310 lbs. in.)
6. Position the throttle handle in vise with the inlet bushing pointing downward.
7. Install the 66435 O-Ring onto the 25256 Governor Housing. Apply some Dynabrade Air Lube to the o-ring. Insert the governor housing through the 25257 Cup Nut. Apply a
small amount of the Loctite®#567 (or equivalent) to the external threads of the governor housing. Use a 10 mm hex key to fasten the governor housing and cup nut onto the
throttle handle. Turn clockwise. (Torque to 34N·m/300 lbs. in.) Note: The position of the throttle lever can be adjusted to any 360˚ location.
8. Apply a few drops of Loctite®#380 (or equivalent) to both sides of the throttle handle (as shown). Install the 25253 Insulating Cover and the 01462 Throttle Lever onto
the throttle handle.
Valve Assembly Complete.
Spindle Lock Assembly:
1. Install a new 97156 Ring onto the plunger and apply a small amount of the Dynabrade Air Lube 10W/NR (P/N 95842 or equivalent) to the o-ring and plunger.
2. Install 98285 Spring onto the housing bushing and insert the 25273 Plunger Assembly through the spring.
3. Install the plunger assembly into the spindle lock bushing. Note: Rotating the plunger while inserting prevents damage to the o-ring.
Spindle Lock Assembly Complete.
Motor Assembly:
1. Install 01010 Spacer onto the rotor front mandrel.
2. Select .003" (.08mm) thickness shims from the 01121 Shim Pack and install these into the 25236 Front Bearing Plate.
3. Install 98242 O-Ring into front bearing plate groove and install 01007 Bearing, into the front bearing plate.
4. Position the rotor in a vise with aluminum or bronze jaws so that the rotor spindle is pointing up. Install the front bearing/plate onto the rotor.
5. Apply a small amount of the Loctite®#243 (or equivalent) to the external threads on the rotor stem and install the pinion gear. (Torque to 17N·m/150 lbs. in.)
Using a hook/pin spanner wrench. Remove the assembly from the vise.
6. Use a .001" (0.3mm) thick feeler gauge to check the clearance between the front bearing plate and the face of the rotor. The clearance should be .001"-.0015" (0.3-0.4mm).
Note: If the clearance needs adjustment repeat steps 2-6 adding or removing shims as required.
7. Lubricate 25234 Vanes (4) with the 95842 Dynabrade Air Lube 10W/NR (or equivalent) and install these into the rotor.
8. Install 25235 Cylinder over the rotor so that the air inlet opening of the cylinder will line up with the air inlet opening on the 25237 Rear Bearing Plate.
9. Install 01206 Bearing into 25237 Rear Bearing Plate.
10. Use the raised inner diameter of 96244 Bearing Press Tool and the arbor press to install the rear bearing plate onto the rotor.
Note: Carefully press the bearing/plate down until it just touches the cylinder. This will establish a snug fit between the bearing plates and the cylinder.
11. Fasten the pinion gear in a vise with aluminum or bronze jaws so that the rear bearing/plate pointing up.
12. Apply a small amount of the Loctite®#567 (or equivalent) to the external threads of governor assembly. Install it onto the rotor using an 19 mm crowfoot and
torque wrench. LEFT HAND THREAD Turn counterclockwise. (Torque to 9N·m/80 lbs. in.)
13. Carefully slide the motor assembly into the housing.
14. Place padding around the housing and carefully hold the housing stationary in a vise. Apply a small amount of the Loctite®#567 (or equivalent) to housing external threads.
Use an adjustable wrench tighten 25257 Cup Nut onto housing. Turn clockwise. (Torque to 30N·m/265 lbs. in.)
Important: Allow 30 minutes for the adhesives to cure before operating the tool.
Run the tool to make sure that the air motor is functioning properly before installing the right angle gears. Motor Assembly Complete.
Spindle/Gear Assembly:
1. Position the spindle in the arbor press so that the threaded end is pointing down.
2. Use a 19/32" deep well socket as a press tool, install the 01036 Bearing onto the spindle and against the step.
3. Use a 19/32" deep well socket as a press tool and install the 25241 Bevel Pinion onto the spindle.
4. Prepare the 25264 Wick by soaking in 95848 Gear Oil and then install the wick onto the spindle.
5. Press 02057 Bearing using 96243 Press Tool (sold separately) onto spindle until the spindle is flush with the bearing top.
6. Place padding around the housing and carefully hold the housing stationary in a vise with the right angle spindle opening facing up.
Important: Follow these steps to adjust the fit or “backlash” of the spiral bevel gear/pinion gear.
7. Install the spindle assembly into the housing align wick shape to housing contour. Mesh bevel and pinion gears together.
8. Apply a small amount of downward force on the spindle and rotate the spindle 360˚. The rotation should be smooth without any tight feel or binding of the gear teeth. Next,
rotate the spindle forward and backward to check the amount of backlash (free movement between the gear teeth). The correct fit should be minimal backlash without any
binding of the gear teeth. Add or remove shims to adjust the gear “backlash”.
9. Place the 53609 Felt Seal into the 25265 Retainer recess bore.
10. Apply a small amount of the Loctite®#567 (or equivalent) to the threads of the retainer and use the 97782 Pin wrench to install the retainer onto the housing.
LEFT HAND THREAD Turn counterclockwise. (Torque to 23N·m/203 lbs. in.)
11. Re-check the fit of the gears by hand before connecting the tool to the air supply. The correct fit should be minimal backlash without any binding of the gear teeth. Add or
remove shims to adjust the gear fit if necessary.
12. Use the 95541 Lubricant Gun to apply the 95848 Gear Oil Lubricant required for the lubricating wick prime the plunger before adding gear oil to housing. Inject three full
plunges of the gear oil into the 01041 Gear Oil Fitting on the front of housing.
Note: Inject three full plunges of gear oil into the lubricant fitting after operating the tool every 24-hour interval of use.
Right Angle Assembly Complete:
Muffler Assembly:
1. Install 25282 Silencer (Cross section size: 7.5 mm) up and inside recess diameter of 25278 Muffler Cover.
2. Install the 98281 O-Ring (Cross section size: 2.4 mm) into the inside groove of the muffler cover.
3. Install the 98282 O-Ring (Cross section size: 2.0 mm) into the outside groove of the muffler cover.
4. Install 25278 Muffler Cover (the side with the smaller hole) onto 25281 Muffler Stem Assembly.
5. Install 25283 Silencer (Cross section size: 13 mm) into housing cavity.
6. Apply a small amount of the Loctite®#243 (or equivalent) to the external threads of the 25281 Muffler Stem Assembly. Install the 25217 Muffler Assembly
onto the housing. Rotate 25281 Muffler Stem Assembly until slot aligns with housing raised boss. Thread socket head cap screw into housing using a 5/32" hex key
(Torque to 7N·m/60 lbs. in.).
Muffler Assembly Complete.
Locking Random Orbital Sanding Head Assembly:
1. Insert 61393 Pin into 61395 Switch Spring and then place into 61322 Housing.
2. Apply a small amount of Loctite®567 (or equivalent) to the external threads of 61398 Locking Pin Bushing.
3. Thread bushing into Housing with screw driver slot visible. Use 96364 Large Slotted Screwdriver to tighten bushing until it is fully seated.
4. Place 61397 Spring into 61393 Pin.
5. Place 61396 Locking Pin Insert in 61393 Pin and on top of 61397 Spring.
6. Apply a small amount of Loctite®242 (or equivalent) to the external threads of 61326 Shoulder Bolt.
7. Place 61325 Rotary Switch on top of 61396 thread 61326 through hole in 61325 into Housing.
8. Use 95252 2.5mm Hex Key to tighten 61326 Shoulder Bolt. (continued on page 8.)

This service chart is published as a guide to expectant life of component parts. The replacement levels are based on average tool
usage over one year. Dynabrade Inc. considers one year usage to be 1,000 hours.
Parts Common to all Models:
Preventative Maintenance Schedule
For Model All 5" & 6" Dynalocke
®
Head Sanders
Index Part Description Number High Wear Medium Wear Low Wear Non-Wear
# Number Required 100% 70% 30% 10%
125265 Retainer 1 X
253609 Felt Seal 1 X
3See Note Spindle 1 X
401036 Bearing 1 X
598288 Shim 1 X
698287 Shim 1 X
725230 Bevel Gear Set 1 X
825264 Wick 1 X
902057 Bearing 1 X
10 98243 Wave Spring 1 X
11 25273 Plunger Assembly 1 X
12 98285 Spring 1 X
13 See Note Housing 1 X
14 25283 Silencer 1 T
15 25217 Muffler Assembly 1 X
16 98282 O-Ring 1 X
17 98281 O-Ring 1 X
18 25282 Silencer 1 T
19 25278 Muffler Cover 1 X
20 25281 Muffler Stem Assembly 1 X
21 53134 Vibration Dampening Handle 1 X
22 01007 Bearing 1 T
23 01294 Shim 1 T
24 01293 Shim 1 T
25 98242 O-Ring 1 T
26 25236 Front Bearing Plate 1 X
27 01010 Spacer 1 X
28 25233 Rotor 1 X
29 25234 Vane (4/Pkg.) 1 T
30 25235 Cylinder 1 X
31 96411 Pin 1 X
32 25237 Rear Bearing Plate 1 X
33 01206 Bearing 1 T
34 98279 Pin 2 X
35 25290 Governor Cage 1 X
36 25291 Governor Weight 2 X
37 25293 Governor Valve 1 X
38 25294 Governor Spring 1 X
39 25298 Shim 1 X
40 25299 Shim 1 X
41 25292 Governor Spindle 1 X
42 25295 Pin 1 X
43 66435 O-Ring 1 T
44 25256 Governor Housing 1 X
45 25257 Cup Nut 1 X
46 12132 Pin 1 T
47 01462 Safety-Lock Lever 1 X
48 25247 Valve Stem Assembly 1 T
49 25245 Throttle Handle 1 X
50 51945 Valve Seat 1 X
51 25249 Tip Valve 1 T
52 25250 Spring 1 T
53 96442 O-Ring 1 T
54 51940 Spacer 1 X
55 25213 Inlet Bushing 1 X
56 25253 Insulating Cover 1 X
57 61326 Bolt 1 X
58 61325 Rotary Switch 1 X
59 96027 Screw 2 X
60 61322 Housing 1 X
61 61328 Counterweight 1 X
62 61329 Screw 1 X
63 61396 Pin 1 X
64 61397 Spring 1 X
65 61393 Pin 1 X
66 61395 Spring 1 X
67 61398 Locking Pin Bushing 1 X
68 61327 Counterweight 1 X
69 56052 Bearing 1 X
70 59084 V-Seal 1 X
71 61324 Balancer Shaft 1 X
72 See Note Pad 1 X
96100 – Motor Tune-Up Kit
LEGEND
TIncluded in Tune-Up Kit
XType of wear, no other
comments apply.
LEasily lost. Care during
assembly/disassembly.
DEasily damaged during
assembly/disassembly.
RReplace each time tool is
disassembled.
7
Note: Please refer to page 4 for specific part number and description.

DYNABRADE
®
DYNABRADE, INC., 8989 Sheridan Drive • Clarence, NY 14031-1419 • 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., 2010 PRINTED IN USA
Visit Our Web Site: www.dynabrade.com Email: Customer[email protected]
Optional Accessories
Dynabrade Angle Gear Oil
• Specifically formulated to saturate wick system in right
angle gear head.
95848: 2.5 oz. tube
95541: Gear Oil Gun
96100 Motor Tune-Up Kit
• Includes assorted parts to help
maintain and repair motor.
FIND THE MOST CURRENT OFFERING OF SUPPORT DOCUMENTS AND ACCESSORIES @ WWW.DYNABRADE.COM
Machine Specifications
Model Motor Motor Sound Maximum Air Flow Spindle Air Pressure Weight Length Height
Number hp (W) RPM Level SCFM (LPM) Thread PSIG (Bars) Pound (kg) Inch (mm) Inch (mm)
5" Models 1.3 (969) 12,000 84 dB(A) 43 (1218) 5/8"-11 90 (6.2) 7 (3.2) 10-1/2 (267) 5-3/8 (136)
6" Models 1.3 (969) 12,000 84 dB(A) 43 (1218) 5/8"-11 or M14 x 2 90 (6.2) 7 (3.2) 10-3/4 (273) 5-3/8 (136)
Additional Specifications: Air Inlet Thread 3/8" NPT • Hose I.D. 3/8" (10mm)
Sound Level is the pressure measurement according to the method outlined in ISO regulation ISO-15744
Apply 2-3
plunges
into lubrication
fitting every
24 hours of
operation.
Expect a gear life
of 500 hours
minimum, with
proper lubrication.
Special Greasing Instructions
• Lubricate wick system through the angle gear oil fitting with 2-3 plunges for every 24
hours of use, to achieve maximum gear life. Prime pump to insure good oil flow.
Important: Use only the recommended angle gear oil for the wick system.
Do not contaminate the wick with any other oil or grease product. Insure that all 3 plunges of
oil are injected through the fitting.
(Order 95848 Gear Oil and 95541 Gun)
Reference Contact Information
1. American National Standards
Institute – ANSI
25 West 43rd Street
Forth Floor
New York, NY 10036
Tel: [phone]
Fax: [phone]
3. Power Tool Institute, Inc.
P.O. Box 818
Yachata, Oregon 97498-0818
Tel: [phone]
Fax: [phone]
4. European Committee for Standardization
Rue de Stassart 36
B - 1050 Brussels, Belgium
2. Government Printing Office – GPO
Superintendent of Documents
Attn. New Orders
P.O. Box 371954
Pittsburgh, PA 15250-7954
Tel: [phone]
9. Place 59084 V-Seal onto shaft of 61324 Pad Balancer Shaft.
10. Apply a small amount of Loctite®609 (or equivalent) to the shaft of 61324.
11. Use 57091 Bearing Press Tool and Arbor Press to press 56052 Bearing onto 61324.
12. Apply a small amount of Loctite®609 (or equivalent) to the outside diameter of 56052.
13. Use an arbor press to press Balancer Shaft Assembly into Housing until fully seated.
14. Lock Head Assembly in Orbital mode.
15. Engage Plunger on tool to lock spindle and thread Head Assembly onto tool, with the Plunger still engaged use 95823 21mm Open End Wrench to tighten Head Assembly.
16. Replace Pad.
Locking Random Orbital Sanding Head Assembly is complete.
Final Assembly:
Important: Allow 30 minutes for the adhesives to cure before operating the tool. Install and properly position all guarding and auxiliary side handle. Before installing
mounting flanges or any abrasive product, the air tool must be tested for proper operation. Follow these steps to verify the correct rated operating speed of the tool.
1. Supply 3 drops of 95482 Dynabrade Air Lube 10W/NR (or equivalent) into the air inlet bushing of the tool while the throttle lever is depressed. Allowing the oil to flow into
the air motor.
2. Release the throttle lever.
3. With the air supply valve in the OFF position, carefully connect the tool to the air supply hose. Note: Use a wrench to hold the air inlet bushing on the tool stationary when
installing the air supply connection.
4. Once the tool is connected to the air supply, turn the supply valve to the ON position. Run the tool and use a tachometer to verify the rated operating speed (RPM) of the tool.
The tool should operate within 5% of the maximum rated RPM. The tool RPM must never exceed the maximum rated RPM with the operating air supply pressure reading 90
PSIG (6.2 bar g) at the air inlet of the tool. To adjust free speed add or remove shims. Adding shims will increase the speed, removing shims will reduce the tool free speed.
Once the correct rated operating speed for the tool is verified, disconnect the tool from the air supply and install the proper flanging and abrasive product.
Final Assembly Complete. Tool Assembly Complete.