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DMP0145, SMALL AIR ROUTER KIT

USER MANUAL

© Dark Matter Composites Ltd

Page 2 of 23

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+44 (0)1582 79100

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.darkmattercomposites.com

Unit 8 Redbourn Industrial Estate, High Street, Redbourn, Hertfordshire, AL3 7LG, UK

Registered in England & Wales No: 5395870

User & Warranty Information

IMPORTANT USER &

WARRANTY INFORMATION

PLEASE READ IN FULL PRIOR TO USE

The Dark  Matter  Composites  ‘Small Air  Router Kit’  comprises  of  a  modified  Dynabrade  Air
Motor and vacuum  extraction  assembly designed  specifically  for trimming composite
materials/parts and  preparation  of  cured  composite  surfaces  for  co-bonding  and  secondary
bonding operations.

Prior  to  use,  please  read  all  ‘Dynabrade’  and  ‘Dark  Matter  Composites’  documentation
provided  with  this  ‘Small Air  Router Kit’  and  within  this  User  Manual  in  full.    No  part  of
this  kit  can  be  considered  ‘typical’  or  ‘independent’  from the  tool  kit  as  a  whole. The
following documents are provided with this kit:
Dynabrade, Pneumatic Tool Safety & Operating Guidelines
Dynabrade, Industrial Pneumatic Tools Lifetime Warranty
Dynabrade, Required Tool Maintenance
Dynabrade, Operating, Maintenance and Safety Instructions
Dynabrade, Air Tools Specifications
Dark Matter Composites Ltd, Small Air Router Kit User Manual (this document)

The  Dynabrade air motor supplied  as  part  of  the  kit  is  specified  uniquely  to  Dark  Matter
Composites  Ltd. The  Dynabrade  manual  PD10

12 ‘Air  Tool  Manual - Safety,  Operation  and

Maintenance’ is applicable to the air motor supplied as part of this kit as well as the instructions
related directly to the ‘Small Air Router Kit’ in this manual.

The  instructions  provided within  this  ‘User  Manual’  are  in  addition  to  the  Dynabrade
documentation included within the ‘Small Air Router Kit’.

This  tool  kit  has  also  been  designed  to  be  used  in  conjunction  with  a  suitable  portable/mobile
dust  extraction  unit  suitable  for  use  with ‘on-tool’  dust  extraction.    Dark  Matter  Composites
provides  a  range  of  dust  extraction  units  that  are  compatible  with  this  tool  kit.    Assessment  of
the  suitability  and  end  use  of  third  party  extraction  units  is  the  sole  responsibility  of  the
purchaser.

Use  of  this  tool  kit  outside  of  the  applications  identified  or  the  instructions  provided  within  this
user manual are not covered by the warranty.

In order to provide a full product support service, Dark Matter Composites offers training
courses  on  how  to  use  and  get  the  best  from  the  tool  kit  as  well  as  a  full  range  of
recommended electric and air driven portable dust extraction units.

Summary of Contents for DMP0145

Page 1: ...hinery Directive Declaration of Conformity 3 Dynabrade PD10 12 Air Tool Manual Safety Operation and Maintenance 5 1 Diamond Routing Bits 13 Special Notes 13 2 Fitting Removal of Diamond Routing Bits 1...

Page 2: ...ools Specifications Dark Matter Composites Ltd Small Air Router Kit User Manual this document The Dynabrade air motor supplied as part of the kit is specified uniquely to Dark Matter Composites Ltd Th...

Page 3: ......

Page 4: ......

Page 5: ...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...

Page 6: ...Tools exhaust may contain lubricants bearing grease and other materials Direct exhaust away from operator Do not use cut off wheels or router bits in this tool Note the tool rundown time Control the...

Page 7: ...SIG at Air Tool Air Compressor and Receiver Drain Valve Air Hose 90 PSIG MAX 6 2 Bar Air Flow Refrigerated Air Dryer Filter Regulator Lubricator 90 PSIG 6 2 Bar 1 DROP MIN 20 SCFM LUBRICATOR SETTING L...

Page 8: ...96016 O Ring 24 52882 Felt Muffler 25 Cover 52883 Model 52861 52884 Model 52862 52888 Model 52863 52889 Model 52864 26 01464 Seal 27 58365 Tip Valve 28 52880 Retainer Cover 29 01468 Spring 30 01494 In...

Page 9: ...t bearing plate shims and the 01479 Spacer Air Motor Disassembly Complete Air Motor Assembly 1 Install the 01479 Spacer onto the rotor 2 Select 003 08mm thickness shims from the 54529 Shim Pack and in...

Page 10: ...Use a small flat blade screwdriver to push the valve stem over so that the tip valve will fit into the air inlet opening properly 8 Use needle nose pliers to grasp the back of the 58365 Tip Valve and...

Page 11: ...ng by turning it counterclockwise 3 Use the 96076 Wrench 12mm to hold the 01435 Collet Body stationary while using the 95262 Wrench 14mm to loosen the 01484 Collet Cap by turning it counterclockwise 4...

Page 12: ...use due to unclean air wet air or insufficient lubrication Provides accurate air pressure regulation and two stage filtration of water contaminates FIND THE MOST CURRENT OFFERING OF SUPPORT DOCUMENTS...

Page 13: ...aminates In some cases small localised debris between 1 4mm maybe projected locally which falls but does not become airborne Fluted Router Bits For fine laminates and sandwich panels to ensure effecti...

Page 14: ...lvent or detergent overnight Brush the degraded resin from the surface planer using a fine wire brush and continue to clean as above It is difficult to assess the level of wear or the life of diamond...

Page 15: ...roud pipe assembly onto the collar adaptor hold the airline swivel joint so that it does not interfere with the vacuum tube and to support the end of the air motor 8 Rotate the body of the air motor t...

Page 16: ...ase Ensure a minimum of two full threads are engaged 2 revolutions Hold the vacuum shroud pipe assembly and tighten the lock nut with the 30mm spanner 3 Zero Adjustment of Routing Bits SAFETY NOTICE A...

Page 17: ...router assembly and check the router bit is level with the base using a straight edge 7 If required loosen the locknut make any fine adjustments necessary and tighten the locknut 8 Using a fine perma...

Page 18: ...adjustment is achieved using a 1mm metric thread pitch 0 039 on the router collar adaptor Note that 0 001 of depth is lost per full thread due to conversion from metric to imperial If required make a...

Page 19: ...s removed part of the router base may become suspended above the part surface Do NOT hold the air motor hold the router assembly at the vacuum shroud Press down on the vacuum shroud where the base mak...

Page 20: ...eck correct operation over the full speed range and then cease operation of the air motor 10 If there is any problem with the setup of the air router or any unusual imbalance or vibration present ceas...

Page 21: ...s manual the following cleaning and maintenance activities should be followed Routing Bits Remove and clean the routing bits as detailed in section 1 Router Assembly The following parts of the router...

Page 22: ...h a compatible portable extraction unit The combination of a lightweight Dynabrade air motor with a bespoke vacuum shroud and bespoke cutters requires very specific extraction Advice for Dust Free Ope...

Page 23: ...oes not become airborne The presence of debris varies dependant upon the quality of the laminate and the feed rate used We have much more information available please contact us to discuss your requir...

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