Rockler Dust Right Manual

Assembly

REQUIRED TOOLS
Large Hex Key (included, not shown)
Small Hex Key (included, not shown)
Wrench (included, not shown)

1. Attach the curved Frame Bottom Rails (1) and Frame Middle Rails (2) to the Frame Uprights (3) using all 32 M5 x 6mm Pan-Head Screws (4) and the Smaller Hex Key (21). The Uprights have integrated weld nuts to accept the screws. Note that the Uprights must be oriented with the single sets of holes toward the center of the frame and the vertical ribs facing inward. Also, for easiest assembly, tighten all screws lightly until the entire frame is constructed; then make sure the components are at right angles to each other and fully tighten the screws.
   
2. Attach the two Handles (6) to the Frame Cap (5) with two M6 x20mm Pan-Head Screws (7) and two M6 Nuts (8) for each Handle. Make sure to fit the M6 Nuts in the recesses molded into the bottom of the Frame Cap. Use the Larger Hex Key (20) to tighten the bolts.
   
3. Fit the Frame Cap (5) over the top Frame Uprights (3) and align the mounting holes. Secure the Frame Cap to the Frame Uprights with M5 x 10mm Flat-Head Screws (9), using the Smaller Hex Key (21).
   
4. Locate the Housing (10). Because it can be difficult to fit the M6 x 14mm Pan-Head Screw (11) in the hole directly beneath the inlet when the Housing is attached to the External Cone (13), we recommend fitting it into the hole now by tilting it slightly to clear the inlet. Fig. 4. Alternatively, the M6 x 14mm Pan-Head Screw (11) can be installed from the bottom, with an M6 Nut (8) on the top, after the Housing and External Cone have been attached.
   

NOTICE
Before you begin the next step, it is important to decide which way you want the inlet on the Housing (10) to face in your application. For example, if you want the inlet to point toward the right (opposite of what is shown in Fig. 5), you must rotate the Housing in that direction before fastening it to the External Cone (13) and Wall Bracket (13). The placement of the mounting holes allows you to rotate the Housing in 30° increments.

To make mounting and demounting the frame and Frame Cap (5) easier when emptying the Bag (17), make sure that the External Cone (13) is positioned so that two of the posts on the bottom line up at 90° to the Wall Bracket. This will position the Handles (6) on the Top Cap for easiest access.

5. Position the Ring Gasket (12) between the Housing (10) and the External Cone (13), aligning the mounting holes of all three. Make sure that you have the Housing positioned so the inlet is where you want it to be. If you installed an M6 x 14mm Pan-Head Screw (11) in the hole directly beneath the inlet of the Housing (10) in Step 4, fit it into the holes in the Ring Gasket and External Cone. This can help with aligning the three parts.
6. Keeping the Housing (10), Ring Gasket (12) and External Cone (13) aligned, position the Wall Bracket (14) underneath the External Cone. Working from above the Housing, fit four M6 x 14mm Pan-Head Screws (11) into mounting holes located at 0°, 90°, 180° and 270° and thread on four M6 Nuts (8) from underneath. Use the Larger Hex Key and the Wrench to tighten the screws and nuts. Fig. 5.
7. Install the remaining M6 x 14mm Pan-Head Screws (11) in the open holes in the assembly and thread on and tighten the M6 Nuts (8) from underneath.

8. Fit the Separator Cone (16) into the opening of the External Cone (13) and up toward the opening in the Housing (10). From the top, fit the Separator Outlet (15) into the opening in the Housing and then thread it into the Separator Cone until the parts are snug.
   
9. Unfold the Bag (17). Before fitting it over the Frame, make sure that the clear window will end up between the Frame Uprights (3) so that you will be able to monitor the fill level. Carefully slip the bag onto the Frame; it's a snug fit, so take your time. The Bag is fully on when the elastic top slightly overlaps the Frame Cap (5). Secure the Bag in place with the Clamp (18), fitting the latch in the middle set of teeth.
   
10. Connect the Frame Cap (5) with attached Frame and Bag (17) to the main assembly by fitting the keyhole slots in the Frame Cap onto the posts on the bottom of the External Cone (13) and twisting the Frame Cap with attached Frame and Bag clockwise to secure the parts together. Fig. 7.

Choosing a Mounting Location

THESE WARNINGS PERTAIN TO ALL REMAINING STEPS:

• The Dust Separator must be secured using all four included 5/16" x 3" Lag Screws driven into structurally sound wooden wall studs or into 2 x 4 wooden cleats securely attached to wooden wall studs. All cleats spanning wall studs must be long enough that both ends of the cleats can be bolted to studs.
• Do NOT use wall anchors or drywall anchors to mount the Dust Collector.

NOTICE
The top set of Lag Screws must be located at least 38" from the floor to provide the needed clearance when removing and emptying the Bag. However, many people find that the most comfortable mounting height puts the Handles of the Frame Cap at chest level.
The mounting holes on the 4" Wall Mount Cyclone Dust Separator are spaced horizontally 16" on center to correspond to the common spacing for wall studs. If your desired mounting location on an open-stud wall does not line up with studs spaced 16" on center – or if you are mounting to a finished wall – you MUST first bolt a horizontal 2 x 6 wooden cleat to wooden wall studs and then mount the Dust Collector to the cleat. The cleat must be long enough that both ends can be bolted to a wooden wall stud.
To locate and mark wooden wall studs in a finished wall, use a stud finder. As you locate the studs in your desired mounting area, be sure to mark both edges and the centerline of each stud. Fig. 8. Be aware that stud spacing can vary. Take your time identifying and marking the studs to be sure you are certain of their locations. If you have any doubts that you have located the studs properly, seek professional installation assistance.

Mounting to Open Studs Spaced 16" On Center

1. Determine the mounting location. Use a level to mark a horizontal line on both studs at the desired height for the top set of the Dust Separator's mounting holes.
2. Measure down 3" and use the level to make a horizontal line on both studs; this will help you place the pilot hole locations for the bottom set of the unit's mounting holes.
   
3. Use a level or other straightedge to make vertical marks across the horizontal marks at the center of each stud. Measure to double-check that the intersections of these marks are 16" apart. Fig. 9.
4. Drill 3/16" diameter pilot holes 2½" deep at the four cross marks. Fig. 9.
5. Using a 1/2" wrench, drive a 5/16" x 3" Lag Screw at each location, stopping when the heads of the Lag Screws are about 1" out from the surface.
6. Obtain help, if necessary, and lift the Dust Separator onto the four 5/16" x 3" Lag Screws, fitting the keyhole openings in the Mounting Bracket (13) over the heads of the Lag Screws. Fully tighten the Lag Screws.
   
7. Connect a 4" dust hose from your dust collector to the Separator Outlet (15), using hose clamps to secure it. Connect a 4" dust hose from your tools to the inlet on the Housing (10).

Mounting with a Cleat

1. Determine the mounting location. If mounting to a finished wall, you should have marked the edges and centerlines of the studs at the desired location in Choosing a Mounting Location. If you have not done so, review the section and mark all stud locations now; be sure to identify at least one stud beyond the intended footprint of the Dust Separator on each side so that both ends of the cleats will be bolted to a stud.
2. Measure the distance between the outside edges of the two outside studs located in Step 1 and cut a 2 x 6 cleat to that length.
3. Transfer the stud locations (including centerlines) from the wall onto the cleat to determine the location of all pilot holes and counterbores needed to accept 5/16" x 4" Lag Screws and Washers (not included). Lag screws must be installed at every stud the cleat crosses and at both ends of the cleat.
4. At the center of each stud location on the cleats, use a 1" Forstner bit to drill counterbores of sufficient depth to accommodate a Washer and the head of the Lag Screw.
5. Drill a 5/16" through hole centered in each counterbore.
6. Hold the cleat to the wall at the desired mounting location and align the pilot holes with the stud centerlines. Check that it's level; then use the pilot holes in the cleat to mark the drilling locations. Make sure the marks are centered on the studs.
7. Drill 3/16" diameter holes through the drywall (if applicable) and into the studs at the spots you just marked.
8. Use 5/16" x 4" Lag Screws and Washers (not included) to securely mount the cleat to the studs.
9. On the cleat, mark a level horizontal line and then measure down 3" and mark a second level horizontal line.
   
10. Make vertical marks 16" apart on the top line and use a level to transfer the vertical marks to the bottom line. Fig. 11.
11. Drill 3/16" diameter pilot holes at these locations.
12. Using a 1/2" wrench, drive a 5/16" x 3" Washer Head Lag Screw at each location, stopping to leave the heads of the Screws about 1" out from the surface.
13. Obtain help, if necessary, and lift the Dust Separator onto the four 5/16" x 3" Lag Screws, fitting the keyhole openings in the Mounting Bracket (13) over the heads of the Lag Screws. Fully tighten the Lag Screws.
    
14. Connect a 4" dust hose from your dust collector to the Separator Outlet (15), using hose clamps to secure it. Connect a 4" dust hose from your tools to the inlet on the Housing (10).

Emptying the Bag

When you can see through the clear window that the Bag (17) is getting full, take hold of the Handles (6) on the Frame Cap (5) and rotate the Frame Cap counterclockwise to release the Frame Cap from the External Cone (12).

Tip the Bag assembly upside down to empty the Bag (17) through the hole in the Frame Cap (5). Then reinstall the Bag assembly on the bottom of the External Cone (12).

GENERAL SAFETY WARNINGS

This product is designed only for specific applications as defined in the instructions and should not be modified or used for any manner not described in these instructions. Use only recommended accessories. Before using the 4" Wall Mount Cyclone Dust Separator: READ, UNDERSTAND and FOLLOW ALL INSTRUCTIONS AND SAFETY WARNINGS. KEEP THESE INSTRUCTIONS READILY AVAILABLE FOR FUTURE REFERENCE.

• Always confirm that you are using the most recent version of the instructions and safety warnings for your product (see the instructions link on the product page at Rockler.com).
• Before using another tool with this product, always read, understand and follow the instructions and safety warnings in the owner's manual for that tool. If you do not have the owner's manual, obtain one from the tool's manufacturer before using it with this product.
• Before using any chemical with this product, always read, understand and follow all safety warnings and guidelines in the manufacturer's Safety Data Sheet (SDS; formerly called "MSDS"), especially regarding:
  • How to safely use the chemical, including potential hazards and recommended first aid measures;
  • Personal safety equipment required to safely use the chemical (e.g. gloves, eye protection, mask/respirator, etc.);
  • Proper and safe handling, storage and disposal of the chemical.
• Before using this product, review and verify that all tools to be used with it have safety equipment installed and are in proper working order as defined by the tool's owner's manual.
• Do not use this product until you have read and are confident you understand:
  • Product Specific Safety Warnings;
  • Assembly;
  • Choosing a Mounting Location;
  • Mounting to Open Studs Spaced 16" On Center;
  • Mounting with a Cleat;
  • Emptying the Bag.
• The user assumes all risk and responsibility for the proper and safe use of this product and for ensuring product suitability for the intended application.
• It is the sole responsibility of the purchaser of this product to ensure that anyone you allow to use this product reads and complies with all instructions and safety precautions outlined in this manual prior to use.
• Follow all standard shop safety practices, including:
  • Keep children and bystanders away from the tool operating area;
  • Do NOT use power tools in explosive environments, or in the presence of flammable liquids, fumes or dust;
  • TURN OFF AND UNPLUG all power tools BEFORE making any adjustments or changing accessories;
  • Remain alert and use good judgment. Do not use this product if you are in any way impaired by medications, alcohol, drugs or fatigue;
  • Keep your work area well lit and clean;
  • Dress appropriately. Secure loose clothing, remove all jewelry and tie up long hair before using this product;
  • ALWAYS wear safety glasses, hearing protection and respiratory protection that complies with NIOSH/OSHA/ANSI safety standards;
  • Use dust collection tools and dust face masks to reduce exposure to dust;
  • Use safety equipment such as featherboards, push sticks and push blocks, etc., when appropriate;
  • Maintain proper footing at all times and do not overreach;
  • Do NOT force woodworking tools.
• These warnings and instructions do NOT represent the total of all information available regarding tool safety, use and technique. Always seek out opportunities to learn more and improve your skills and knowledge.

Drilling, sawing, sanding or machining wood products can expose you to wood dust, a substance known to the State of California to cause cancer. Avoid inhaling wood dust or use a dust mask or other safeguards for personal protection. For more information go to www.P65Warnings.ca.gov/wood.

Danger indicates a hazardous situation that, if not avoided, will result in death or serious injury.

Warning indicates a hazardous situation that, if not avoided, could result in death or serious injury.

Caution indicates a hazardous situation that, if not avoided, may result in minor or moderate injury or property damage.
NOTICE
Notice indicates important or helpful information and/or user tips.

PRODUCT SPECIFIC SAFETY WARNINGS

• Be sure to read, understand and follow all instructions and safety warnings in the owner's manual that came with the dust collector to which you will be connecting the 4" Wall-Mount Cyclone Dust Separator.
• The Dust Separator must be secured using all four included 5/16" x 3" Lag Screws driven into structurally sound wooden wall studs or into 2 x 4 wooden cleats securely attached to wooden wall studs. All cleats spanning wall studs must be long enough that both ends of the cleats can be bolted to studs.
• Do NOT use wall anchors or drywall anchors to mount the Dust Collector.
• Do NOT use to pick up liquids, flammable or combustible liquids or materials, such as gasoline, or use in areas where they may be present. Do NOT use to pick up anything that is burning or smoking, or toxic materials. Do NOT use to pick up metal items/shavings. Items not to be picked up with this machine include (but are not necessarily limited to):
  • Fuels
  • Oil-based paints
  • Coal dust
  • Gunpowder
  • Hot ashes
  • Lighter fluid
  • Natural gas
  • Magnesium dust
  • Cigarettes
  • Cleaners
  • Hydrogen
  • Grain dust
  • Matches
• Do NOT put any object into openings. Do NOT use with any opening blocked by debris; keep free of dust, lint, hair, and anything that may reduce airflow.
• For household use only.
• Do NOT hang from the wall-mount dust separator or allow anyone else to do so.
• Periodically inspect dust bag for cuts, rips or tears. Do NOT use with damaged parts, bags, or hoses.
• Check and empty dust bags regularly. The window on the bag allows you to monitor when the bag is becoming full.

Check Rockler.com for updates. If you have further questions, please contact our Technical Support Department at 1-800-260-9663 or support@rockler.com

Distributed by Rockler Companies, Inc.
4365 Willow Dr. Medina, MN 55340
1-800-279-4441
www.rockler.com