Dynabrade DYNABUFFER 57126 User's Manual
Contents
1. 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 Motor Disassembly Complete Valve Disassembly 1 2 3 4 5 6 Place the 52296 Repair Collar around the 57319 Housing and secure it in a vise so that the air inlet is pointing up 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 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 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 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 Use a 2 5mm dia drive punch to remove the 12132 Pin and the throttle lever Valve Disassembly Complete Valve Assembly Important Clean and inspect all parts before assembling 1 2 3 4 a cooON 2 Place the 52296 Repair Collar around the 57319 Housing and secure i2. For Serial No 03A1145 and Higher Models 57126 3 Dynabuffer Parts Page Reorder No PD03 10 Effective February 2003 Supercedes PD02 47 3 Dynabuffer Air Motor and Machine Parts AWARNING Index Key No ANDO KR WP gt Description 3 Pad Shroud Snap Ring Balancer Shaft Bearing Shield Bearing Seal Bearing Motor Shaft Balancer Key Lock Ring O Ring Bearing Bearing Plate Rotor Blade 5 pkg Set Cylinder Assembly Includes 98462 Pin Pin Se ee LILE jog Bearing Plate Bearing Retaining Ring Hang Plate Housing Gasket Lock Nut Collar O Ring Insert Assembly Housing 57126 Throttle Lever Safety Lock Lever Opt Pin Valve Stem Retaining Ring O Ring O Ring Speed Regulator Assy Seal Tip Valve Spring Air Control Ring Retaining Ring O Ring Muffler Base Felt Muffler Muffler Cap O Ring Spacer Inlet Adapter Muffler Assembly 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 ah OME BS Sane 51360 Overmold Grip 50679 26mm open end Qo O Air Lube KY arresi A Loctite 609 A Loctite 271 Ag Loctite 567 Qoru Nem x 8 85 In Ibs Important Operating Maintenance and Safety Instructions Car
3. e Includes assorted parts to Lock Ring Tool has a 3 8 in square socket two handed operation ki help maintain and repair motor for use with 3 8 in drive breaker bar id 3 ratchet head or torque wrenches om 53209 Ergo Handle e This anti vibration handle 57091 Bearing Press Tool provides increased comfort e Use with a 2 arbor press to achieve for the operator accurate press of bearings and motor parts Filter Regulator Lubricator 96525 Tool Repair Kit j e Provides accurate air pressure regulation two stage disassembly assembly of the tool filtration of water contaminants and lubrication of e Includes all above listed tools i pneumatic components u Visit Our Web Site www dynabrade com Email Customer Service Dynabrade com DYNABRADE DYNABRADE INC 8989 Sheridan Drive e Clarence NY 14031 1490 Phone 716 631 0100 Fax 716 631 2073 International Fax 716 631 2524 DYNABRADE EUROPE S r l Zone Artisanale L 5485 Wormeldange Haut Luxembourg Telephone 352 76 84941 Fax 352 76 8495 1 DYNABRADE INC 2004 PRINTED IN USA PDO3 10_Rev 1_02 04
4. fits against the 51366 Bearing Plate Apply a small amount of the Loctite 567 or equivalent to the threads of the lock ring 15 Apply the 95842 Dynabrade Air Lube 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 59058 Lock 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 fit the 51361 Shroud over the counter balance and thread the shroud onto the external threads of the 02099 Housing Use the 56058 Lock Ring Tool to thread the 59058 Lock 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 Nem 250 in lbs Motor Assembly Complete Tool Assembly Complete Throttle Positioning Procedu
5. 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 56145 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 Maintenance 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 pe
6. Loctite Corp Disc pad Change 1 Insert 50679 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 Length Height Number HP W RPM Level CFM SCFM LPM PSIG Bars Thread Pound kg Inch mm Inch mm 57126 16 119 10 000 74 dB A 3 23 651 80 5 5 5 16 24 female 2 0 91 8 5 16 211 3 3 4 96 Additional Specifications Air Inlet Thread 1 4 NPT Hose I D Size 3 8 10mm Tool Vibration Data Per ISO 8662 8 2 0 s Optional Accessories 80030 Training and Maintenance Test Equipment Kit 57092 Repair Collar 80025 Load Cell measures tool RPM under load and useful for training operators for proper buffing pressure operation Electronic tachometer pick up securely fastens to wear plate e 94315 Pressure Gage to ensure peak operating performance e 95842 Air Lube formulated for pneumatic tools Prevents rust and formation of gum sludge for longer tool operation with greater power and less downtime e 96368 Tachometer used to measure tool RPM Model Motor Motor Sound Maximum Air Flow Air Pressure Spindle Weight e Specially designed collar for use in vise to prevent damage to motor housing during disassembly assembly prevent damage to valve body during disassembly assembly gt 53163 Handle 96537 Motor Tune Up Kit i C O ae p 56058 Lock Ring Wrench e Handle is designed for
7. dards 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 e Please refer to Dynabrade s Warning Safety Operating Instructions Tag Reorder No 95903 for more complete safety information e 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 One Year Warranty Following the reasonable assumption that any inherent defect which might prevail in a product will become apparent t
8. efully 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 Lubricator 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
9. es so that the back up pad is facing up Use the 50679 Wrench 26mm to remove the back up pad Insert the 56058 Lock Ring Wrench into the tabs of the 59058 Lock Ring and loosen the lock ring from the 02099 Housing by turning it counterclockwise Remove the 51361 Shroud from the 02099 Housing by turning it counterclockwise Pull the motor assembly out of the 02099 Housing and remove the 58357 Cylinder Seal Use retaining ring pliers to remove the 95626 Retaining Ring Fasten the 96346 Bearing Separator between the 51367 Bearing Plate and the 58358 Cylinder Assembly 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 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 Remove the rotor vanes and the 56047 Key from the motor shaft balancer Remove the 51366 Bearing Plate from the 57088 Bearing Fasten the bearing separator between the counter balance and the 57088 Bearing and use the arbor press to remove the bearing 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 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
10. he 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 asmall amount of the Loctite 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 Loctite 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 Drawing 1 57091 Bearing Press Tool 56052 Bearing Shaft Step i Bearing Seal and Bearing Shield Balancer Shaft Assembly Drawing 2 57091 ar Bearing Press Tool 57088 Bearing tt Motor Shaft Balancer e Balancer Shaft Assembly Drawing 3 57091 Bearing Press Tool 51366 Front Bearing Plate 57088 Bearing Motor Shaft Balancer Balancer Shaft Assembly E Drawing 4 woe 57091Bearing Press Tool 51367 Rear Bearing Plate with 01206 Bear
11. ing Line Up Pin T 53858 Cylinder T ete Assemb i w Rotor and Vanes 51366 Front Bearing Plate with 57088 Bearing Motor Shaft Balancer Balancer Shaft Assembly Motor Assembly Disassembly Instructions 3 Dynabuffer continued 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 Lube 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 59058 Lock Ring with the 50659 O Ring over the counter balance of the motor shaft balancer so that the o ring
12. ir motors should be lubricated Dynabrade recommends using Dynabrade Air Lube P N 95842 1 pt 473 ml at a rate of 1 drop per minute lf Dynabrade Air Lube 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 An Air Line Filter Regulator must be used with this air tool to maintain all warranties Dynabrade recommends the following 11405 Air Line Filter Regulator Lubricator Provides accurate air pressure regulation two stage filtration of water contaminants and micro mist lubrication of pneumatic components Operates 40 SCFM 100 PSIG has 3 8 NPT female ports 5 Use only genuine Dynabrade replacement parts To reorder replacement parts please specify the Model Serial and RPM 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 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 Stan
13. o 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 contingent 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 contact wheels rotor blades etc are not covered under this warranty Motor Assembly Disassembly Instructions 3 Dynabuffer Important Manufacturer 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 Motor Disassembly 1 2 Po COON S oI 10 11 12 13 14 15 16 Disconnect the tool from the air supply Invert the tool and place the 57092 Repair Collar around the 02099 Housing and the 51361 Shroud above the two handle boss
14. re 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 Lock Nut 3 With a firm hold on the 02099 Housing use a 34mm or an adjustable wrench to turn the 01461 Lock Nut counterclockwise to loosen the 02099 Housing from the valve housing 4 Orient the throttle lever to the operators desired grip and positioning Note Allow for additional rotation of the 02099 Housing as the 01461 Lock Nut is tightened 5 With a firm hold on the 02099 Housing to reduce its rotation use a 34mm or an adjustable wrench to tighten the 01461 Lock Nut Torque to 45 Nem 400 in Ibs 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 Lube 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 Loctite is a registered trademark of the
15. rform 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 Load 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 a
16. t in a vise so that the air inlet is pointing up Install the 01469 Speed Regulator Assembly includes o rings into the valve housing and secure it in place with the 95558 Retaining Ring Insert the 01449 Valve Stem so that the end with the hole fits into the 01469 Speed Regulator Assembly Install the 01464 Seal into the inlet so that it is laying flat 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 Install the 01468 Spring so that the smaller end of the spring fits against the center of the tip valve Place the 01543 Air Control Ring against the air inlet opening of the 57319 Housing Install the 01468 Spring so that the smaller end of the spring fits against the center of the tip valve 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 Loctite 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 t
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