ROUTER 241-0834 OPERATOR’S MANUAL CAUTION: To Reduce The Risk Of Injury, User Must Read And Understand Operator’s Manual. Save These Instructions For Future Reference. For questions / comments, technical assistance or repair parts – Please Call Toll Free: 1-866-917-4374. (M-F 8:30am-5:00pm Est.
TABLE OF CONTENTS Safety Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2 Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3 Overview/Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY SYMBOLS Some of these following symbols may be used on this tool. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to operate the tool better and more safely.
SAFETY INSTRUCTIONS The purpose of safety symbols is to attract your attention to possible dangers. The safety symbols, and the explanations with them, deserve your careful attention and understanding. The symbol warnings do not, by themselves, eliminate any danger. The instructions and warnings they give are no substitutes for proper accident prevention measures.
SAFETY INSTRUCTIONS GENERAL POWER TOOL SAFETY WARNINGS WARNING: Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference. The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool. WORK AREA SAFETY 1. Keep work area clean and well lit. Cluttered and dark areas invite accidents. 2.
SAFETY INSTRUCTIONS POWER TOOL USE AND CARE 1. Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and more safely at the rate for which it was designed. 2. Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired. 3.
SAFETY INSTRUCTIONS 9. The direction of feeding the bit into the material is very important and it relates to the direction of bit rotation. When viewing the tool from the top, the bit rotates clockwise. Feed direction of cutting must be counter-clockwise. NOTE: inside and outside cuts will require different feed direction, refer to section on feeding the router.
OVERVIEW ON/OFF switch Handle Spindle lock Chip shield LED worklight Base plate 1/2” collet LED display screen Electronic keyboard Power indicator Fine-adjustment dial Depth-indicator ring 1/64 0 3/64 Motor clamp Coarse-adjustment button Pattern guide Page 7 Collet wrench Lock nut Dust-extraction adaptor Dust-extraction adaptor 1/4” collet sleeve
SPECIFICATIONS Rated voltage 120 V~ 60 Hz Rated power Input 14 A Max HP 2.5 HP Speed 10,000–25,000 RPM Collet capacity 1/4” & 1/2” Fixed-base range 1-3/4” Fixed base dimension 6” Inside base diameter 2’’ Micro-fine depth 1/64” Weight 9 lb. (4.1 kg) ASSEMBLY CONTENTS WARNING: If any part is broken or missing, DO NOT attempt to plug in the power cord or operate the tool until the broken or missing part is replaced. Failure to do so could result in possible serious injury.
ASSEMBLY SELECTING THE CUTTER BIT FIG. 1b 1/4” Collet sleeve This router comes with 1/2”collet and 1/4” collet sleeve that accept cutter bits with 1/2” and 1/4” shanks, respectively. The 1/2” collet is equipped on the tool, the 1/4” collet sleeve can be installed inside the 1/2” collet. INSTALLING THE 1/4” COLLET SLEEVE (FIG. 1) 1. 2. 3. 4. Disconnect the plug from the power supply. Remove the router motor from the base; refer to the section “REMOVING MOTOR FROM BASE”.
ASSEMBLY FIG. 2 INSTALLING MOTOR IN FIXED BASE (FIG. 3) Cutter Bit shank FIG. 3 Spindle-lock button Coarseadjustment button 7. With the cutter bit inserted and the spindle-lock button pressed in to engage the shaft, place the wrench on the collet and turn it clockwise until the cutter bit is firmly tightened in the collet. NOTICE: To ensure proper gripping of the cutter bit shank and minimize run-out, the shank of the cutter bit must be inserted into the collet at least 5/8”.
ASSEMBLY REMOVING MOTOR FROM THE FIXED BASE (FIG. 3) 1. 2. 3. 4. 5. Disconnect the plug from the power supply. Place the router on a flat surface. With the back of the router facing you, open the router motor clamp. Push in the coarse-adjustment button while you lift the router motor out of the fixed base. Set the motor upside down on its top cap with the collet pointing up and remove the cutter bit. INSTALLING THE DUST-EXTRACTION ADAPTOR (FIG. 4) FIG.
OPERATION ADJUSTING THE DEPTH OF CUT bit 1/32”. One full turn clockwise 360° (zero “0” to zero “0”) lowers the bit 1/16”. WARNING: Your router should never be turned on or be connected to the power source when you are assembling parts, making adjustments, installing or removing collets and cutter bits, cleaning or when it is not in use. Disconnecting the router will prevent accidental starting, which could cause serious personal injury.
OPERATION DEEP CUTS • The proper cutting depth for each pass, is always determined by the material, the cutter bit size and type, and the power of the motor. Always make several progressively deeper cuts by starting at one depth and then making several passes, each time increasing the cutting depth until your desired depth is reached. Making a cut that is too deep will stress the motor and the cutter bit, and it may burn the workpiece and dull the cutter bit.
OPERATION “LIVE TOOL INDICATOR” LIGHT (FIG. 10) FIG. 10 Live tool indicator Bit Size and Speed Setting Material Hardness 0-1” 1.252” 2.252.5” 3-3.5” Plastic 6 4 3 2 Softwood 6 4 2 1 Hardwood 5 3 2 1 The speed chart in the next column indicates the relationship between the speed setting and the cutting application. Exact settings are determined through operator experience and preference and by recommendations from manufacturers of cutter bits.
OPERATION EDGE ROUTING OR INTERNAL ROUTING (FIG. 12) For ease of operation and to maintain proper control, your router has two handles, one on each side of the router base. When operating the router, always hold it firmly with both hands (FIG. 12). FIG. 12 WARNING: Removing the cutter bit from the workpiece while it is still rotating could damage the workpiece and result in loss of control, causing serious personal injury. INTERNAL ROUTING WITH FIXED BASE (FIG. 13) 1. 1/64 0 3/64 2. 3. FIG.
OPERATION injury. If using a router table, large cutter bits should be used for edging only. WARNING: Removing the cutter bit from workpiece while it is still rotating could damage the workpiece and result in loss of control, causing serious personal injury. FREEHAND ROUTING WITH THE FIXED BASE (FIG. 14) FIG. 14 1/64 0 3/64 NOTICE: A core-box bit or V-groove bit is often used for routing letters and engraving objects. Straight bits and ball mills are often used to make relief carvings.
OPERATION TOP EDGE SHAPING (FIG. 15) FIG. 15 Motor housing Spindle lock Fixed base sub-base Cutter bit Work piece Pilot TOP EDGE SHAPING Whenever the workpiece thickness, together with the desired depth of cut (as adjusted by the cutting-depth setting) are such that only the top part of the edge is to be shaped (leaving at least a 1/16”. thick uncut portion at the bottom), the pilot can ride against the uncut portion, which serves to guide it (FIG. 15). WHOLE EDGE SHAPING (FIG.
OPERATION DIRECTION OF FEED - EXTERNAL CUTS (FIG. 17) The cutter bit rotates clockwise. (When installed on a router table, the rotation is counterclockwise.) Feeding the bit from left to right will cause the bit to pull the router towards the workpiece (FIG. 17). If the router is fed in the opposite direction (right to left), the rotating force of the cutter bit will tend to throw the bit away from the workpiece. This is called “Climb-Cutting”.
OPERATION FIG. 19 FEEDING TOO RAPIDLY (FIG. 20) GUIDE INSIDE FIG. 20 BIT ROTATION GUIDE Bit shank THRUST Cut BIT ROTATION ROUTER FEED DIRECTION TOO FAST Cutter If there is a choice, the set-up in FIG. 19 is easier to use, but there is the possibility of “Climb Cutting” around curves. In either case, Fig. 18 or Fig. 19, the sideways thrust of the router cutting is always against the guide, as is proper.
OPERATION FEEDING TOO SLOWLY (FIG. 21) FIG. 21 Bit shank When the cutting bit is scraping instead of cutting, the router is more difficult to control as you feed it. Cut TOO SLOW When you feed the cutting bit too slowly, the rotating cutting bit does not cut into new wood rapidly enough to take a bite. Instead, it scrapes away sawdust-like particles. This scraping produces heat, which can glaze, burn, and mar the cut in the workpiece and, in extreme cases, overheat the cutting bit.
MAINTENANCE Before cleaning or performing any maintenance, verify that the router has been disconnected from the power supply. Keep all ventilation openings clean. Avoid using solvents when cleaning plastic parts. Most plastics are susceptible to damage from various types of commercial solvents. Use a clean cloth to remove dirt, oil, and grease. If the supply cord is damaged, it must be replaced by a specially prepared cord available through the service organization.
TROUBLESHOOTING PROBLEM CAUSE SOLUTION The router does not work. Plug is not plugged into the power source. Plug the cord into the power source. Switch is in “OFF” position. Move the switch to “ON” position. The carbon brushes have worn out completely. Remove the brush caps and replace the old brushes with new ones. The bit is dull. Change to a sharp bit. Routing at an inappropriate bit speed. Select an appropriate bit speed. Bit size is inappropriate for the collet.
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ROUTER WARRANTY 90-DAY MONEY BACK GUARANTEE: This MASTERFORCE® brand power tool carries our 90-DAY Money Back Guarantee. If you are not completely satisfied with your MASTERFORCE® brand power tool for any reason within ninety (90) days from the date of purchase, return the tool with your original receipt to any MENARDS® retail store, and we will provide you a refund – no questions asked.
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