ROUTER 241-0835 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 Electronic keyboard LED display screen ON/OFF switch Power indicator Fineadjustment dial Handle Depth-indicator ring 1/64 0 3/64 Motor clamp Spindle lock Chip shield Base plate 1/2” collet Plunge-depth locking lever LED worklight Coarseadjustment button Lock nut Fine-adjustment dial Pattern guide Handle Depth-stop nut Lock nut Depth-stop rod Straight-edge guide Chip shield Depth-stop turret Base plate Hex wrench Page 7 Dustextraction adaptor Collet wrench Screws Dust-ex
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” Plunge stroke 2” Base dimension Fixed base 6”; Plunge base 6-11/16” Inside base diameter 2” Micro-fine depth 1/64” Weight 12 lb. 12 oz. (5.8 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.
ASSEMBLY SELECTING THE CUTTER BIT FIG. 2 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. 1-2) 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. 3 INSTALLING MOTOR IN FIXED BASE (FIG. 4) Cutter Bit shank FIG. 4 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 INSTALLING MOTOR IN PLUNGE BASE (FIG. 5) FIG. 5 REMOVING MOTOR FROM THE PLUNGE BASE (FIG. 5) 1. 2. 3. Arrow Lock lever Motor clamp 1. 2. 3. 4. 5. 6. Disconnect the plug from the power supply. Place the plunge base on a flat surface. With the back of the plunge base facing you, open the motor clamp and make sure that the plunge action is in the “DOWN” position, with the plunge-lock lever locked. With the arrows aligned, lower the motor housing into the plunge base.
ASSEMBLY INSTALLING THE DUST-EXTRACTION ADAPTORS (FIG. 6) HEAVY-DUTY EDGE GUIDE (FIG. 7) FIG. 7 Edge-guide adjustment button FIG. 6a Fixed base 1/64 0 3/64 Lock nut Dust-extraction adaptor The router combo kit comes with a heavyduty edge guide. This edge guide can be used as an aid in routing applications such as decorative edging, straight-edge planning and trimming, grooving, dadoing and slotting. FIG.
OPERATION INSTALLING THE PATTERN GUIDE (FIG. 8) To attach the pattern guide onto either the fixed or plunge base, position and secure it to the base with the screws (included); as shown in fig. 8. NOTICE: All depth adjustments on the fixed base must be made with the motor clamp open. NOTICE: For fixed base routers, the cutter bit depth equals the amount of the cutter that is exposed below the surface of the sub-base. The fixed base is designed with a fine adjustment system.
OPERATION DEPTH ADJUSTMENT WITH THE PLUNGE BASE PLUNGING ACTION (FIG. 11) FIG. 10 1/64 0 3/64 FIG. 11 5. 6. Turn the fine-adjustment dial clockwise to lower the bit to the desired depth of cut. Turn the dial counterclockwise to raise the cutter bit. Once the depth of cut is set, close the motor clamp securely. 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.
OPERATION PLUNGE ACTION WITH DEPTHSTOP ROD AND DEPTH-STOP TURRET (FIG. 12) FIG. 12 Plunge-depth locking lever Depth-stop rod Plastic depth indicator Depth scale Depth-stop rod locking knob Depth-stop turret The depth-stop rod and the depth-stop turret are used to control the plunge-action cutting depth as follows: 1. Disconnect the plug from the power supply. 2. Place the router on a flat surface. 3.
OPERATION MICRO-ADJUSTMENTS WITH THE DEPTH-STOP ROD AND DEPTH-STOP TURRET TOGGLE “ON/OFF” SWITCH (FIG. 14) FIG. 14 The depth-stop rod has a micro-adjustment knob that turns a screw (inside the rod) either clockwise or counterclockwise to lower or raise the depth-stop rod on the turret for micro-fine adjustments of the plunge depth. 1/64 0 3/64 Each complete revolution of the microadjustment knob adjusts the plunging depth by approximately 1/32”.
OPERATION LED WORKLIGHTS (FIG. 15) FIG. 15 FIG. 17 Your router motor has 3 built-in worklights located around the collet to provide high visibility of the workpiece when cutting. These lights are always “On” when the toggle switch is in the “ON” position. “LIVE TOOL INDICATOR” LIGHT (FIG. 16) FIG. 16 Live tool indicator Your router also has a “live tool indicator” green light, located on the motor housing top cap where the power cord enters the motor housing.
OPERATION DIAL SETTING RPM 1 10,000/11500 2 13,000/14500 3 16,000/17500 4 19,000/20500 5 22,000/23500 6 25,000 FIG. 18 APPLICATION Hardwoods, larger diameter cutter bits 1/64 0 3/64 Softwoods, plastics, countertops, smaller diameter cutter bits NOTICE: Reduce the speed when using very large bits (1-inch or greater in cutting diameter) or heavy cutting bits. Changing the router rate of feed can also improve the quality of the cut. EDGE ROUTING (FIG. 19) 1.
OPERATION 6. Unplug the router from the power source, and inspect the finished cut. WARNING: Always securely clamp your workpiece and keep a firm grip on the router base with both hands at all times. Failure to do so could result in loss of control causing possible serious personal injury. 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. 20) 1. 2.
OPERATION 5. When the cutter bit comes to a complete stop, unlock the plunge-lock lever (Up) and the plunge action will automatically retract the cutter bit from workpiece. 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. 6. Unplug the router from the power source, place the router on worktable, and inspect the finished cut in the workpiece.
OPERATION TOP EDGE SHAPING (FIG. 23) FIG. 23 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. 23). WHOLE EDGE SHAPING (FIG.
OPERATION DIRECTION OF FEED - EXTERNAL CUTS (FIG. 25) 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. 25). 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 When the guide is positioned on the right-hand side of the router, the router travel should be from left to right and counterclockwise around curves (FIG. 26). This counterclockwise action around the curve could cause “Climb cutting”. Always be alert and exercise extreme caution to maintain control of the router when making this type of cut around curves. FEEDING TOO RAPIDLY (FIG. 28) FIG. 28 Bit shank Cut When the guide is positioned as shown in FIG.
OPERATION FEEDING TOO SLOWLY (FIG. 29) FIG. 29 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 COMBO 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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