20. Avoid gaseous areas. Do not operate portable electric tools in Warning:

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1 For Serial No. 0A1000 and Higher Parts Page Reorder No. PD01 94 Effective November, 2001 Supersedes PD96 09 Models: Electric Dynafile II V / 60 Hz Kit 120 V / 60 Hz Abrasive Machine! WARNING Always operate, inspect and maintain this tool in accordance with the safety standards established by OSHA, Underwriters Laboratories, Inc., The Canadian Standards Association and The American National Standards Institute (ANSI). Dynabrade, Inc. assumes no responsibility for any damage or accidents resulting from the misuse of this tool, its misapplication or non-adherence to precautionary safety measures. General Safety Rules Read and save all instructions before operating this power tool. 20. Avoid gaseous areas. Do not operate portable electric tools in Warning: gaseous or explosive atmospheres. Motors in these tools When using electric tools, basic safety precautions should always be followed to normally spark, and the sparks can ignite fumes. reduce the risk of a fire, electric shock, and personal injury, including the following: 21. Do not alter or misuse tool. This tool is precision built. Any 1. Keep work area clean. Cluttered areas and benches invite accidents. alteration or modification not specified is misuse and may result in a dangerous condition. Only these accessories and attachments that 2. Consider work area environment. Do not expose tools to rain. Keep are found in this instruction manual are acceptable for use with this work area well lit. Do not use power tools in damp or wet locations. tool. The use of any other accessory or attachment might present a risk Do not use tools in the presence of flammable liquids or gases. to the operator. 3. Guard against electric shock. Prevent body contact with grounded 22. Replacement parts. When servicing, use only identical replacement surfaces. For example; pipes, radiators, ranges, refrigerator enclosures. parts. When ordering replacement parts, please specify model and 4. Keep children away. Do not let visitors contact tool or extension cord. serial numbers of your machine. All visitors should be kept away from work area. Voltage Warning 5. Store idle tools. When not in use, tools should be stored in a dry, or locked Before connecting the tool to a power source (receptacle, outlet, place - out of the reach of children. etc.), be sure the voltage supplied is the same as what is specified 6. Do not force tool. It will do a better and safer job at its intended rate. on the nameplate of the tool. A power source with greater than that 7. Use the right tool. Do not force a small tool or attachment to do the job of a heavy duty tool. Do not use tool for purposes not intended. specified for tool can result in serious injury to the user as well as damage to the tool. Using a power source with voltage less than the 8. Dress properly. Do not wear loose fitting clothing or jewelry. Clothes can nameplate rating is harmful to the tool s motor. If in doubt, do not be caught in moving parts. Rubber gloves and non-skid footwear are plug in the tool. recommended when working outdoors. Wear protective hair covering to contain long hair. Double Insulation Your Electric Dynafile II is double-insulated to give you added 9. Use safety glasses. Also use face-shield or dust mask if operation area is dusty. safety. This means that the tool is constructed throughout with two 10. Do not abuse cord. Never carry tool by cord or yank it to disconnect from separate layers of electrical insulation, or one double thickness of receptacle. Keep cord from heat, oil and sharp edges. insulation between you and the tool s electrical system. 11. Secure work. Use clamps or a vice to hold workpiece. It s safer than Tools built with this type of insulation system are not intended to be using your hand and it frees up both hands to operate tool. grounded. As a result, your Electric Dynafile II is equipped with a two prong plug which permits you to use extension cords without concern 12. Do not overreach. Keep proper footing and balance at all times. for maintaining a ground connection. 13. Maintain tools with care. Keep tools clean for better use and safer Note: Double-insulation does not take the place of normal safety performance. Follow instructions for lubricating and changing accessories. precautions when operating this tool. The insulation system is Inspect tool cords periodically and if damaged, have repaired by authorized added for protection against injury resulting from a possible service facility. Inspect extension cords periodically and replace if damaged. electrical insulation failure within the tool. Keep handles dry, clean and free from oil and grease. 14. Do not leave tool running. Disconnect tools when not in use, before Caution: When servicing double-insulated tools, use only identical servicing, when changing belts, contact arms, etc. replacement parts. Repair or replace damaged cords. 15. Remove keys and wrenches. Form a habit of checking to see that all Extension Cords keys and adjusting wrenches are removed from tool before turning it on. Double-insulated tools have two-wire cords, and can be used with 16. Avoid accidental starting. Do not carry around plugged in tool with finger either two-wire or three-wire extension cords. Only round jacketed on lever. Be sure lever is off when plugging in. extension cords should be used, and we recommend that they be listed by Underwriters Laboratories (UL) - (CSA in Canada). If the 17. Out-door use extension cords. When tool is used outdoors, use only extension cords will be used outside, the cord must be suitable for extension cord suitable for outdoor use. They should be marked with the outdoor use. They should be marked with the suffix W-A (for UL) or suffix W-A (for UL) or W (for CSA in Canada). W (for CSA in Canada). Any cord marked as an outdoor cord can 18. Stay alert. Watch what you are doing. Use common sense. also be used for indoor work. Do not operate tool when you are tired. Polarized Plugs: To reduce the risk of electric shock, this equipment has 19. Check damaged parts. Before further use of the tool, a guard or other a polarized plug (one blade is wider than the other). This plug will fit part that is damaged should be carefully checked to determine that it will in a polarized outlet only one way. If the plug does not fit in the outlet, operate properly and perform its intended function. Check for alignment of reverse the plug. If it still does not fit, contact a qualified electrician to moving parts, breakage of moving parts, binding of moving parts, mounting install the proper outlet. Do not change the plug in any way. and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced by an Warning: Keep extension away from the immediate working area. authorized service center unless otherwise indicated elsewhere in this instruction manual. Have defective switches replaced. Do not use tool if switch does not turn tool on or off.

2 Important Operating 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. Operating Instructions: Warning: Eye, face, respiratory, sound 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. Connect power source to tool. Be careful not to depress paddle switch in the process. 3. Hold tool by the motor housing only. One or two hands may be used. Do Not hold tool by head/housing assembly. Keep hands away from all grinding/sanding edges and moving parts. A side handle is included for two hand operation of tool. (See Installing Side Handle instructions.) 4. Depress paddle switch (trigger) and hold to start tool. Release switch to stop tool. 5. While tool is running, Adjust belt tracking by tuning Rough Adjustment Knob to the left or right accordingly, so as abrasive belt rides evenly over contact arm. 6. Always work off the return-side of the abrasive belt. This will ensure superior tracking and reduce downtime of tool. Abrasive /Contact Arm Change Instructions To Change : 1. Disconnect power source. 2. Remove Guard by pulling backwards and upwards over the Button Latch Assembly. To Change Contact Arm Assembly: 1. Disconnect power source. 2. Remove Guard by pulling backwards and upwards over the Button Latch Assembly. 3 Pull back on tension arm assembly. 3. Pull back on tension arm assembly and remove abrasive belt. 4. Remove and replace abrasive belt and belt guard. 4. Remove Rough Adjustment Knob. 5. Connect power source. 6. Adjust belt tracking by turning Rough Adjustment Knob 5. Remove contact arm and replace with desired arm, making sure that the tab on the end of the arm is facing downward. to the left or right accordingly while machine is running. 6. Replace Knob. 7. Install abrasive belt and replace belt guard. 8. Connect power source and adjust belt tracking by turning Knob. Housing Angle Adjustment: To pivot housing, loosen Screw on housing with the supplied 9/64" hex wrench (P/N 95134). Pivot housing to desired angle and retighten Screw. Installing Side Handle: The side handle may be installed on either side of the rotor housing for right or left hand operation. Position the side handle on the side offering the best comfort and control of the tool. To install, thread side handle into side handle socket on desired side of motor housing and tighten securely. Safety Instructions: Products offered by Dynabrade should not be converted or otherwise altered from original design without expressed written consent from Dynabrade, Inc. Warning: Eye, face, respiratory, sound 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. 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 30 seconds before application to workpiece to determine if machine is working properly and safely before work begins. Always disconnect power supply before changing abrasive or making machine adjustments. Inspect abrasives and accessories for damage or defects prior to installation on tools. Please refer to Dynabrade s Warning/Safety Operating Instructions Tag (Reorder No ) for more complete safety information. Warning: Hand, wrist and arm injury may result from repetitive work, motion and overexposure to vibration. Full One Year Warranty Following the reasonable assumption that any inherent defect which might prevail in a product will become apparent to the user within one year from the date of purchase, all equipment of our manufacture is warranted against defects in workmanship and materials under normal use and service. We shall repair or replace at our factory, any equipment or part thereof which shall, within one year after delivery to the original purchaser, indicate upon our examination to have been defective. Our obligation is 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. 2

3 Index Key No. Part # Description Head/Housing Assembly 1 Contact Arm Assembly (See Chart on pg.6) Plug Guide Post Spring Tension Arm Spring Knob Assembly Dust Cover Tension Shaft Screw Guard Hex Nut Housing Screw Motor Lock Screw Drive Wheel Adapter Set Screw Electric Motor Washer Side Handle Note: Shaded parts represent Housing Assembly. 20 Electric Motor only (See page 4 for Electric Motor Parts Breakdown) Extension Cords Grounded tools require a three wire extension cord. Double insulated tools can use either a two or three wire extension cord. As the distance from the supply outlet increases, you must use a heavier gauge extension cord. Using extension cords with inadequately sized wire causes a serious drop in voltage resulting in loss of power and possible tool damage. Refer to the table below to determine the required minimum wire size. Nameplate Extension Cord Length Ampere 25' 50' 75' 100' 150' 200' *Based on limiting the line voltage drop to live volts at 150% of the rated ampere. The smaller the gauge number of the wire the greater the capacity of the cord. For example a 14 gauge cord can carry a higher current than a 16 gauge cord. When using more than one extension cord to make up the total length, be sure each cord contains at least the minimum wire size required. If you are using one extension cord for more than one tool, add the nameplate ampere and use the sum to determine the required minimum wire size. Guidelines For Using Extension Cords If you are using an extension cord outdoors, be sure it is marked with the suffix W-A ( W in Canada) to indicate that it is acceptable for outdoor use. Be sure your extension cord is properly wired and in good electrical condition. Always replace a damaged extension cord or have it repaired by a qualified person before using it. Protect your extension cords sharp objects, excessive heat and damp or wet areas. Read and save all instructions for future reference 3

4 40520 Motor Assembly Index Key No. Part # Description Cord Protector Cord Set Service Nameplate Kit Trigger Dia. x 1-3/8" Rivet Motor Housing O-Ring Left Brush Holder Switch Cover x 5/8" Pan Hd. Slt.Plast. T Brush Right Brush Holder Brush Spring Rubber Bumper Rear Bearing Volt Field x 2-1/2" Pan Hd. Slt. Plast T Volt Armature (Includes Fan) Fan x 3/8" Pan Hd. Slt. Plast. T Front Bearing Pinion /4-28 Hex Lock Nut x 5/8" Pan Hd. Slt.Plast T Gear Case Assembly (Incl. All Shaded Index #'s) Needle Bearing Coil Spring Spiral Bevel Gear Internal Retaining Ring Bearing Spindle Hub x 1/2" Pan Hd. Slt. Taptitet T Spindle Shim Cap Coil Spring O-Ring Lock Pin To order replacement parts, specify model number and serial number of your machine. 4

5 Dynafile II Contact Arms Optional Adapter allows use of 24" long belts; extends reach to 7" when used with contact arm. Arms for 4" to 17" workable reach Work on broad areas, leaves in-line scratch, blend stainless. Size: 1/2" W x 24" L. Contact Wheel: 5/8" dia. x 3/8" W, rubber. Platen: 1/2" wide. Size: 1/2" W x 18" L. Contact Wheel: 5/16" dia. x 3/8" W, rubber. Platen: 1/2" wide Uses 20-1/2" s Grind on contact wheel or platen; has 5-1/4" workable reach. 45 PSI maximum. Enter channels as small as 7/16". Size: 5/8" or 3/4" W x 20-1/2" L Contact Wheel: 3/4" dia. x 5/8" W, rubber. Platen: 3/4" wide. Size: 1/2" W x 18" L. Contact Wheel: 5/16" dia. x 3/8" W, steel. Platen: 1/2" wide The Banana Arm Enter 5/16" x 3/4" openings. 2-1/2" Size: 1/4" W x 18" L. Contact Wheel: 5/8" dia. x 1/8" W, rubber. Platen: 1/4" wide * steel platen available. 6-3/4" workable reach. Order for heavy-duty version. Rubber Work on broad areas; leaves in-line scratch; blend stainless. Size: 1/2" W x 18" L. Contact Wheel: 5/8" dia. x 3/8" wide, rubber. Platen: 1/2" wide. Grind over contact wheel or platen Guide-Cut Size: 1/2" W x 18" L. Contact Wheel: 5/8" dia. x 3/8" W, rubber. Platen: 1/2" wide. Removes raised material within.020" or less without undercutting. Guide Wheels Prevent Undercutting Size: 1/2" W x 18" L. 60 to 80 grit. Contact Wheel: 5/8" dia. x 3/8" W, rubber Unique Offset Design Extra Length Arm 17" workable reach. Strap polish is easy with this arm! Size: 1/2" W x 44" L. Contact Wheel: 5/8" dia. x 3/8" W, rubber. Platen: 1/2" wide. Size: 1/4" or 1/2" W x 18" L. Contact Wheel: 1" dia. x 3/8" W, rubber. Platen: None due to offset design Excellent for cleaning oxide off electrical bus bars. Arm has a 12" workable reach Bus Bar Order for Heavy Duty/Steel Construction version. Size: 3/4" W x 34" L. Contact Wheel: 5/16" dia. x 5/8" W, steel. Platen: 3/4" wide, optional. Size: 5/8" or 3/4" W x 18" L. Contact Wheel: 3/4" dia. x 5/8" wide, rubber. Platen: 3/4" wide Strap polish here tapered 11220, 11300, 11301, Polish Turbine Blades Grind corners, enter grooves, strap polish. Offset design and miniature contact wheels. 2" strap polish in offset area; polish turbine blades and other contours. Sizes: uses 5/8" or 3/4" W x 18" L. All others use 1/2" W x 18" L. Contact wheels description for each above arm: 11220: 5/16" dia. x 5/8" W, steel : 1/4" dia. x 3/8" W, steel : 5/16" dia. x 3/8" W, steel : 5/16" dia. x 3/8" W, rubber. Size: 1/4" W x 18" L. Contact Wheel: 1" dia. x 3/8" wide, urethane, tapered. Platen: No platen due to offset design. *Standard Contact Arm for Electric Dynafile II 5

6 Dynafile II Contact Arm Assembly Parts List Contact Wheel Assembly Includes wheel, bearings and shaft. Bearing Contact Wheel Contact Arm Bearing Shaft Dynafile II Standard Contact Arms Part Abrasive Contact Wheel Contact Wheel Contact Wheel Bearing Number Size Description Comments Assembly Only (2) Req. Shaft /2" x 18" 5/8" Dia. x 3/8" W Rubber Stroke-Sander Arm (2) (2) (4) (2) 1/2" W Platen /2" x 18" 5/16" Dia. x 3/8" W Steel 1/2" W Platen /4" x 18" 5/8" Dia. x 1/8" W Rubber 1/4" W Platen /2" x 18" 5/8" Dia. x 3/8" W Rubber 1/2" W Platen /4" or 1/2" x 18" 1" Dia. x 3/8" Wide Loose Application Radiused Rubber /8" or 3/4" x 18" 3/4" Dia. x 5/8" W Rubber 3/4" W Platen /8" or 3/4" x 18" 5/16" Dia. x 5/8" W Steel Polish Turbine Blades /4" x 18" 1" Dia. x 3/8" Wide No Platen/Offset Design Tapered Urethane /2" x 24" 5/8" Dia. x 3/8" W Rubber 1/2" W Platen /8" or 3/4" x 20-1/2" 3/4" Dia. x 5/8" W Rubber 3/4" W Platen /2" x 18" 1/4" Dia. x 3/8" W Steel Polish Turbine Blades /2" x 18" 5/16" Dia. x 3/8" W Steel Polish Turbine Blades /2" x 18" 5/8" Dia. x 3/8" W Rubber Stroke-Sander Arm -1/2" W Platen /2" x 18" 5/8" Dia. x 3/8" W Rubber H.D. Version of Arm /2" x 18" 5/8" Dia. x 3/8" W Rubber Offset Arm prevent gouging /2" x 18" 5/8" Dia. x 3/8" W Rubber Contains two Guide Wheels Prevents Undercutting /2" x 18" 5/8" Dia. x 3/8" W Rubber 1/2" W Steel Platen /8" or 3/4" x 18" 3/4" Dia. x 5/8" W Rubber H.D. Version of Arm /2" x 44" 5/8" Dia. x 3/8" W Rubber 1/2" W Platen/17" Reach /2" x 18" 5/16" Dia. x 3/8" W Rubber Polish Turbine Blades /4" x 34" 5/16" Dia. x 5/8" W Steel Bus Bar Arm/11" Reach

7 Abrasive s Coated Aluminum Oxide Abrasive Grit /8" /4" /2" /8" /4" " /8" /4" /2" " Ceramic Coated Aluminum Oxide Abrasive Grit /4" /2" /8" /4" " /4" /2" " and Wider: 50 s = Unit. All Other s: 200 s = Unit. Coated Alumina Zirconia Abrasive Grit /4" /2" /8" /4" " /4" /2" " " and Wider: 50 s = Unit. All Other s: 200 s = Unit. Coated Silicon Carbide Abrasive Grit /8" /4" /2" /8" /4" " /8" /4" /2" " s = Unit. Abrasive Impregnated Non-Woven Nylon Grade Super Fine Very Fine Medium Coarse 1/4" /2" /8" /4" " /2" Long 3/4" /4" /2" " " and Wider: 10 s = Unit. All Other s: 20 s = Unit. Cloth Polishing s Part Number Use With 1/2" Dynafile II Adapter 7

8 Dynapad Platen Pads Part Pkg. Number Used On Size Material Qty Dynafile II (11286 Arm) 1/2" W x 3" L (bolts on) Steel Dynafile, Dynafile II 1/2" W x 7" L x 1/8" Thk Soft/Sponge Dynafile, Dynafile II 1/2" W x 7" L x 1/8" Thk Hard/ Cork Dynafile, Dynafile II 1/2" W x 7" L x 1/32" Thk Thin Dynafile (11228 Arm) 1/2" W x 3" L (bolts on) Steel Dynafile 1/4" W x 7" L x 1/8" Thk Soft/ Sponge Dynafile 1/4" W x 7" L x 1/8" Thk Hard/ Cork Dynafile 1/4" W x 7" L x 1/32" Thk Thin Dynafile II 3/4" W x 7" L x 1/8" Thk Hard/ Cork Dynafile II 3/4" W x 7" L x 1/8" Thk Soft/ Sponge Dynafile II 3/4" W x 7" L x 1/32" Thk Thin 5 Note: Dynapad Platen Pads are PSA mounted and easily trimmed to size. Exceptions: and Steel Platens bolt on; clamps on. Unit = 10 packages each. Abrasive Types and Cloth Polishing s Coated Aluminum Oxide The most widely used abrasive grain. This tough durable synthetic is used for grinding and deburring high carbon steels, general metalworking and for sanding certain hardwoods. Ceramic Coated Aluminum Oxide Synthetic grain two-to-three times tougher than conventional aluminum oxide. Coated Silicon Carbide Excellent for sanding primer and sealer. This sharp, fast-penetrating grain is used for sanding soft materials such as glass, plastics and fibrous wood. Coated Alumina Zirconia Effective for coarse stock removal of metal and wood. This synthetic grain has self-sharpening characteristics and provides continuous new cutting edges for longer life and greater efficiency. Abrasive Impregnated Non-Woven Nylon A non-woven synthetic fiber and an abrasive mineral are bonded together to form a tough, open web that is chemically resistant and long-lasting. This web design allows controlled conformable contact to workpiece contours, corners and edges. The product wears away slowly, exposing new abrasive leaving a uniform, consistent surface. It also conditions surfaces without removing or damaging the base material and is excellent for deburring, cleaning, blending and final finishing of metal, wood and plastics. It is available in many forms such as belts, discs and wheels. Various mineral grades are available ranging from very coarse to ultra-fine. Cloth Polishing s Used on power tools in conjunction with Dynuba polishing compounds. The result is brilliant cut, color and luster on metals such as stainless steel, aluminum, copper and brass. Machine Specifications Model Motor Sound Abrasive Size Max. SFPM Weight Length Height Number RPM Level Inch (mm) Voltage Current Phase Frequency (SMPM) Pound (kg) Inch (mm) Inch (mm) , db(a) 1/4-3/4 (6-19) W x ( ) L 120 V (AC) 5.5 Amps 1 60 Hz 2,300 (699) 5.5 (2.5) 15.0 (381) 4.0 (102) Visit Our Web Site: DYNABRADE DYNABRADE, INC., 8989 Sheridan Drive Clarence, NY Phone: (716) Fax: International Fax: DYNABRADE EUROPE S.àr.l., Zone Artisanale L-5485 Wormeldange Haut, Luxembourg Telephone: Fax: DYNABRADE, INC., Customer.Service@Dynabrade.com PRINTED IN USA

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