Astro Pneumatic Tool DS2000 User manual

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1
• Save significant time and cost in the removal
of damaged door skins
• Forged and hardened steel de-crimping head
• Designed to unfold the steel flanges of a damaged
door skin with a minimum of physical effort
• De-crimping head can be repositioned at various
angles based on operator preference
• Secondary handle can be installed in either vertical
or horizontal position and adds stability to
help keep the tool oriented
• Patent Pending
Use of this product can expose you to chemicals
such as phthalates which are known to the State
of California to cause cancer, and birth defects or
other reproductive harm. For more information go
to www.P65Warnings.ca.gov/product. Always wear
ANSI approved safety equipment, safety glasses
and clothing when using this product. Study,
understand, and follow all instructions provided
with this product. Failure to read and follow all
warnings and operating instructions may
result in damages and serious injury or death.
Always wear ANSI approved goggles when using
this product.
Always select the correct accessories of the
correct size and design for the job that you are
attempting to perform.
Always work in a clean, safe, well-lit, organized
and adequately equipped area.
Do not begin repairs without assurance that
vehicle is in secure position, and will not move
during repair.
Caution: To help prevent personal injury
Safety Precaution
Foreseen Use of the Tool
Do not use the tool outside of the design intent.
Never modify the tool for any other purpose, or for its use.
Unpacking
When unpacking, check the parts diagram and part number listing
on page 5 to make sure all parts are included. If any parts are
missing or damage, please call your distributor
Important
Read these instructions carefully before
operating this tool.
Keep these instructions in a safe accessible place.
Model: Product Type:
DS2000
PNEUMATIC DOOR SKIN REMOVER TOOL
PNEUMATIC DOOR SKIN REMOVER TOOL
www.astrotools.com
•Astro Pneumatic Tool Co. warrants our products to the original user against
defective material or workmanship for a period of 1 year (except where noted on our
price schedule) from the date of 1st use. Astro reserves the right to determine
whether the product failed because of defective material, workmanship or other
causes and to charge back for missing parts. Astro Pneumatic Tool Co., at its
discretion, will repair products covered under this warranty free of charge. The
distributor should direct the original user to return the product (with the exceptions
listed below) with the distributor’s name, address, adequate proof of date of
purchase or a copy of warranty card, and a short note explaining the problem.
Failures caused by accident, alteration, or misuse are not covered by this
warranty.
•Astro Pneumatic Tool Co. or its authorized service representatives must perform all
warranty repairs. Any repair to the product by unauthorized service representatives
voids this warranty. The rights under this warranty are limited to the original user and
may not be transferred to subsequent owners.
•This warranty is in lieu of all other warranties, expressed or implied, including
warranties of merchantability and fitness for a particular purpose. Some states do
not allow the exclusion of limitations of incidental or consequential damages so the
above limitations may not apply to you. All claims must be sent to:
Astro Pneumatic Tool Company
372 Old US Highway 52 South
Mt. Airy, NC 27030
1 YEAR LIMITED WARRANTY
PLEASE CALL 1-800-221-9705
FOR REPAIR AND RETURN INSTRUCTIONS
Product Information:

2
DS2000 PNEUMATIC DOOR SKIN REMOVER TOOL: BACKGROUND, FEATURES & BENEFITS
Model:
DS2000
Industry Background:
• Removing door skins has always been a very tedious and labor-intensive job typically done using a grinder or carbide burr
to remove the edge of the folded door skin flange, and then using heat to soften the adhesive and finally prying off the
damaged door skin and the remaining flange.
• Other tools have been designed over the years to simplify this job, but none offered a significant improvement or are
just another variation to the typical method.
• A very deliberate sustained effort, to develop a better way of removing a door skin, resulted in the development of a new
way to un-crimp, or un-fold the crimped flange of a damaged door skin resulting in the DS2000 pneumatic power tool.
Features of the DS2000:
• Precision machined aluminum body components, hardened shafts, and ball bearing construction throughout,
for long life and maximum durability to provide many years of trouble free service for real world professional use.
• Forged and hardened steel de-crimping head is specially designed to un-fold the steel flanges of a damaged door skin
with a minimum of physical effort.
• The DS2000 is manufactured to be very versatile with provisions to reposition the un-crimping head to various angles
based on operator preference.
• A secondary handle which can be installed in either the vertical or horizontal position adds stability to help keep the tool
oriented in the proper position.
• Powerful pneumatic drive motor with planetary gear reduction reduces the speed and allows for maximum range of motion
of the un-crimping head.
• Design allows tool to maneuver around inner and outer curves as well as most body design features.
• Close tolerance design and manufacturing, results in a tool that is incredibly smooth, and easy to use.
Benefits to technicians:
• Drastic reduction in the time required to remove a door skin. As much as an hour can be expected improving your bottom
line in a commission or rate environment.
• Significant reduction in operator fatigue, leads to fewer cases of carpal tunnel syndrome and other repetitive motion ailments.
• Light weight and maneuverable yet very powerful.
Benefits to management:
• The drastic reduction in the time required to remove a door skin significantly reduces labor costs.
• Significant reduction in operator fatigue, leads to fewer cases of carpal tunnel syndrome and other repetitive motion ailments
which reduces potential workman's comp claims and costs.
• Elimination of damage to the frame of the door skin eliminates additional labor to repair the damage.
• The reduction in labor, results in a very short payback period on your investment. In many cases the "DS2000" tool pays
for itself within weeks.

3
DS2000 OPERATING INSTRUCTIONS
Thank you for purchasing a DS2000 Pneumatic Door Skin Remover Tool from
Astro Pneumatic tool Company. We are confident that you will be very pleased
with this tool. The DS2000 Door Skinner Tool is very straight forward and simple
to operate, however, spending a few minutes to read through these instructions
and tips could make you proficient in the use of the DS2000 much more quickly.
The DS2000 makes short work of opening the crimp of a factory door skin on
either straight or smoothly contoured door edges. It can be used successfully in
areas as short as 3 inches or infinitely longer. The DS2000 employs a new technique
in removing door skins or other auto body panels. Rather than grinding all around
the edge of a damaged skin, the DS2000 simply de-crimps, or folds the crimp of the
skin open. Secondly, applying a prying force upon the unfolded flange with pliers
typically breaks the adhesive (if any) and facilitates easy removal of the damaged skin,
in a very short period of time without damage to the door frame.
Preparation:
There are a few that must be done to make your job successful.
First, consider your personal safety. Jagged edges of steel are very common in the auto body industry, and
your operating hand will be in close proximity to an edge. Use common sense and Always wear approved
safety equipment and clothing when using this product. Wear an appropriate pair of mechanics gloves while
operating the DS2000 tool, to help prevent personal injury.
Operation:
Now you are ready to un-crimp with the DS2000.
1)
2)
3)
Model:
DS2000
We manufacture an accessory hand tool that is made specifically to assist in starting to unfold a small section
of the crimp, and can also be used in tight body lines where the DS2000 cannot be maneuvered.
Alternately, conventional hand tools like a hammer and sharp chisel can be used to accomplish this task.
Once a small section of the flange has been started, hook the tip of the DS2000 un-crimping head on the started
flange, and apply power to the tool. The reciprocal motion of the head quickly and easily unfolds the flange
as you move the tool along the edge of the damaged door skin.
It is important to note that the crimp must be un-folded in one pass.
The un-crimping head of the DS2000 tool is installed at a 20 degree angle to the body of the tool.
The inside edge of the un-crimping head must be kept parallel to the edge of the door. In other words,
the body of the DS2000 must be kept at a 20 degree angle to the door edge. This angle of operation will keep
your hand free of the ragged steel edge as you move the tool. The head can be removed and re-installed
at different angles in 30 degree increments relative to the body of the tool, should you find it necessary.
A secondary handle is also included with your DS2000 to assist in keeping the tool in the proper position.
This handle can be installed in either of two positions vertical or horizontal based on your preference.
Make sure you have the DS2000 connected to good clean shop air at 90 to 120 PSI.
The DS2000 is designed to be very maneuverable. It is capable of negotiating inside curves,
outside curves, concave and convex door edges, and many style lines.
With a little practice, you will experience outstanding results both on the
exterior surfaces of the door and the inside flange, and save LOTS of time as well.

4
Model:
8) Slip/Trip/Fall is a major reason of serious injury or death.
Beware of excess hose left on the walking or work surface.
9) Wearing eye/face protector could reduce the danger to
person from high speed splinters being emitted from the
tool or work surface.
10) Wearing correct breathing protection will help avoid
inhaling dust or handling debris form work process that
can be harmful to your health.
12) High sound level can cause permanent hearing loss.
Use hearing protection while operating tool.
13) Due to the material being processed, there may be a
risk of explosion or fire. Be aware of work surface dangers
prior to beginning work.
14) There is a risk of being cut due to high speed
rotation. Do not touch high speed rotating parts.
15) This power tool is not insulated. If contact is made with
an electric current injury may occur.
16) Dust created by sanding, sawing, grinding, drilling and
other related activities may expose the user to dust and/or
microscopic particles that may contain chemicals known to
the State of California to cause cancer, birth defects or
other reproductive harm.
Users of this tool should review the chemical composition
of the work surface and any products used in conjunction
with the operation of this tool for any such chemicals prior
to engaging in any activity that creates dust and/or
microscopic particles.
Users should obtain the Material Safety Data Sheets for all
identified chemicals, either from the manufacturer or their
employer, and proceed to study, understand, and follow all
instructions and warnings for exposure to such chemicals.
Some examples of these chemicals are: lead from lead-
based paints; crystalline silica from bricks, cement and
other masonry products; and arsenic and chromium from
chemically treated lumber. A listing of the chemicals can
be obtained from www.oehha.ca.gov under Proposition 65.
In order to reduce their exposure to such chemicals, users
should always:
*work in well-ventilated areas.
*wear appropriate safety equipment and clothing that are
specifically designed to filter out microscopic particles.
Maintenance instruction:
1)Lubrication:
After 3 to 4 hours of operation, oiling
may be necessary again.
2)Tightness of parts:
Regularly check whether all connecting parts are
fastened securely. Follow this procedure daily
before beginning work.
3)Cleanness:
Dust may accumulate around spindle inside
shield. It is recommended to remove
the dust on daily basis.
4)Storage:
Avoid storing the tool in a location subject to high
humidity. If the tool is left unused, the residual
moisture inside the tool can cause rust. Before
storing and after operation, oil the tool at the air
inlet with spindle oil and run it for a short period.
5)Disposal:
Follow national legislation of Waste disposal. Never
drop into fire.
6)Ordering service part:
For further operational and handling information or
for replacement of parts and components, contact the
sales agent from where you purchased the tool, or the
service division of our company.
*In ordering parts and components, give each part
number, name and quantities.
1) The tool shall not be used in potentially explosive
atmospheres.
2) Disconnect the air hose before changing or
adjusting any inserted tools.
3) Before using tool, please confirm all couplings
and plugs are fixed securely. Air hose that is under
pressure may lash out when disconnected
and could lead to serious injuries.
4) Prevent loose clothes, long hair or any other
personal accessories from coming close to moving
parts to reduce the risk of being caught, trapped
or drawn into the rotating spindle.
5) Excessive high air pressure, that exceeds the
maximum pressure, may cause injuries to user.
6) Exposure to strong vibration for extended time
may cause harm to operator.
7) Make sure of the rotation direction before starting
the tool to reduce hazardous situations due to
unexpected rotation direction.
Cautions for Use
1) Always wear ear protection and safety glasses when using
this tool. Gloves and protective clothing are recommended.
2) Personal protection and dust collection devices shall be
chosen according to the material being worked upon. Please
consult provider of such devices.
3) Basic safety instructions and warnings must always be
followed. in addition, safety instructions & warnings identified
in ANSI B186.1 Safety Code for Portable Air Tools must be
followed. For further ANSI information see www.ansi.org or
call [phone]
DS2000

49
5
DS2000
Call 1.800.221.9705 for questions concerning performance of the product
or other inquiries.
372 Old US Highway 52 South
Mount Airy, NC 27030
DS2000-01
DS2000-02
DS2000-03
DS2000-04
DS2000-05
DS2000-06
DS2000-07
DS2000-08
DS2000-09
DS2000-10
DS2000-11
DS2000-12
DS2000-13
DS2000-14
DS2000-15
DS2000-16
DS2000-17
DS2000-18
DS2000-19
DS2000-20
DS2000-21
DS2000-22
DS2000-23
DS2000-24
DS2000-25
Motor Housing
Lever
Pin
Inlet
Valve Bushing
O-Ring
O-Ring
Valve Stem
Valve Spring
Air Regulator
O-Ring
O-Ring
Valve Plug
Ball Bearing
Rear End Plate
Pin
Cyllinder
Rotor Blade
Rotor
Front End Plate
Internal Gear
Planet Gear
Planet Carrier
Baller Bearing
Spacer
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
4
1
1
1
3
1
2
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Index
No.
DS2000-26
DS2000-27
DS2000-28
DS2000-29
DS2000-30
DS2000-31
DS2000-32
DS2000-33
DS2000-34
DS2000-35
DS2000-36
DS2000-37
DS2000-38
DS2000-39
DS2000-40
DS2000-41
DS2000-42
DS2000-43
DS2000-44
DS2000-44P
DS2000-45
DS2000-46
DS2000-47
DS2000-48
DS2000-49
Retainer Ring
Needle
Needle Plate
Drive Spindle
Angle Head
Screw
Screw
Ball Bearing
Retainer Ring
Retainer Ring
Spacer
Spacer
Ball Bearing
Spacer
Retainer Ring
Spindle
Blade
Plate
Screw
Spring Washer
Handle
Hex Wrench
Cover
Gasket
Door Skin Starter Pliers
1
13
1
1
1
2
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
44P
45
46
47
48
49
Index
No.

6
Foreseen Use of the Tool
Do not use the tool outside of the design intent.
Never modify the tool for any other purpose, or for its use.
Model: Product Type:
ASTRO PRODUCTS AVAILABLE FOR AIR FILTRATION:
2618 - AIR CONTROL UNIT - 120CFM CAPACITY
2616 - 3/8" FILTER, REGULATOR & LUBRICATOR WITH GAUGE
DS2000
PNEUMATIC DOOR SKIN REMOVER TOOL
INSTRUCTIONAL VIDEO