Benchtop Router Table

Transcription

1 MODEL # Benchtop Router Table IMPORTANT: Read and Save these Instructions. IMPORTANT: Keep Instructions for Future Reference. Please retain these instructions for future reference. If you encounter any problems or difficulties please do not return this product to the store. Please contact our toll free customer service department at: (California only) Fax 1431 VIA PLATA, LONG BEACH, CA Made in China. COPYRIGHT 2003, ALLTRADE TOOLS LLC. REV. 1

2 Table of Contents Content Page Router Safety Instructions Parts Tools and Fasteners Required Router Table Operation and Assembly Fence Assembly Instructions Table 1 (For Installing the Router) Table 1a Metric (For Installing the Router) Installing the Adaptor Plate Attaching Router Power Cord to the Switch Box Operating the Switch Box Installing and Adjusting Router Bit Using the Router Table Attaching Wet/Dry Vac to Fence Attaching Tabletop Inserts to the Router Table Routing Using the Fence Adaptor Plate Template

3 WARNING Read all Instructions Failure to follow instructions may result in electric shock, fire and/or serious injury. Router Safety Instructions Operation Area Do not operate power tools in the presence of flammable liquids, gases or dust. Always make sure the work surface is free from nails and other foreign objects. Never lay work piece on top of hard surfaces, like concrete or stone. Use Safety Equipment Always wear eye protection that conforms to ANSI Standard Z87.1. To avoid possible hearing damage, always wear ear plugs when using your router for long periods of time. Wear a dust mask. Some dust created by power sanding, sawing, grinding and drilling contains chemicals known to cause cancer, birth defects or other reproductive harm. Personal Safety Use common sense when operating a power tool. Stay alert. Do not use tool if tired or under the influence of drugs, alcohol or medication. Do not wear loose clothing or jewelry. Keep hair, clothing and gloves away from moving parts. Be sure switch is OFF before plugging in. Remove adjusting keys and wrenches before turning the tool ON. Do not overreach. Make sure your body is balanced at all times. Always secure work with clamps prior to using router. Never place hands near or below the cutting surface. Never hold the work piece in your hand while using the tool. Make a push stick to move small work pieces across the cutting area. Never touch the bit during or immediately after use. Never put your fingers under the overhead guard when the router is plugged into an electrical outlet or when the router bit is rotating. Never lay the tool down until the motor has come to a complete standstill. Electrical Safety To prevent shock, hold tool by insulated gripping surfaces when performing an operation. Use extra care when cutting tool may contact hidden wiring or its own cord. 3

4 Power Tool Safety Cont. Never carry tool by the power cord or use the cord to pull the plug from the outlet. Keep cord away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately. When operating a power tool outside, use an outdoor extension cord marked WA or W. Router (Only) Use and Care Maintain tools with care. Never use dull or damaged bits. Keep cutting tools sharp and clean. Do not force tool. Use the correct tool for your application. Never use bits that have a cutting diameter greater than the opening in the base. Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tool s operation. If damaged, have the tool serviced before using. After changing bits or making any adjustments, make sure the collet nut and any other adjustment devices are securely tightened. Never start the bit while tool is engaged in the material. Always hold the tool in both hands during start-up. Always feed the work piece AGAINST the rotation of the cutter or router bit. Only use accessories that are recommended by the manufacturer of your router model. Clean router after use. The use of a wet/dry vacuum is recommended. Check the function of the guard before each use. Remove all dust, chips, and any other foreign particles that can affect its function. Router Table (Power Tool & Table) Use and Care Do not use this product until all assembly and installation steps have been completed. Make sure you have read and understood all safety and operational instructions in this owner s manual. Make sure that the router bit is properly positioned and clamped in the router before making any cuts. Before use and periodically during use, check all fasteners to make sure that all are tight and secure. Fastenings can become loosened by vibrations during use. Do not use the router table as a workbench or work surface. Doing so may damage it, causing it to be unsafe to use. A workbench should be used for this purpose. This product is designed for cutting flat woodwork pieces only. Do not attempt to cut work pieces that are rounded or that are made from metal or any other non-wood material. Use auxiliary in-feed and out-feed supports when routing long work pieces to prevent the router table from tipping over. Always make sure that the work surface of the router table is clean and free from dust, chips, and foreign particles that can interfere with the cut you are going to make. The use of a wet/dry vacuum is recommended. The fence that comes with the router table has a dust collector to which a wet/dry vac can be attached. 4

5 Power Tool Safety Cont. Some routers, when positioned in an upside down position (such as on a router table), will drop or fall out of the router base when the base clamp is loosened to adjust height and depth of cut. Therefore, it is extremely important to support the router from below when making these adjustments or whenever the base clamp is loosened. Always look at the router box switch box when turning the router ON or OFF. Never reach under the router table for any reason when the router is running, except to turn it OFF. Before making any cut, make sure the router is turned OFF, the router bit is not rotating, and the power cord is unplugged from the electrical outlet. Then make a trial pass to be absolutely sure that the overhead guard clears the router bit and the work piece. Never leave the router unattended while the router is running. Turn the router OFF before leaving the table for any reason. Service Always take tools to professionals for servicing. Service or maintenance performed by unqualified personnel could result in risk or injury. Use only identical replacement parts. 5

6 Parts Make sure all parts pictured below are included in package. 6

7 Tools and Fasteners Required Tools Required 1/4" (6,35mm) Slotted and #1 Phillips screwdriver. Small or medium sized adjustable wrench (or a set of nut drivers, open end wrenches or box wrenches) Electrical drill One or more of the following drill bit sizes: 1/8" (3,18mm), 3/16" (4,76mm), 1/4" (6,35mm), 9/32" (7,14mm), or 11/32" (8,73mm). 3/4" (19,05mm) diameter x 81 steel countersinking tool. Fasteners Required One or more of the following sets of fasteners will be required. Consult the Table 1/1a on Page to see which set of fasteners you will need. Two 5/16-18 x 5/8" (7,9mm x 15,9mm) long flat countersunk head machine screws. Three 5/16-18 x 5/8" (7,9mm x 15,9mm) long flat countersunk head machine screws. Four 5/16-18" x 7/8" (7,9mm x 15,9mm) long flat countersunk head machine screws. Three #10-24 x 3/4" (19,0mm) long flat countersunk head machine screws. Three #10-32 x 1/2" (12,7mm) long flat countersunk head machine screws. Three 1/4-20 x 1-1/4" (6,35mm x 31,75mm) long flat countersunk head machine screws and three 1/4-20 hex machine screw nuts. Three #8-32 x 3/4" (19,0mm) long flat countersunk head machine screws and three #8-32 hex machine screw nuts. Three #8-32 x 3/8" (9,5mm) long flat countersunk head machine screws. Two M6 x 1 x 15mm (M6 x 25,4mm x 15mm) long metric flat countersunk head machine screws. Four M4 x.7 x 10mm (M6 x 17,8mm x 15mm) long metric flat countersunk head machine screws. Three M6 x 1 x 15mm (M6 x 25,4mm x 15mm) long metric flat countersunk head machine screws. Other--depends upon the router, screws must be of the flat countersunk head type must be on the left side of the router table after assembly. Fasteners Included X 28 These fasteners will be used for the majority of fastening of the router table. X 4 For metal mounting plate and router. X 5 X1 X7 X1 For multi-angle fence assembly. 7

8 Router Table Operation and Assembly Read Instruction Manual thoroughly before operating router table. For your safety heed all warnings and recommendations. These fasteners will be used for the majority of fastening of the router table. Use these fasteners in this order for optimal fastening. Product 1 2 Attach the outlet box to one of the legs. Attach the leg with the outlet box to the table as shown. Note where the hole on the table is in comparison to the outlet box Line up the extensions to the table making sure that the tracks on the table and extension lines up. Attach extension and table with fasteners, but do not over tighten. You may need to adjust the tracks when table is complete. Adjustment is made by loosening these screws. 8

9 Router Table Operation and Assembly cont. 5 6 Secure extension supports in 3 places. Attach all 4 extension supports. Turn router table over. Table should look like this. Fence Assembly Instructions 1 Fence 2 Using the smallest carriage bolts, fasten fence face plate to table bracket fence. Use washers and knobs as shown. Fasten fence face plate to vacuum adapter bracket shown above. 3 Fence Using small carriage bolts, attach table bracket fence to vacuum adapter bracket. 9

10 4 #1 Fence Assembly Instructions cont. #1 #2 #2 Place completed fence bracket on table so holes line up with table slits. There are 2 remaining lengths of carriage bolts (one medium and one long). Use the medium one on hole #1 and long one on hole #2. See completed. 5 6 Insert pin into chip guard and fence bracket as shown. OPTIONAL: Use holes on the bottom of table legs to mount table to a surface or to power tool stand. Fasteners not included. 7 Completed router table should look like this. You are now ready to install your router. 10

11 Table 1 (For Installing the Router) Router Model # Number Hole Size Recommended Type of Holes Diameter Fasteners Porter Cable # /32" Four 5/16-18 x 7/8" Long Flat Base Plate Removed; Porter Cable #690 & /32" Three #10-24 x 3/4" Long Flat Base Plate Removed; Skil # /32" Three #10-32 x 1/2" Long Flat Base Plate Not Removed; Skil # /32" Three #10-32 x 1/2" Long Flat Base Plate Not Removed; Skil # /32" Three #10-32 x 1/2" Long Flat Base Plate Not Removed; Sears # /32" Three #10-32 x 3/8" Long Flat Base Plate Removed; Sears # /32" Three #10-32 x 3/8" Long Flat Base Plate Removed; Sears # /32" Three 1/4-20 x 1-1/4" Long Flat Base Plate Removed; Bosch # /32" Three 1/4-20 x 1-1/4" Long Flat Base Plate Not Removed; Screws and Nuts Dewalt#DW /4" Two M6 x 1 x 15MM Long Metric Flat Base Plate Removed; Ryobi #R /32" Two 5/16-18 x 5/8" Long Flat Base Plate Not Removed; Ryobi #RE /32" Two 5/16-18 x 5/8" Long Flat Base Plate Not Removed; Ryobi #R160K 3 11/32" Two 5/16-18 x 5/8" Long Flat Base Plate Removed; Ryobi #R160U 3 11/32" Three 5/16-18 x 5/8" Long Flat Base Plate Removed; Ryobi #R /32" Three 5/16-18 x 5/8" Long Flat Base Plate Removed; Ryobi #R /32" Three 5/16-18 x 5/8" Long Flat Base Plate Removed; Sears # /32" Three 5/16-18 x 5/8" Long Flat Base Plate Removed; Sears # /32" Three 5/16-18 x 5/8" Long Flat Base Plate Removed; Sears # /32" Three 5/16-18 x 5/8" Long Flat Base Plate Removed; Black and Decker 3 3/16" Three #8-32 x 3/4" Long Flat Base Plate Not Removed; Screws and Nuts Dewalt #DW /16" Three #8-32 x 3/8" Long Flat Base Plate Removed; Makita #3612C 4 3/16" Four M4 x.7 x 10mm Long Metric Flat Base Plate Removed; Dewalt #DW /4" Three M6 x 1 x 15mm Long Metric Flat Base Plate Removed; 11

12 Table 1a Metric (For Installing the Router) Router Model # Number Hole Size Recommended Type of Holes Diameter Fasteners Porter Cable # ,7mm Four 7,9mm x 22,2mm Long Flat Base Plate Removed; Porter Cable #690 & ,3mm Three #10-24 x 19,0mm Long Flat Base Plate Removed; Skil # ,3mm Three #10-32 x 12,7mm Long Flat Base Plate Not Removed; Skil # ,3mm Three #10-32 x 12,7mm Long Flat Base Plate Not Removed; Skil # ,3mm Three #10-32 x 12,7mm Long Flat Base Plate Not Removed; Sears # ,3mm Three #10-32 x 9,5mm Long Flat Base Plate Removed; Sears # ,3mm Three #10-32 x 9,5mm Long Flat Base Plate Removed; Sears # ,3mm Three 6,35mm x 31,75mm Long Flat Base Plate Removed; Bosch # ,1mm Three 6,35mm x 31,75mm Long Flat Base Plate Not Removed; Screws and Nuts Dewalt#DW ,35mm Two M6 x 1 x 15MM Long Metric Flat Base Plate Removed; Ryobi #R ,7mm Two 7,9mm x 15,9mm Long Flat Base Plate Not Removed; Ryobi #RE ,7mm Two 7,9mm x 15,9mm Long Flat Base Plate Not Removed; Ryobi #R160K 3 8,7mm Two 7,9mm x 15,9mm Long Flat Base Plate Removed; Ryobi #R160U 3 8,7mm Three 7,9mm x 15,9mm Long Flat Base Plate Removed; Ryobi #R ,7mm Three 7,9mm x 15,9mm Long Flat Base Plate Removed; Ryobi #R ,7mm Three 7,9mm x 15,9mm Long Flat Base Plate Removed; Sears # ,7mm Three 7,9mm x 15,9mm Long Flat Base Plate Removed; Sears # ,7mm Three 7,9mm x 15,9mm Long Flat Base Plate Removed; Sears # ,7mm Three 7,9mm x 15,9mm Long Flat Base Plate Removed; Black and Decker 3 4,77mm Three #8-32 x 19,0mm Long Flat Base Plate Not Removed; Screws and Nuts Dewalt #DW ,77mm Three #8-32 x 9,5mm Long Flat Base Plate Removed; Makita #3612C 4 4,77mm Four M4 x 17,8mm x 10mm Long Base Plate Removed; Metric Flat Dewalt #DW ,35mm Three M6 x 25.4mm x 15mm Long Base Plate Removed; Metric Flat 12

13 Installing the Adaptor Plate Using Table 1/1a (pg.11-12) and the template provided at the end of this manual, mark and punch a 1/4" (6,35mm) hole in the template as shown. Insert 1/4" (6,35mm) Shaft through paper template into collet of router. Using the template and router base, locate and mark the center of router plate retaining screws Using the punch, make hole through the template on all router plate retaining screws. Take router adapter plate and place over template, making sure to align edge correctly. Router adapter plate and template properly aligned. 13

14 Installing the Adaptor Plate cont Using adhesive tape, secure template and adapter on all four edges. Rotate the template and router adapter on to its back and mark with center punch holes for router retaining screws. Using Table1/1a (pg.11-12), drill the correct hole size on all marked spots Using 3/4" (19,05mm) dia. x 81º steel countersinking tool, countersink all holes. Remove router base plate if required. (See Table 1/1a pg.11-12) 14 Using Table 1/1a (pg ) use correct countersunk screws to secure router adapter to router. (Please Note! Screw must be flush with top of adapter for proper alignment).

15 Installing the Adaptor Plate cont. (Figure 1) Countersunk Screw Installing the Adapter Plate: Figure1 shows the correct installation of a countersunk screw. The countersunk screw must be flush or below the top of the adapter plate. If the screw protrudes above the adapter plate, the adapter plate may not properly seat against the bottom of the router table. WARNING: An improperly placed screw can lead to unsafe operation and may result in personal injury. 13 Tighten all 4 screws to metal mounting base and router. 15

16 Attaching Router Power Cord to the Switch Box Plug router into the switch box. Make sure to secure left over cord away from moving parts. Attach wet/dry vacuum to router table. Be sure that all cords are secured away from moving parts or components. Attaching Router Power Cord to the Switch Box WARNING: The switch box power cord must be UNPLUGGED from the electrical outlet before performing this procedure. Failure to unplug the cord could lead to serious injury. 1. Flip the router switch box to the OFF position. 2. Plug the router power cord into one of the outlets on the switch box. 3. Loop the excess power cord and wrap two pieces of friction tape around opposite sides of the coil. 4. Leave enough slack so the cord can reach the wall socket without stretching. 5. Plug the power cord from an accessory you will be using, such as a wet/dry vac or light, into the other outlet. 6. Plug the power cord from the router into the electrical outlet only AFTER the setup is completed. WARNING: The power cords from the router, the accessories, the switch box or any extension cord MUST NOT COME IN CONTACT with the router or any moving parts of the router. Make sure they are out of the way of both the tool and the work piece BEFORE turning the power switch on. 16

17 Operating the Switch Box Removable Safety Key prevents accidental switching on of Router. Switch box On/Off positions with removable safety key inserted. Operating the Switch Box 1. Make sure the switch on the router is turned ON (It maybe necessary to leave router in the lock on position) and the switch box lever is in the OFF position. 2. Plug the switch box power cord into the electrical outlet. 3. Insert the safety key into the switch box. 4. To turn router ON, flip switch box lever to the ON position. 5. To turn router OFF, press switch box lever to OFF. WARNING: NEVER leave router UNATTENDED until it has come to A COMPLETE STOP. 6. To lock the switch box in the OFF position, remove the safety key. WARNING: For your own SAFETY and the SAFETY OF OTHERS, make sure the router table is secure when not in use: 1. Flip the switch box lever to the OFF position and remove the safety key. 2. Unplug the switch box power cord from the electrical outlet. 3. Turn the router OFF. 4. Remove the router bit from the router. 5. Make sure the router collet assembly is below the top of the router table. 6. Store the switch box safety key out of the reach of children. In the event of a power failure, blown fuse, or the router stalling out while routing: 1. Turn the router OFF by pushing the switch box lever to the OFF position. 2. Remove the safety key from the switch box. 3. UNPLUG the switch box cord from the electrical outlet until the source of the problem has been corrected. 17

18 Installing the Router Bit Installing and Adjusting Router Bit 1. Make sure the router bit is the right size for your router. 2. Install the bit so that the router collet engages 3/4" (19,05mm) of the router bit shank. 3. If the shank of the router bit bottoms out in the collet, back out the router bit approximately 1/16" (1,59mm) to allow for proper tightening. WARNING: Never install router bits with less than 3/4" (19,05mm) of shank engagement in the collet. Adjust height of router bit so that it falls flush to table. Adjusting the Router Bit 1. Using a scrap piece of wood the same height as the work piece, raise and lower the router until the top of the router bit cutting edge lines up with the top of the scrap wood. (Refer to your Router Owner s Manual for instructions on how to adjust your particular brand of router.) 2. Make sure the router is securely tightened in the router base. 3. Check that the router bit is securely tightened in the router chuck. 4. Remove the board from the fence and lower the overhead guard down to the operating position. Adjusting the Fence Facing: The fence facings control the width of the opening beside the router bit. They are mounted on the front face of the router table fence. Loosen the hand knobs on the back of the fence to adjust the fence facings to fit your project, then tighten them securely when the facings are positioned correctly. Securely tighten the fence with the hand knobs when positioned correctly. The fence can also be adjusted forward or backward a distance equal to the amount of material to be removed by the router bit To adjust loosen the two hand knobs on the back of the fence on either the left or right side and slide the fence forward and backward to desired position. WARNING: Using the Router Table Do not operate the router if any part of the router bit contacts the overhead or the right and left fence facing 18

19 Using the Router Table cont. Fence adjustments sliding along table length are used to control the width of the opening along side the router bit. Fence adjustments sliding across table width. Adjust the amount of material removed with each pass. Mitre slide adjustment. Attaching Wet/Dry Vac to Fence Attaching Wet/Dry Vac to Fence Operating the router table without a wet/dry vac can result in an excessive build-up of sawdust and chips under the fence assembly and the overhead guard. This can hinder the performance of the router table and the fence assembly. To prevent this, the router table fence assembly has a port in the back where a wet/dry vac hose up to 2-1/2" (6,35cm) in diameter can be connected. Just hold the router table fence assembly in place and push the nozzle into the port. Cleaning the Fence Remove the sawdust and wood chips from under the fence assembly and the overhead guard as needed. Keeping this area clean will guarantee better router performance. Before cleaning: 1. The router and the switch box must be turned OFF. 2. The router bit must not be turning. 3. The router power cord must be UNPLUGGED from the switch box. 4. The power cord from the switch box must be UNPLUGGED from the electrical outlet. 19

20 Attaching Tabletop Inserts to the Router Table Table Top Inserts to the Router Table This router table comes with three tabletop inserts in the following hole sizes: 1-1/4" (3,18cm) diameter, for use with router bits with diameters up to 1-1/8" (2,86cm) 1-7/8" (4,76cm) diameter, for use with router bits with diameters up to 1-3/4" (4,45cm) 2-1/8" (5,39cm) diameter, for use with router bits with diameters up to 2" (5,08cm) WARNING: A 2-3/4" (6,98cm) diameter router bit is the LARGEST router bit that can be used on this router table. Router must be turned OFF and UNPLUGGED. 1. Select the tabletop insert that accommodates the router bit to be used. 2. Push the insert into the large hole in the top of the router table. 3. Press down the tabs on the insert until they snap into place. 4. To remove, place a finger in the insert hole and gently pull up until the tabs disengage. WARNING: DO NOT attempt to remove tabletop insert from the tabletop unless router bit has been removed from the router. Routing Using the Fence Routing Using the Fence: 1. Set the speed control to the required speed (if you are not sure of the correct speed, experiment until you find a speed that creates the desired cut easily). 2. Set the depth of the cut (1/4" (6,35mm) to 3/8" (9,53mm) is absolute maximum for one pass). 3. Loosen the plunge lock and press the main body up to the stop. Lock the body in position. 4. Check that the line of the cut is clear. Make sure no fingers, foreign objects or power cables are in the way. WARNING: Failure to keep your fingers, hands and other body parts out of the way of the router bit can result in serious bodily injury. 5. Allow the motor to reach full speed and move the cutter into the work piece. 6. Hold the work piece firmly. Be prepared for a small kick as the cutter engages the wood. Move the wood against the direction of rotation, pushing or pulling depending on the orientation of the work piece. Continue moving the work piece along the line of the cut until you reach the end of the wood. WARNING: The overhead guard must be down in the operating position when using the miter gauge. 20

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