Dark Matter DMP0145 User manual

dark matter composites ltd
t/f [phone] www.darkmattercomposites.com
Unit 8 Redbourn Industrial Estate, High Street, Redbourn, Hertfordshire, AL3 7LG, UK
Registered in England & Wales No: 5395870
‘Small Air Router Kit’
Product Code - DMP0145
USER MANUAL
Contents
User & Warranty Information..............................................................................2
Dynabrade ‘EC Machinery 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.................................................14
Fitting .........................................................................................................14
Removal.....................................................................................................15
3. Zero Adjustment of Routing Bits..................................................................16
4. Depth Adjustment of Routing Bits................................................................18
Special Notes.............................................................................................18
Depth Adjustment.......................................................................................18
5. Using the Router Vacuum Guide Base........................................................19
Special Notes.............................................................................................19
Using the Vacuum Guide Base..................................................................20
6. Cleaning & Maintenance..............................................................................21
7. Compatible Portable Extraction ...................................................................22
Advice for Dust Free Operations................................................................22

DMP0145, SMALL AIR ROUTER KIT
USER MANUAL
© Dark Matter Composites Ltd
Page 2 of 23
t/f [phone] www.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.

SAFETY INSTRUCTIONS
Carefully Read all instructions before operating or servicing any Dynabrade®Abrasive Power Tool.
Products offered by Dynabrade are not to be modified, converted or otherwise altered from the original design.
Tool Intent: Pencil Grinder Tools are ideal for engraving, light deburring, deflashing, surface preparation, cleaning and finishing using the proper abrasive
stones, abrasive mounted wheels, points, molded abrasives, and carbide burrs.
Do not use tool for anything other than its intended applications.
This power tool is not intended for use in potentially explosive atmospheres and is not insulated against contact with electrical power.
Training: Proper care, maintenance, and storage of your tool will maximize performance.
• Employer's Responsibility – Provide Pencil Grinder operators with safety instructions and training for safe use of tools and accessories.
Accessory Selection:
• Abrasive/accessory RPM (speed) rating MUST be approved for AT LEAST the tool RPM rating.
(continued on next page)
Parts Page Reorder No. PD10•12
Effective February, 2010
Supersedes PD06•17
25,000 RPM Pencil Grinder
Air Tool Manual – Safety, Operation and Maintenance
SAFETY LEGEND
WARNIN
G
WARNING
Read and understand tool manual before
work starts to reduce risk of injury to
operator, visitors, and tool.
WARNING
Eye protection must be worn at all times,
eye protection to conform to ANSI Z87.1.
WARNING
Respiratory protection to be used when exposed to
contaminates that exceed the applicable threshold
limit values required by law.
WARNING
Practice safety requirements. Work alert,
have proper attire, 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/or regulations.
WARNING
Air line hazard, pressurized supply lines and flexible
hoses can cause serious injury. Do not use damaged,
frayed or deteriorated air hoses and fittings.
Read and understand this tool manual before operating your air tool. Follow all safety rules for the protection of operating personnel
as well as adjacent areas. Always operate, inspect and maintain this tool in accordance with the American National Safety Institute
(ANSI) Safety Code for Portable Air Tools – B186.1. For additional safety information, refer to Safety Requirements for the Use, Care
and Protection of Abrasive Wheels – ANSI B7.1, Code of Federal Regulation – CFR 29 Part 1910, European Committee for Standards
(EN) Hand Held Non-Electric Power Tools – Safety Requirements and applicable State and Local Regulations.
SAVE THIS DOCUMENT, EDUCATE ALL PERSONNEL
Models:
WARNING
Some dust created by sanding, sawing, grinding, drilling, and other construction activities contain chemicals known to cause cancer,
birth defects or other reproductive harm. Some examples of these chemicals are:
• Lead from lead-based paints
• Crystalline silica from bricks and cement and other masonry products
• Arsenic and chromium from chemically treated lumber
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well
ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.
FIND THE MOST CURRENT OFFERING OF SUPPORT DOCUMENTS AND ACCESSORIES @ WWW.DYNABRADE.COM
5286X

2
SAFETY INSTRUCTIONS (Cont.)
• Before mounting an accessory, visually inspect for defects. Do not use defective accessories.
• Always match collet insert with accessory shaft size. i.e. 1/8" shaft = 1/8" collet insert
• Follow tool specifications before choosing size and type of accessory (see pg. 7 for ANSI Group W plain wheels).
• Only use recommended fittings and air line sizes. Air supply hoses and air hose assemblies must have a minimum working pressure rating of 170 PSIG
(10 Bars, g) or working pressure limited to 113 PSIG for all 25,000 RPM Pencil Grinders.
• If a grinding bit is broken, a careful investigation should be made by the user to determine and correct the cause.
OPERATING INSTRUCTIONS
Warning: Always wear personal protection equipment. Operator of tool is responsible for following: accepted eye, face, respiratory, hearing, hand and
body protection. Adjacent personnel must be protected from potential injury.
Caution: Hand, wrist and arm injury may result from repetitive work, motion and overexposure to vibration.
Operation: Be sure that any loose clothing, hair and all jewelry is properly restrained. Keep hand and clothing away from working end of the air tool.
• BEFORE MOUNTING AN ACCESSORY, after all tool repairs and whenever a pencil grinder is issued for use, check tool RPM (speed) with tachometer
with air pressure set at 90 PSIG while the tool is running. If tool is operating at a higher speed than the RPM marked on the tool housing, or operating
improperly, the tool must be serviced and corrected before use.
Caution:Tool RPM must never exceed abrasive/accessory RPM rating. Check accessory manufacturer for details on maximum operating speed or special
mounting instructions.
• With power source disconnected from air tool check the collet to assure it is in good condition. If so mount the recommended accessory.
• Make sure tool is off and then connect power source.
Do not expose air tool to inlet pressure above 90 PSIG or (6.2 Bars).
Caution: After installing the accessory, before testing or use and/or after assembling tool, the pencil grinder must be started at a reduced speed to check
for good balance. Make sure no one is in the unguarded plane of the accessory. Gradually increase tool speed. DO NOT USE if tool vibration is
excessive. Correct cause, and retest to insure safe operation. Run tool for 1 minute of operating speed in a protected area.
• Make sure that work area is uncluttered, and visitors are at a safe range from the tools and debris.
• Use a vise or clamping device to hold work piece firmly in place.
• Do not apply excessive force on tool or apply “rough” treatment to it.
• Always work with a firm footing, posture and proper lighting.
• Ensure that sparks and debris resulting from work do not create a hazard.
• Debris from working certain materials may have the tendency to create a spark/ignition hazard, understand the properties and associated risk of the
materials being worked.
• 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 tool as if it were under power.
• Use long shank burrs (1.9" or longer) with caution. They are subject to bending, whipping, and breaking when run at high speeds.
• The rated RPM of a mounted point is lowered if the overhang (end of collet to abrasive) exceeds .5 inches (12.7mm).
Refer to the included tables. Reference ANSI B 7.1 for a more complete listing and additional information.
• Always use/replace collet cover after accessory changes. To avoid risk of injury due to rotating collet always operate tool with collet cover in place.
• Use hearing protection when working with materials that produce high process noise levels. Permanent hearing loss can result from high sound levels.
• Mineral spirits are recommended when cleaning the tool and parts. Do not clean tool or parts with any solvents or oils containing acids, esters,
ketones, chlorinated hydrocarbons or nitro carbons.
• Do Not set the tool down until the on/off valve is OFF and the tool has stopped turning.
• If power source is interrupted ensure tool is in OFF position before setting tool down.
Report to your supervisor any condition of the tool, accessories, or operation you consider unsafe.
MAINTENANCE INSTRUCTIONS
Important: A Preventative Maintenance Program is recommended for this tool. The program should include inspection of air supply lines, air line pressure
and repair of tools. Refer to ANSI B186.1 for additional maintenance information.
• Use only genuine Dynabrade replacement parts to insure quality. To order replacement parts, specify Model#, Serial# and RPM of your air tool.
• All Dynabrade Air Tools must be used with a Filter-Regulator-Lubricator to maintain all warranties.
Routine Preventative Maintenance:
• It is strongly recommended that all Dynabrade rotary vane air tools be used with a Filter-Regulator-Lubricator to minimize the possibility of misuse due
to unclean air, wet air or insufficient lubrication. Dynabrade recommends the following: 11411 Air Filter-Regulator-Lubricator (FRL) – Provides accurate
air pressure regulation and two stage filtration of water contaminates. Operates Up to 55 SCFM/1,558 LPM @ 100 PSIG with 1/2" NPT female ports.
• Dynabrade recommends Dynabrade Air Lube (P/N 95842 1pt. (473ml).
• DO NOT clean or lubricate tools with chemicals that have a low flash point (example: WD-40®).
• Air tool markings must be kept legible at all times. User is responsible for maintaining specification information i.e.: Model #, S/N, and RPM.
• Blow air supply hose out prior to initial use.
• Visually inspect air hoses and fittings for frays, visible damage and signs of deterioration. Replace damaged or worn components.
• Check free speed of pencil grinder using a tachometer on a regular basis.
• Refer to Dynabrade's Warning/Safety Operating Instructions Tag (Reorder No. 95903) for safety information.
Handling and Storage:
• Use of tool rests, hangers and/or balancers is recommended.
• Protect tool inlet from debris.
• DO NOT carry tool by air hose.

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. Air pressure easily forces dirt or water contained in the air supply into motor bearings causing early failure. Dirt
and water often score the inner workings of the tool 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 maintenance during the use of this tool.
3
Air System
• Dynabrade Air Power Tools are designed to
operate at 90 PSIG (6.2 Bar/620 kPa) maximum
air pressure at the tool inlet, when the tool is
running. Use recommended regulator to control
air pressure at each work station, if the supply
pressure is high.
• Ideally the air supply should be free from
moisture. To facilitate removing moisture
from air supply, the installation of a
refrigerated air dryer after the compressor
and the use of drain valves at each
tool station is recommended.
MAINTENANCE INSTRUCTIONS - CONTINUED
Handling and Storage:
• Protect abrasive accessories from exposure to water, solvents, high humidity, freezing temperature and extreme temperature changes.
• Store accessories in protective racks or compartments to prevent damage.
To Tool Station
Closed Loop Pipe System
Ball
Valve
Ball
Valve
Filter
Regulator
Lubricator
Air Flow
Drain
Valve
Drain
Valve
PSIG 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)
1DROP/MIN.
20 SCFM
LUBRICATOR SETTING
➤➤
➤
➤
➤
➤
Lifetime Warranty
All Dynabrade portable pneumatic power tools are rigorously inspected and performance tested in our factory before shipping to our customers. If
a Dynabrade tool develops a performance problem and an inherent defect is found during normal use and service, Dynabrade will warrant this tool
against defects in workmanship and materials for the lifetime of the tool. Upon examination and review at our factory, Dynabrade shall confirm that
the tool qualifies for warranty status, and will repair or replace the tool at no charge to the customer. Normally wearable parts and products are
NOT covered under this warranty. Uncovered items include bearings, contact wheels, rotor blades, regulators, valve stems, levers, shrouds,
guards, O-rings, seals, gaskets and other wearable parts. Dynabrade’s warranty policy is contingent upon proper use of our tools in accordance
with factory recommendations, instructions and safety practices. It shall not apply to equipment that has been subjected to misuse, negligence,
accident or tampering in any way so as to affect its normal performance. To activate lifetime warranty, customer must register each tool at
www.dynabrade.com. Dynabrade will not honor lifetime warranty on unregistered tools. A one-year warranty will be honored on all unregistered
portable pneumatic power tools. Lifetime warranty applies only to portable pneumatic tools manufactured by Dynabrade, Inc. in the USA. Lifetime
warranty applies only to the original tool owner; warranty is non-transferable.

101484 Collet Cap
2Collet Insert
01495 1/8 in.
01496 3mm
01485 1/4 in.
01497 6mm
352881 Tactile Grip
452879 Collet Cover
52898 Thread Guard (Optional)
552885 Housing
652897 Grip
701435 Collet Body
802649 Bearing
954529 Shim Pack (3/Pkg.)
10 02038 Front Bearing Plate
11 01479 Spacer
12 01480 Vane (4/Pkg.)
13 01475 Rotor
14 01476 Cylinder
15 50767 Pin
16 52871 Rear Bearing Plate
17 02696 Bearing
18 52872 Air Inlet Gasket
19 52875 Manifold
20 97416 Pin
21 98459 O-Ring
22 52876 Plunger
23 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 Inlet Bushing
Index Key
No. Part # Description
Adhesive: A3= Loctite #242
A7= Loctite #222
A8= Loctite #567
Torque: N•m x 8.85 = In. - lbs.
A
T
KEY
4
97787 Adjustable Spanner Wrench
1
96076 12mm Wrench
95262 14mm Wrench
Special Repair Tools
Part # Description
17 N•m
T
A8
O1
O
1
O1
23 N•m
T
A
8
Pencil Grinder Complete Assembly
3
2
11
10
9
8
7
17
16
15
14
13
24
23
30
29
28
27
26
25
20
22
18
4
5
6
Models:
52861, 52862
52863, 52864
19
12
21
Always follow adhesive manufacturers
cleaning and priming recommendations.

Disassembly/Assembly Instructions – 25,000 RPM Pencil Grinder
Important: Manufacture warranty is void if tool is disassembled before warranty expires by anyone other than a Dynabrade authorized repair technician.
Notice: All of the special tooling referred to in these instructions can be ordered from your Dynabrade Distributor. Please refer to this parts page
for correct part identification. Before servicing this air tool always shut off the air supply valve and dissipate the remaining air pressure before
disconnecting the tool from the air supply.
Valve Disassembly:
1. Remove the collet cover with grip from the 52885 Housing by turning it counterclockwise.
2. Use the 96076 Wrench (12mm) to hold the 01435 Collet Body stationary while using the 95262 Wrench (14mm) to remove the 01484 Collet Cap by
turning it counterclockwise.
3. Place the 52296 Repair Collar around the thickest portion of the 52885 Housing.
4. Fasten the tool with the repair collar into a vise so that the collet body is pointing down.
5. Use two wrenches, one to hold the 01494 Inlet Bushing stationary, and one to remove the 96229 Male Fitting from the inlet bushing. Turn
the fitting counterclockwise.
6. Use a wrench to remove the 01494 Inlet Bushing by turning it counterclockwise.
7. Remove the 52880 Cover Retainer, cover, and 52882 Felt Muffler.
8. Remove the 01468 Spring, 58365 Tip Valve, 01464 Seal, and 52876 Valve Stem.
Valve Disassembly Complete.
Access Air Motor:
1. Remove the 96016 O-Ring.
2. Use a HOT AIR GUN to apply heat to the 52875 Twist Valve Manifold.
3. Use an adjustable wrench to remove the twist valve manifold from the 52885 Housing by turning it counterclockwise.
4. Remove the 52872 Air Inlet Gasket from the twist valve manifold.
5. Push the air motor assembly out of the 52885 Housing.
Air Motor Disassembly:
1. Fasten the 96346 2" Bearing Separator around the portion of the 01476 Cylinder that is closest to the 52871 Rear Bearing Plate. Place the bearing
separator on the table of the 96232 #2 Arbor Press so that the collet body is pointing down. Use a 3/16" or 5mm diameter flat end drive punch as a
press tool and push the rotor out of the 02696 Bearing. Use the 96210 Bearing Removal Tool and the arbor press to remove the 02696 Bearing from
the rear bearing plate.
2. Fasten the vane slot portion of the rotor in a vise with aluminum or bronze jaws so that the collet body is pointing up.
3. Use an adjustable wrench to remove the collet body by turning it counterclockwise.
4. Remove the front 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 install these into the 02038 Front Bearing Plate.
3. Install the 02649 Bearing into the front bearing plate.
4. Position the rotor in a vise with aluminum or bronze jaws so that the rotor spindle is pointing up. Install the front bearing/plate/shims onto the rotor.
5. Install the 01435 Collet Body onto the rotor. (Torque to 17N·m/150 in. lbs.)
6. Remove the assembly from the vise.
7. Use a .001" (0.3mm) thick feeler gauge to check the clearance between the front bearing plate and the face of the rotor. The clearance should
be .001"-.0015" (0.3-0.4mm). Note: If the clearance needs adjustment repeat steps 2-6, adding or removing shims as required.
8. Lubricate the 01480 Vanes (4) with the 95842 Dynabrade Air Lube 10W/NR (or equivalent) and install these into the rotor.
9. Install the 01476 Cylinder over the rotor so that the air inlet opening of the cylinder will line up with the air inlet opening in the 52871 Rear Bearing Plate.
10. Use the raised outer diameter of the 96216 Bearing Press Tool and the 94232 #2 Arbor Press to install the 02696 Bearing into the
52871 Rear Bearing Plate.
11. Use the raised inner diameter of the 96216 Bearing Press Tool and the arbor press to install the rear bearing/plate onto the rotor.
Note: Carefully press the bearing/plate down until it just touches the cylinder. This will establish a snug fit between the bearing plates and the cylinder.
12. Install the 52872 Air Inlet Gasket into the twist valve manifold carefully so that the air inlet is completely open.
13. After threaded surfaces have been properly cleaned and primed, apply a small amount of the Loctite®#567 to the external threads of the 52875 Twist
Valve Manifold.
14. Position the air motor so that the 52871 Rear Bearing Plate fits into the 52875 Twist Valve Manifold.
15. Carefully slide the motor assembly into the 52885 Housing and thread the twist valve manifold into the housing.
(Torque to 17N·m/150 in. lbs.)
16. Install the 96016 O-Ring onto the 52875 Twist Valve Manifold.
Air Motor Assembly Complete.
Valve Assembly:
1. Position the tool with the 52296 Repair Collar in a vise so that the opening for the 52876 Valve Stem is facing up.
2. Install the 52876 Valve Stem along with the 98459 O-Ring into the 52875 Twist Valve Manifold.
3. Install the 52882 Felt Muffler into the deep curved recess in the cover and carefully slide the cover onto the twist valve manifold.
4. Position the tool with the 52296 Repair Collar in a vise so that the air inlet opening is facing up. (continued on next page)

This service chart is published as a guide to expectant life of component parts. The replacement levels are based on average tool
usage over one year. Dynabrade Inc. considers one year usage to be 1,000 hours.
Parts Common to all Models:
Preventative Maintenance Schedule
For All 25,000 RPM Pencil Grinders
Index Part Description Number High Wear Medium Wear Low Wear Non-Wear
# Number Required 100% 70% 30% 10%
101484 Collet Cap 1 X
2See Note Collet Insert 1X
352881 Tactile Grip 1 X
452879 Collet Cover 1 L
552885 Housing 1 X
652897 Housing 1 X
701435 Collet Body 1 X
802649 Bearing 1 T
954529 Shim Pack (3/Pkg.) 1 T
10 02038 Front Bearing Plate 1 X
11 01479 Spacer 1 X
12 01480 Vane (4/Pkg.) 1 T
13 01475 Rotor 1 X
14 01476 Cylinder 1 X
15 50767 Pin 1 X
16 52871 Rear Bearing Plate 1 X
17 02696 Bearing 1 T
18 52872 Air Inlet Gasket 1 T
19 52875 Manifold 1 X
20 97416 Pin 1 D
21 98459 O-Ring 1 T
22 52876 Plunger 1 T
23 96016 O-Ring 1 T
24 52882 Felt Muffler 1 T
25 See Note Cover 1X
26 01464 Seal 1 T
27 58365 Tip Valve 1 T
28 52880 Retainer Cover 1 X
29 01468 Spring 1 T
30 01494 Inlet Bushing 1 X
6
LEGEND
XType of wear, no other
comments apply.
LEasily lost. Care during
assembly/disassembly.
DEasily damaged during
assembly/disassembly.
RReplace each time tool is
disassembled.
Disassembly/Assembly Instructions – (Continued)
5. Install the 52880 Cover Retainer onto the cover.
6. Install the 01464 Seal into the air inlet opening so that it lays flat.
7. 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 insert it into the air inlet opening.
9. Use needle nose pliers to install the 01468 Spring into the air inlet opening so that the small end of the spring fits against the Tip valve.
10. After threaded surfaces have been properly cleaned and primed, apply a small amount of the Loctite® #567 onto the external threads of the 01494 Inlet
Bushing and install the inlet bushing into twist valve manifold. (Torque to 23N·m/200 in. lbs.)
11. Using two wrenches, one to hold the 01494 Inlet Bushing stationary, and one to install the 96229 Male Fitting into the inlet bushing by
turning it clockwise.
12. Remove the tool from the vise.
13. Install the collet insert and cap onto collet body.
14. Install the collet cover and grip assembly onto the 52885 Housing by turning it clockwise.
Valve Assembly Complete. Assembly Complete. Allow adhesive to cure (follow adhesive manufacturers recommendations) before operating tool.
Important: Tool should now be tested for proper operation at 90 PSIG. If tool does not operate properly or operates at a higher RPM than marked on the
tool, the tool should be serviced to correct the cause before use. Before operating, place 2-3 drops of Dynabrade Air Lube (P/N 95842) directly into air inlet
with cover turn to the on position. Operate tool for 30 seconds to determine if tool is operating properly and to allow lubricating oils to properly permeate motor.
Note: Please refer to page 4 of tool manual for specific part number or number required.

Note: Reprinted with permission of United Abrasives Manufacturers Association From (ANSI B7.1). For more information on other type mounted wheels refer
to (ANSI B7.1) Safety requirements for use, care and protection of Abrasive wheels.
7
Pencil Grinder Reference Tables
Collet Insert/Accessory Mounting Instructions
Changing A Collet Insert/Accessory:
1. Disconnect tool from power source.
2. Remove the collet cover with grip from the
52885 Housing 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. Insert desired bit into collet insert a minimum of one inch or
at least half the overall length of the accessory and tighten 01484
Collet Cap using 95262 Wrench (14mm) while holding 01435
Collet Body stationary using 96076 Wrench (12mm).
Note: See table 27 above for overhang limits for plain
wheels (Group W).
5. Attach collet cover with grip onto 52885 Housing
by turning it clockwise.
Collet Insert Housing
Collet Cap Collet Cover Collet Body

DYNABRADE
®
DYNABRADE, INC., 8989 Sheridan Drive • Clarence, NY 14031-1419 • Phone: [phone] • Fax: [phone] • International Fax: [phone]
DYNABRADE EUROPE S.àr.l., Zone Artisanale • L-5485 Wormeldange—Haut, Luxembourg • Telephone: [phone] • Fax: [phone]
© DYNABRADE, INC., 2010 PRINTED IN USA PD10.12_02/10
Visit Our Web Site: www.dynabrade.com Email: Customer[email protected]
Optional Accessories
Machine Specifications
Model Motor Sound Maximum Air Flow Air Pressure Collet Weight Length Height
Number RPM Level SCFM (LPM) PSIG (Bars) Size Pound (kg) Inch (mm) Inch (mm)
52861 25,000 79 dB(A) 16 (445) 90 (6.2) 1/8" 1.1 (.48) 5-5/8 (144) 1-1/2 (39)
52862 25,000 79 dB(A) 16 (445) 90 (6.2) 3mm 1.1 (.48) 5-5/8 (144) 1-1/2 (39)
52863 25,000 79 dB(A) 16 (445) 90 (6.2) 1/4" 1.1 (.48) 5-5/8 (144) 1-1/2 (39)
52864 25,000 79 dB(A) 16 (445) 90 (6.2) 6mm 1.1 (.48) 5-5/8 (144) 1-1/2 (39)
Additional Specifications: Air Inlet Thread 1/4" NPT • Hose Size 1/4" (6mm)
Sound Level is the pressure measurement according to the method outlined in ISO regulation ISO-15744
Model 93351
• 1/8" Carbide Burr Kit, Includes 12 burrs for
grinding, deburring, and finishing metal.
10681 Filter-Regulator-Lubricator
• Minimize the possibility of misuse 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 AND ACCESSORIES @ WWW.DYNABRADE.COM
94994 Over Hose Assembly
• Over Hose Assembly directs exhaust
away from operator.
52898 Optional Thread Guard
• Gives a tactile warning near the
working end of the tool.
97787 Spanner Wrench
• Assembly/Disassembly tool, used to
properly hold housing.
52877 Tool Hanger
• Allows for tool to be suspended by a
tool hanger for ease of use.
52296 Repair Collar
• Specially designed collar for use in vise to
prevent damage to valve body housing
during disassembly/assembly.
Dynabrade Air Lube
• For pneumatic equipment.
• Absorbs up to 10% of its weight in water.
• Prevents rust and formation of sludge.
95821: 4 oz. (118 ml)
95842: 1 pt. (473 ml)
95843: 1 gal. (3.8 L)
Reference Contact Information
1. American National Standards
Institute – ANSI
25 West 43rd Street
Forth Floor
New York, NY 10036
Tel: [phone]
Fax: [phone]
3. Power Tool Institute, Inc.
P.O. Box 818
Yachata, Oregon 97498-0818
Tel: [phone]
Fax: [phone]
4. European Committee for Standardization
Rue de Stassart 36
B - 1050 Brussels, Belgium
2. Government Printing Office – GPO
Superintendent of Documents
Attn. New Orders
P.O. Box 371954
Pittsburgh, PA 15250-7954
Tel: [phone]

DMP0145, SMALL AIR ROUTER KIT
USER MANUAL
© Dark Matter Composites Ltd
Page 13 of 23
t/f [phone] www.darkmattercomposites.com
Unit 8 Redbourn Industrial Estate, High Street, Redbourn, Hertfordshire, AL3 7LG, UK
Registered in England & Wales No: 5395870
1. Diamond Routing Bits
The tool kit is supplied with a pair of diamond routing bits, either parallel or fluted. The use of
diamond grit provides the most effective material for removing composite materials with air
tools. The diamond grit also has low wear rates. The diamond routing bits are supplied in 2
grits to accommodate a wide range of commonly used composite materials. The table below
provides details of the diamond routing bits supplied in the kit which are also available as spare
parts.
Description & Application
Part No. & Image
This kit is supplied with diamond
routing bits in two styles to
address effective cutting and
dust removal from different
materials
Parallel Router Bits
For general purpose
routing of solid laminates.
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 effective dust
capture. The flutes
prevent debris being
projected from the front of
the cutter.
36/44 Diamond Grit
Suitable for cutting and grinding
back abrasive filled composites or
heavy woven roving.
DMP0145-SP01
DMP0145-SP03
44/60 Diamond Surface Planer
Suitable for general purpose
cutting and grinding over a range
of composite materials.
DMP0145-SP02
DMP0145-SP04
Material
Solid Laminates
Sandwich Panels (up to
15mm)
Wet Lay-Up Glass / Polyester or Vinyl
Ester
up to 6mm
6mm total skin thickness
Infused Glass / Vinyl Ester or Epoxy
up to 5mm
5mm total skin thickness
Pre-preg Glass / Phenolic or Epoxy
up to 4mm
4mm total skin thickness
Infused Carbon / Phenolic or Epoxy
Up to 4mm
4mm total skin thickness
Pre-preg Carbon / Phenolic or Epoxy
up to 3mm
3mm total skin thickness
Special Notes
The geometry also allows for effective dust capture when used with a suitable on-tool dust
extraction unit. Use of this tool kit without a suitable on-tool dust extraction unit is not
recommended.

DMP0145, SMALL AIR ROUTER KIT
USER MANUAL
© Dark Matter Composites Ltd
Page 14 of 23
t/f [phone] www.darkmattercomposites.com
Unit 8 Redbourn Industrial Estate, High Street, Redbourn, Hertfordshire, AL3 7LG, UK
Registered in England & Wales No: 5395870
Prior to use, check the diamond surface planer to be used for any signs of corrosion or
damage. Do not use the diamond surface planer if corrosion or damage is present.
After use, remove the diamond surface planer from the tool. To clean the diamond surface
planer run under clean water and use a soft brush to remove any dust/debris from the
diamond surface planer. Ensure the diamond surface planer is completely dry prior to being
stored.
Where the surface planer is incorrectly used,
excessive heat can lead to the surface planer
becoming clogged with burnt resin making the
surface planer ineffective at material removal.
To remove the burnt resin, soak the surface
planer in a suitable resin removing solvent 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 coated
tools when used with composite materials. There will be a notable
reduction in cutting performance when the diamond router bit requires
replacement.
When ordering spare or replacement parts, the part number is laser
engraved on the stem of each diamond router bit.
Where removal of aramid materials is required, please contact Dark
Matter Composites directly for advice.
2. Fitting & Removal of Diamond Routing Bits
SAFETY NOTICE - Always disconnect the air supply to the air router prior to fitting or
adjusting any part of the air router/jig assembly.
Fitting
1. Hold the vacuum shroud/pipe assembly and loosen the
locknut with the 30mm spanner provided. Unscrew the
vacuum shroud from the collar adaptor.
2. Hold the air motor and loosen the collar adaptor using the
30mm spanner. Unscrew the collar adaptor from the air
motor.
3. Check the 6mm collet is fitted within the collet assembly.
Note that the size of the collet is laser engraved on the collet
body.

DMP0145, SMALL AIR ROUTER KIT
USER MANUAL
© Dark Matter Composites Ltd
Page 15 of 23
t/f [phone] www.darkmattercomposites.com
Unit 8 Redbourn Industrial Estate, High Street, Redbourn, Hertfordshire, AL3 7LG, UK
Registered in England & Wales No: 5395870
4. Fully insert the required diamond router bit into the collet
assembly. Tighten the collet assembly with the 12mm and
14mm spanners provided.
5. Screw the collar adaptor onto the air motor. Note - Ensure
the threads of the collar adaptor and air motor are clean and
free from dust. If the threads are contaminated on assembly,
the collar adaptor may loosen during use.
6. Tighten the collar adaptor with the 30mm spanner provided.
7. To refit the vacuum shroud/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 to engage the threads of the
collar adaptor and vacuum base. 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.
Removal
1. Hold the vacuum shroud/pipe assembly and loosen the
locknut with the 30mm spanner provided. Unscrew the
vacuum shroud from the collar adaptor.
2. Hold the air motor and loosen the collar adaptor using the
30mm spanner. Unscrew the collar adaptor from the air
motor.
3. Loosen the collet assembly with the 12mm and 14mm
spanners provided and remove the diamond router bit from
the collet assembly.
4. Screw the collar adaptor onto the air motor and tighten with
the 30mm spanner provided.
.

DMP0145, SMALL AIR ROUTER KIT
USER MANUAL
© Dark Matter Composites Ltd
Page 16 of 23
t/f [phone] www.darkmattercomposites.com
Unit 8 Redbourn Industrial Estate, High Street, Redbourn, Hertfordshire, AL3 7LG, UK
Registered in England & Wales No: 5395870
5. To refit the vacuum shroud/pipe 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.
6. Rotate the body of the air motor to engage the threads of the
collar adaptor and vacuum base. 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 - Always disconnect the air supply to the air router prior to fitting or
adjusting any part of the air router/jig assembly.
Where accurate depth control/adjustment is required, the zero
must be reset on the router assembly whenever the cutting head
is changed, as follows:
1. Fit the required routing bit as detailed in section 2.
2. Hold the vacuum shroud/pipe and loosen the locknut with
the 30mm spanner provided.
3. Stand the router assembly face down on a flat surface and
press the vacuum base firmly against the flat surface.

DMP0145, SMALL AIR ROUTER KIT
USER MANUAL
© Dark Matter Composites Ltd
Page 17 of 23
t/f [phone] www.darkmattercomposites.com
Unit 8 Redbourn Industrial Estate, High Street, Redbourn, Hertfordshire, AL3 7LG, UK
Registered in England & Wales No: 5395870
4. Rotate the router body clockwise until the routing bit makes
contact with the flat surface. A slight resistance in the
rotation of the router body should be felt at this point.
5. Without moving the router assembly, hold the vacuum
shroud/pipe assembly and tighten the locknut with the 30mm
spanner provided.
6. Lift the 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 permanent marker,
mark a horizontal line on the
scale pointer in line with the lower
edge of the collar.
9. Using a fine permanent marker,
mark a vertical line on the collar
adaptor in line with the scaled
edge of the pointer.
10. These two marks represent the positions on the scales that relate to the routing bit at the
face of the base and not protruding i.e. the zero depth position of the routing bit.
11. When required, the marks applied to the scales can be removed with a suitable solvent
cleaner. We recommend the use of the 3M VHB Surface Cleaner Sachets for this purpose.

DMP0145, SMALL AIR ROUTER KIT
USER MANUAL
© Dark Matter Composites Ltd
Page 18 of 23
t/f [phone] www.darkmattercomposites.com
Unit 8 Redbourn Industrial Estate, High Street, Redbourn, Hertfordshire, AL3 7LG, UK
Registered in England & Wales No: 5395870
4. Depth Adjustment of Routing Bits
SAFETY NOTICE - Always disconnect the air supply to the air router prior to fitting or
adjusting any part of the air router/jig assembly.
Special Notes
The collar adaptor is engraved with two laser engraved scales:
The upper scale is in large increments of 0.25mm (≈ 0.010”)
The lower scale is in small increments of 0.05mm (≈ 0.002”)
Depth 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 allowance for this when depth cutting in imperial.
Depth Adjustment
1. Stand the router assembly face down on a flat surface.
2. Hold the vacuum shroud/pipe assembly and loosen the
locknut with the 30mm spanner provided.
3. Rotate the collar adaptor/router assembly:
Clockwise to increase the surface planer depth
Anti-clockwise to reduce the surface planer
depth
Use the laser engraved scales and zero marks for reference.
4. Hold the vacuum shroud/pipe assembly and tighten the lock nut with the 30mm spanner.
Upper scale
0.25mm (≈ 0.010”) increments
Lower scale
0.05mm (≈ 0.002”) increments
Scale Pointer
1.00mm (≈ 0.039”) increments

DMP0145, SMALL AIR ROUTER KIT
USER MANUAL
© Dark Matter Composites Ltd
Page 19 of 23
t/f [phone] www.darkmattercomposites.com
Unit 8 Redbourn Industrial Estate, High Street, Redbourn, Hertfordshire, AL3 7LG, UK
Registered in England & Wales No: 5395870
5. Using the Router Vacuum Guide Base
The router assembly can be used to route surfaces either free hand or to follow guide jigs (not
included with this kit). The base of the vacuum shroud/pipe assembly is also configured as a
vacuum guide base. This can be used to rest up against surfaces and edges of jigs allowing
unusual shapes to be trimmed accurately, as well as surfaces that require uniform abrading for
bonding surface preparation.
Special Notes
The vacuum guide base rests
against the part surface, using it
as a reference surface in terms of
depth. As material is 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 makes contact with the part
surface, the surface planer will
remain in the correct position.
Undue load on the router body
while part of the router base is suspended above the part surface will tip the router body and cut
irregularities in the surface. The air router must be used as a router and not as a sanding or
grinding tool.
Guide Jig Design
The outer edge of the standard vacuum
guide base can be used to rest against the
edge of a guide jig.
Guide jigs and their sequence of use need
to be designed to use the part surface as a
reference surface.
The offset between the edge of the vacuum
guide base and the cutter is:
Offset (mm) = 26mm − Cutter Diameter (mm)
2
The routing bits provided with this kit are
Ø6mm and the guide base offset is 10mm /
3/8”.
If required, please contact Dark Matter
Composites for advice on jig design.

DMP0145, SMALL AIR ROUTER KIT
USER MANUAL
© Dark Matter Composites Ltd
Page 20 of 23
t/f [phone] www.darkmattercomposites.com
Unit 8 Redbourn Industrial Estate, High Street, Redbourn, Hertfordshire, AL3 7LG, UK
Registered in England & Wales No: 5395870
SAFETY NOTICE - Always disconnect the air supply to the air router prior to fitting or
adjusting any part of the air router/jig assembly.
Using the Vacuum Guide Base
1. Select the routing bit to suit the material being removed as detailed in section 1.
2. Fit the required routing bit as detailed in section 2.
3. Zero the routing bit as detailed in section 3.
4. Set the depth of the routing bit (as detailed in section 4) to the depth associated with
material removal operation.
5. Check and adjust the position of the part and ensure it is suitably supported and clamped as
necessary.
6. Check the air motor speed regulator is in the ‘OFF’ position.
7. Connect the compressed air supply hose and vacuum extraction unit hose to the air router
connections.
8. Ensure that the weight of the air and vacuum hoses are fully supported above the
tool using a suitable hanger/support boom. Any side load or restriction applied to
the air router during operation may result in the router tipping and surface planer
digging into the surface of the part.
9. Lift the router assembly just clear of the part surface so that it does not make contact with
the part and turn the air motor speed regulator slowly towards the ‘ON’ position. Check the
correct operation of the air motor and gradually increase the speed to check 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, cease operation of the air router immediately. Disconnect the compressed air
supply and fully check the setup and configuration of the equipment. If required, remove
the equipment from service and conduct repair/maintenance activities on the equipment as
required.
11. If the air router operates correctly, continue with the material removal activity.
12. Ensure that the vacuum extraction connected to the air router is running prior to
starting the air router.
13. Lift the air router just clear of the part surface so that it does not make contact with the part
and move the air motor speed regulator to towards the ‘ON’ position to the desired speed.
14. Where the vacuum guide base is used for free hand material removal, press the router base
against the part surface to cut down into the part surface.
15. Where the vacuum guide base is used to follow a guide jig, rest the edge of the vacuum
guide base against the guide jig and then press the router base against the part surface to
cut down into the part surface.
16. Take care to ensure that the router base is pressed against the part surface where it is
supported by the part surface, not where it is unsupported.
17. Do NOT hold the air motor, hold the router assembly at the vacuum shroud.
18. Move the vacuum guide base in a slow and controlled manner, allowing the side of the
cutting head to remove material in a controlled manner. Do NOT operate the air router in a
swinging motion, back and forth motion, or too fast as the routing bit will rise up the material
and not cut to the required depth.