Versatility Grinder ool Manual Safety, Operation and Maintenance SAVE HIS DOCUMEN, EDUCAE ALL PERSONNEL Parts Page Reorder No. PD0 Effective June, 00 HP Variable Speed Models: 4900 (v) Phase 0/0 Hz 490 (0v) Phase 0/0 Hz HP Variable Speed Models: 490 (0v) Phase 0/0 Hz 490 (40v) Phase 0/0 Hz -/ HP Models: 4904 (v) Phase 0/0 Hz 490 (0v) Phase 0/0 Hz Read and understand this tool manual before operating your tool. Follow all safety rules for the protection of operating personnel as well as adjacent areas. For safety information, refer to Safety Requirements for the Use, Care and Protection of Abrasive Wheels ANSI B., Code of Federal Regulation CFR 9 Part, European Committee for Standards (EN) Hand Held Electric Motor Operated ools Safety Requirements and applicable State and Local Regulations. Read and understand tool manual before work starts to reduce risk of injury to operator, visitors, and tool. SAFEY LEGEND Practice safety requirements. Work alert, have proper attire, and do not operate tools under the influence of alcohol or drugs. Eye protection must be worn at all times, eye protection to conform to ANSI Z8.. Respiratory protection to be used when exposed to contaminants that exceed the applicable threshold limit values required by law. Ear protection to be worn when exposure to sound, exceeds the limits of applicable Federal, State or local statues, ordinances and/or regulations. Electric shock hazard. Avoid bodily contact with grounded objects, bodies of water. Do not damage cord set. GENERAL SAFEY INSRUCIONS Carefully Read and save all instructions before operating or servicing any Dynabrade Abrasive Power ool. Products offered by Dynabrade are not to be modified, converted or otherwise alerted from the original design without expressed written consent from Dynabrade, Inc. Warning: When using electric tools, basic safety precautions should always be followed to reduce the risk of a fire, electric shock, and personal injury, including the following:. Keep work area clean. Cluttered areas and benches invite accidents.. Consider work area environment. Do not expose tools to rain. Keep work area well lit. Do not use power tools in damp or wet locations. Do not use tools in the presence of flammable liquids or gases.. Guard against electric shock. Be certain machine is adequately grounded before operating. 4. Keep children away. Do not let visitors contact tool. All visitors should be kept away from work area.. Do not force tool. It will do a better and safer job at its intended rate.. 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.. Dress properly. Do not wear loose fitting clothing or jewelry. Clothes can be caught in moving parts. Wear protective hair covering to contain long hair. 8. Use safety glasses. Also use face-shield or dust mask if operation area is dusty. (continued on next page)
9. Do not abuse cord. Never carry tool by cord or yank it to disconnect from receptacle. Keep cord from heat, oil and sharp edges.. Do not overreach. Keep proper footing and balance at all times.. Maintain tools with care. Keep tools clean for better use and safer performance. Follow instructions for changing accessories. Inspect tool cords periodically and if damaged, have repaired by authorized service facility. Inspect extension cords periodically and replace if damaged. Keep handles dry, clean and free from oil and grease.. Do not leave tool running. Disconnect tools when not in use, before servicing, when changing belts, contact arms, etc.. Remove keys and wrenches. Form a habit of checking to see that all keys and adjusting wrenches are removed from tool before turning it on. 4. Avoid accidental starting. Be sure switch is off when plugging in.. Out-door use extension cords. When tool is used outdoors, use only extension cord suitable for outdoor use. hey should be marked with the suffix W-A (for UL) or W (for CSA in Canada).. Stay alert. Watch what you are doing. Use common sense. Do not operate tool when you are tired.. Check damaged parts. Before further use of the tool, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment of moving parts, breakage of moving parts, binding of moving parts, mounting 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 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. 8. Avoid gaseous areas. Do not operate electric tools in gaseous or explosive atmospheres. Motors in these tools normally spark, and the sparks can ignite fumes.. Do not alter or misuse tool. his tool is precision built. Any alteration or modification not specified is misuse and may result in a dangerous condition. Only these accessories and attachments that are found in this instruction manual are acceptable for use with this tool. he use of any other accessory or attachment might present a risk to the operator. 0. Replacement parts. When servicing, use only identical replacement parts. When ordering replacement parts, please specify model and serial numbers of your machine.. Do not operate tool without guards. Always replace guards after changing contact arm or abrasive belt.. Do not mix grind material. here is a potential combustion hazard if ferrous and non-ferrous grinding dust is mixed. Clean inside machine between materials.. Use hearing protection. Permanent hearing loss can result from high process noise levels. 4. Use correct width abrasive belt. Using abrasive belt that is narrower than the contact wheel can cause snagging of the workpiece.. Mount tool securely. Always fasten tool to bench or other support structure to prevent tipping. Voltage Warning Before connecting the tool to a power source (receptacle, outlet, etc.), be sure the voltage supplied is the same as what is specified on the nameplate of the tool. A power source with greater than that 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 nameplate rating is harmful to the tool s motor. If in doubt, do not plug in the tool. Polarized Plugs: o reduce the risk of electric shock, this equipment has a polarized plug (one blade is wider than the other). his plug will fit in a polarized outlet only one way. If the plug does not fit in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install the proper outlet. Do not change the plug in any way. Warning: Keep extension away from the immediate working area. Maintenance Instructions he grinder described in this manual has been designed to be maintenance-free. All bearing and moving parts are sealed and lubricated for life. Electric motor maintenance should be performed as recommended by the motor manufacturer. Good housekeeping is essential to insuring long life of any machine tool. By keeping the machine clean and visually inspected for any wear, the machine will provide many years of service. Before each use inspect the contact wheels, idler rolls and drive pulley for any signs of wear. Repairing or replacing worn parts early enough will prevent other parts from becoming damaged. Notice All Dynabrade tools use the highest quality parts and metals available and are machined to exacting tolerances. Our warranty obligation is contingent upon proper use of our tools and cannot apply to equipment which has been subjected to misuse or a lack of maintenance 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 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.
For Models: 4900 490 Versatility Grinder Controls/Features FRON AIR VALVE ON/OFF AIR PRESSURE REGULAOR AIR PRESSURE GAGE SECONDARY CONAC ARM BEL RACKING MOOR SWICH FORWARD OFF REVERSE SPEED CONROL DIAL PIVOING CONAC ARM SUPPOR PRIMARY LINEAR BEL RACKING VACUUM RAY KNOB OPIONAL PIVOING VACUUM SCOOP 49 Assembly Includes: 49 Knob 499 Bottom ray 490 op ray 94 Screw (4) REAR OPIONAL ADAPER 49 Vacuum Hose Adapter 94 Screws () Adapter converts 4" outside diameter to -/4" inside diameter to use with a standard -/" vacuum hose. 4" VACUUM POR (Outside Dia.) Always fasten tool to bench or other support to prevent tipping. BENCH MOUN BRACKE () /" hru Holes, " Spacing
For Models: 4900 490 Versatility Grinder Complete Assembly 9809 90 Elbow () 98 Cord 98 Screw (4) 4 0 Lock Washer (4) 94 Washer (4) 984 Variable Speed Control 494 Support Plate 8 984 Lock Nut 9 9800 Electric Motor - 4900 980 Electric Motor - 490 98 Washer (4) 904 Lock Washer 949 Screw (4) 9888 Cord Grip 4 9 Bolt (4) 94 racking Knob 94 Washer () 494 Bench Mount Bracket 8 94 Screw () 9044 Lock Washer (8) 0 904 Washer (4) 94 Screws () 49 racking Knob Support 98 Hex Nut () 4 944 Snap Ring 494 racking Shaft 94 Locking Knob 49 Locking Hub 8 49 Bronze Bushing 9 904 Screw () 0 49 Restricted Fitting 99 Pressure Gauge 90 Screw () 9894-C Regulator 4* 49 Vacuum ray Knob 94 Bolts () * 499 Bottom Vac ray * 490 op Vac ray 8 4940 Housing 9 49 Slide Valve 40 49 Air Inlet 4 49 Idler Shaft Support () 4 99 Snap Ring () 4 8 Bearing 44 490 Idler Wheel 4 90 Set Screw 4 4944 Idler Wheel Base 4 4949 Idler Wheel Shaft 9 Screw () 49 494 Guide Rod 0 98 Rod Seal () 94 Hex Nut Guide Rod Bushing () 494 Air Cylinder & Nut 4 494 Idler Cylinder Mount 9889 Breather Vent 98 Seal 49 Angular Stop Plate 8 9 Hex Nut () 9 94 Set Screw 4 0 498 /4" ubing (") 988 Right Angle Fitting 49 Pivot Plate Drive Wheel 4 90 Set Screw 9 Pivot Plate Bushing 9 Pivot Plate Washer 9 Pivot Plate Nut 8 98 Nut 9 49 Adapter 0 Adapter Assembly Contact Arm Assembly 9 Clamping Knob ension Roll Assembly (4) 4 498 Housing Cover 494 Pivot Plate Post () 49 Vacuum Hose Adapter 494 ension Roll Cover 8 90 urn Latch () 9 98 Sealing Ring 80 49 Slack Guard 8 9 /4" Lock Washer () 8* 9409 Bolt (4) 8* 94 Washer (4) 84* 994 Hex Nut (4) 9 8 80 8 * 9 4 8 4 * Individual parts that have an asterisk next to the index number designates optional accessories. 0 * 8 4* 9 0 0 8 9 40 8* 84* 8* OPIONAL 49 PIVOING VACUUM SCOOP ASSEMBLY 4 4 4 4 8 0 44 4 4 9 0 4 Note: For complete assembly diagram please refer to page in this tool manual. 4 49 4 4 4 8 9 * 9 0 * 00 N m 4 A 4 8 4 8 Adhesive: = Loctite #09 = Loctite # = Loctite # orque: N m x 8.8 = In. - lbs. KEY
Abrasive Belt Installation ENSION PULLEY BEL CLAMPING KNOB CONAC ARM DRIVE PULLEY Abrasive Belt Installation Instructions. urn speed control dial to "0" and motor switch to "off".. Push air valve towards back of machine to retract tension pulley.. Remove housing cover and tension roll cover. 4. Slide abrasive belt into position shown above in abrasive belt installation diagram, centering belt on pulleys and contact arm. If necessary, loosen clamping knob, and slide contact arm back to allow easier belt positioning. After belt is in place slide contact arm forward to take up belt slack.. Replace housing cover and tension roll cover.. Pull air valve toward front of machine to actuate tension pulley.. Adjust air pressure regulator for belt width (clockwise rotation increases pressure) according to Abrasive Belt ension Diagram below. 8. urn motor switch to forward or reverse. 9. Adjust belt tracking.. Adjust speed control dial to desired belt speed. Abrasive Belt ension Diagram () BEL WIDH IN. (mm) () / () /4 () 0 0 0 (PSIG)
49 Platen/Work Rest Assembly 49 Platen ension Roll Base ension Roll Assembly 90 Screw () 4 49 Work Rest Support 49 Work Rest 494 Platen 9 Platen Screw () 8 49 Platen Base 9 90 Base Screw () 904 Lock Washer () 4 8 9 ension Roll Assembly 4 ension Roll Center ension Roll Caps () 0 Bearing 4 940 Shoulder Screw 99 Spacer 9 Wavy Spring Washer 4
For Models: 490 490 Versatility Grinder Complete Assembly Variable Speed Control 98 40V AC 988 0V AC 98 90 Elbow Wire Connection Parts 9840 ' Flexible Conduit 98 Connector 98 erminal 98409 9' # Black Wire 984 ' # Green Wire 9844 Wire ag 984 Wire ag 984 Wire ag 4 494 Support Angle 49 Vibration Control Mount 49 Support Plate 490 Bumper 8 98 Hp Motor 9 49 Support Angle 98 Screw (4) 0 Lock Washer (4) 94 Washer (4) 9 Bolt (4) 4 94 racking Knob 94 Washer () 494 Bench Mount Bracket 94 Screw () 8 9044 Lock Washer () 904 Washer () 0 94 Screws () 49 racking Knob Support 98 Hex Nut () 944 Snap Ring 4 494 racking Shaft 94 Locking Knob 49 Locking Hub 49 Bronze Bushing 8 904 Screw (9) 9 49 Restricted Fitting 0 99 Pressure Gauge 90 Screw () 9894-C Regulator * 49 Vacuum ray Knob 4 94 Bolts () * 499 Bottom Vac ray * 490 op Vac ray 4940 Housing 8 49 Slide Valve 9 49 Air Inlet 40 49 Idler Shaft Support () 4 99 Snap Ring () 4 8 Bearing 4 490 Idler Wheel 44 90 Set Screw 4 4944 Idler Wheel Base 4 4949 Idler Wheel Shaft 4 9 Screw () 494 Guide Rod 8 8 8 49 98 Rod Seal () 0 94 Hex Nut Guide Rod Bushing () 494 Air Cylinder & Nut 494 Idler Cylinder Mount 4 9889 Breather Vent 98 Seal 49 Angular Stop Plate 9 Hex Nut () 8 94 Set Screw 9 498 /4" ubing (") 0 988 Right Angle Fitting 49 Pivot Plate Drive Wheel 90 Set Screw 4 9 Pivot Plate Bushing 9 Pivot Plate Washer 9 Pivot Plate Nut 98 Nut 8 49 Adapter 9 Adapter Assembly 0 Contact Arm Assembly 8 4 80 4 9 Clamping Knob ension Roll Assembly (4) 498 Housing Cover 4 494 Pivot Plate Post () 49 Vacuum Hose Adapter 494 ension Roll Cover 90 urn Latch () 8 98 Sealing Ring 9 49 Slack Guard 80 9 /4" Lock Washer (4) 8 984 Lock Nut () 8 98 Sealing Ring () 8 980 4 Elbow 84* 9409 Bolt (4) 8* 94 Washer (4) 8* 994 Hex Nut () 8 9 80 4 9 8 4 8 4 0 * Individual parts that have an asterisk next to the index number designates optional accessories. * 0 * 8 9 8 * 9 84* 8* 8* OPIONAL 49 PIVOING VACUUM SCOOP ASSEMBLY 40 44 8 4 4 8 4 49 4 4 4 4 9 4 9 40 0 8 8 0 * Note: For complete assembly diagram please refer to page in this tool manual. 4 4 0 4 8 00 N m 4* A 4 KEY Adhesive: = Loctite #09 = Loctite # = Loctite # orque: N m x 8.8 = In. - lbs.
For Models: 4904 490 9809 90 Elbow 98 Cord 984 Lock Nut 4 9804 Electric Motor - 4904 980 Electric Motor - 490 9 Bolt (4) 94 racking Knob 94 Washer () 8 494 Bench Mount Bracket 9 94 Screw () 9044 Lock Washer (8) 904 Washer (4) 94 Screws () 49 racking Knob Support 4 98 Hex Nut () 944 Snap Ring 494 racking Shaft 94 Locking Knob 8 49 Locking Hub 49 Bronze Bushing 0 904 Screw () 49 Restricted Fitting 99 Pressure Gauge 90 Screw () 4 9894-C Regulator * 49 Vacuum ray Knob 94 Bolts () * 499 Bottom Vac ray 8* 490 op Vac ray 9 4940 Housing 0 49 Slide Valve 49 Air Inlet 49 Idler Shaft Support () 99 Snap Ring () 4 8 Bearing 490 Idler Wheel 90 Set Screw 4944 Idler Wheel Base 8 4949 Idler Wheel Shaft 9 9 Screw () 40 494 Guide Rod 4 98 Rod Seal () 4 94 Hex Nut 4 Guide Rod Bushing () 44 494 Air Cylinder & Nut 4 494 Idler Cylinder Mount 4 9889 Breather Vent 4 98 Seal 49 Angular Stop Plate 49 9 Hex Nut () 0 94 Set Screw 498 /4" ubing (") 988 Right Angle Fitting 49 Pivot Plate 4 Drive Wheel 90 Set Screw 9 Pivot Plate Bushing 9 Pivot Plate Washer 8 9 Pivot Plate Nut 9 98 Nut 0 49 Adapter Adapter Assembly Contact Arm Assembly 9 Clamping Knob 4 ension Roll Assembly (4) 498 Housing Cover 494 Pivot Plate Post () * 49 Vacuum Hose Adapter 8 494 ension Roll Cover 9 90 urn Latch () 0 49 Slack Guard 9 /4" Lock Washer () * 9409 Bolt (4) * 94 Washer (4) 4* 994 Hex Nut (4) 4 9 0 9 Versatility Grinder Complete Assembly 4 8* 8 8 * Individual parts that have an asterisk next to the index number designates optional accessories. * 4 0 9 4* * 0 * OPIONAL 49 PIVOING VACUUM SCOOP ASSEMBLY * 4 4 49 4 4 0 8 40 4 44 4 9 4 44 4 9 8 * Note: For complete assembly diagram please refer to page in this tool manual. 9 0 0 00 N m 4 * 4 A 4 9 8 KEY Adhesive: = Loctite #09 = Loctite # = Loctite # orque: N m x 8.8 = In. - lbs.
Machine Specifications Model HP Electrical SFPM Weight Width Length Height Number (W) Specifications (SMPM) Pound (kg) Inch (mm) Inch (mm) Inch (mm) 4900 (44) V ph 0/0 00-4000 (8-) () (4) (88) (9) 490 (44) 0V ph 0/0 00-4000 (8-) () (4) (88) (9) 490 () 0V ph 0/0 000-8000 (-440) () (4) (88) (9) 490 () 40V ph 0/0 000-8000 (-440) () (4) (88) (9) 4904. () V ph 0/0 400 (4) () (4) (88) (9) 490. () 0V ph 0/0 400 (4) () (4) (88) (9) Grit Material Abrasive Belts /4" x " /" x " " x " -/" x " " x " " x 8" (mm x,80mm) (mm x,80mm) (mm x,80mm) (8mm x,80mm) (mm x,80mm) (mm x,98mm) 40 Alumina Zirconia 80 808 809 8 8 *8 0 Alumina Zirconia 84 84 84 844 84 *84 80 Alumina Zirconia 84 8 849 80 8 8 Alumina Zirconia 89 8490 849 849 849 8494 80 Aluminum Oxide 849 849 849 8498 8499 *800 0 Aluminum Oxide 80 80 80 804 80 *80 Super Fine Non-Woven Nylon *89 80 8 8 8 *84 Very Fine Non-Woven Nylon *8 8 8 88 89 *840 Medium Non-Woven Nylon N/4 84 84 844 *84 Coarse Non-Woven Nylon N/4 84 8 849 *80 Cloth Cloth N/4 *84 *84 *844 *84 *Non-stock item please allow -4 weeks delivery. Minimum order quantities may apply. Reference Contact Information. American National Safety Institute ANSI. Government Printing Office GPO West 4 rd Street Superintendent of Documents Forth Floor Attn. New Orders New York, NY 0 P.O. Box 4 el: () 4-4900 Pittsburgh, P0-94 Fax: () 98-00 el: (0) -80. European Committee for Standardization Rue de Stassart B - 0 Brussels, Belgium Visit Our Web Site: www.dynabrade.com DYNABRADE DYNABRADE, INC., 8989 Sheridan Drive Clarence, NY 40-490 Phone: () -00 Fax: --0 International Fax: --4 DYNABRADE EUROPE S.àr.l., Zone Artisanale L- Wormeldange Haut, Luxembourg elephone: 84 94 Fax: 84 9 DYNABRADE, INC., 00 Email: Customer.Service@Dynabrade.com PRINED IN USA