Charnwood W020 User manual
GENERAL SAFETY RULES
WARNING: Do not attempt to operate the machine until you have read
thoroughly and understood completely all instructions, rules, etc.
contained in this manual. Failure to comply may result in accidents
involving fire, electric shock, or serious personal injury. Keep this
owner's manual and review frequently for continuous safe operation.
1. Know your machine. For your own safety, read the owner's manual carefully. Learn its
application and limitations, as well as specific potential hazards pertinent to this
machine.
2. Make sure all tools are properly earthed.
3. Keep guards in place and in working order. If a guard must be removed for
maintenance or cleaning, make sure it is properly replaced before using the machine
again.
4. Remove adjusting keys and spanners. Form a habit of checking to see that the keys
and adjusting spanners are removed from the machine before switched it on.
5. Keep your work area clean. Cluttered areas and workbenches increase the chance of
an accident.'
6. Do not use in dangerous environments. Do not use power tools in damp or wet
locations, or expose them to rain. Keep work areas well illuminated.
7. Keep children away. All visitors should be kept a safe distance from the work area.
8. Make workshop childproof. Use padlocks, master switches and remove starter keys.
9. Do not force the machine. It will do the job better and be safer at the rate for which it is
designed.
10. Use the right tools. Do not force the machine or attachments to do a job for which
they are not designed. Contact the manufacturer or distributor if there is any question
about the machine's suitability for a particular job.
11. Wear proper apparel. Avoid loose clothing, gloves, ties, rings, bracelets, and
jewellery which could get caught in moving parts. Non-slip footwear is recommended.
Wear protective hair covering to contain long hair.
12. Always use safety glasses. Normal spectacles only have impact resistant lenses.
They are not safety glasses.
13. Do not over-reach. Keep proper footing and balance at all times.
14. Maintain machine in good condition. Keep machine clean for best and safest
performance. Follow instructions for lubrication and changing accessories.
15. Disconnect the machine from power source before servicing and when changing
accessories or (if using a fixed base router) when mounting or remounting the motor.
16. To avoid accidental starting, make sure the switch is in the OFF position before
plugging in the mains cable.
17. Never leave the machine running unattended. Turn the power off. Do not leave the
machine until it comes to a complete stop.
18. Do not use any power tools while under the effects of drugs, alcohol or medication.
19. Always wear a face or dust mask if operation creates a lot of dust and/or chips.
Always operate the tool in a well ventilated area and provide for proper dust removal.
Use a suitable dust extractor.
ADDITIONAL RULES FOR ROUTER TABLES
1. Always hold the work piece against the fence.
2. Never perform any "free hand" operation. Do not use only your hands to support or
guide the work piece. Always use feather boards to help secure the work piece when
cutting smaller pieces.
3. Feed the work piece to the router bit against the rotating direction. Feed direction will
normally be from right to left.
4. Never draw the workpiece back during cutting. Wait until the router bit stops before
drawing back the workpiece.
5. Make sure the portable router has been installed securely before starting the
machine.
6. Make sure the router bit is locked securely before operating.
Features
•Accepts any brand of router
•Large, machined cast iron table
•Table top can be tilted to 45 degrees for easy router adjustment and removal
•Generously sized fence with mounting slots for feather boards
•Two large, easy read scales built into the table top
•Large mitre fence with pre-sets at 90 & 45 degrees
•Two insert rings supplied to match aperture to cutter size
•Outfeed fence adjustable with shims supplied for full-face cuts
•Easy set mounting jig for centralising of router
•Router mounted with clamps – no need for drilling
Specification
Table Surface 680mm x 510mm
Table apertures 92, 60 & 30
Table Height 860mm
Dust Hood Outlet dia. 56/63/68mm internal & 63/68/75mm external
Net Weight 53kg
Rating Trade
Overview of the Router Table
Left Fence Fence Shims Vertical Feather boards Cutter Guard Right Fence
Router Centring Jig Horizontal Feather board Mitre Guide Table Inserts
Unpacking
All parts are packed in one carton.
Unpack the parts carefully and check that
everything is present as in the following
photographs.
If anything is missing contact your retailer
immediately.
The cast iron table is protected with oil
which should be removed with a suitable
degreaser, such as WD40. The table is
heavy and you might require assistance
when removing it from the carton and
attaching to the leg stand.
Assembling the Floor Stand
Upper Side Brace Lower Rear Brace Front Upper Brace Reinforcing Leg
Rubber Foot Lower Front Brace Lower Side Brace Stand Leg
Important: All nuts and bolts should be fastened only finger tight until
assembly is complete.
Lay the two upper side braces and front upper
brace on a suitable flat surface, ensuring that
the table fixing holes are positioned exactly as in
the photograph
Attach the tops of the four legs to the upper
braces
Fit the two reinforcing legs and rear lower brace
to the stand rear legs. Please note the rear
lower brace is the one with the required
mounting holes for the reinforcing braces
Attach the front and side lower braces to the
legs
Fit a rubber foot to the end of each leg
Invert the leg stand and place on a level surface.
After checking the stand is square and the upper
braces are level, tighten all nuts/bolts using a
spanner
Attaching the table to the stand
Remove the two rubber bumpers and two bolts
from the table side brackets.
Mounting Bolts
Rubber Bumpers
With assistance, lift the table onto the stand, so
that the holes in supporting brackets align with
those in the upper side braces. Note that the
hinged side of the table is at the front of the
stand, in line with the front upper brace.
Attach the table support brackets to the stand
with two M8 nuts & bolts and the M10 rubber
bumper bolts.
Adjust the height of the bumpers in order to level
the table.
Remove the bolts, nuts and washers from the
table tilt support lever bottom collars and with
one washer behind the bolt head, assemble as
in the photograph – one for each lever.
Threaded Support Collar
Washer
Support Bolt
Support Strut
Attach the two lifting handles to the rear of the
table using a 5mm hex key.
Assembling the Fence and Cutter Guard
Place the aluminium angle fence carrier on the
cast iron table, aligning the two long slots with a
pair of tapped holes as illustrated.
Clamp the fence carrier using the two long
handles with M8 studs.
There are a series of holes which allow the
fence to be adjusted according to the size/type
of router cutter being employed and type of
operation being undertaken.
Slide the heads of two hex head bolts into the
channel in the rear of the fence and fit them
through the two holes in the fence carrier.
Secure with two washers and castellated knobs.
Repeat for the other side of the fence.
Fence fixing bolt
Fit the dust extractor port as shown using the
two long screws provided.
Adaptors are available to enable a variety of
extractor hose diameters to be connected.
Take the two bolts that are fitted with tri-wing
knobs and slide each bolt head into the channel
in the front of the fence.
Fit the cutter guard slots over the bolts and
tighten the knobs.
By loosening these knobs and sliding the guard
up and down, different sizes of cutter and work
piece can be accommodated.
When operating, slide the fences in or out to
support the work piece as close to the cutter as
is practical.
Locate the hinge pin in the underside of the
mitre fence into the hole in the runner.
Secure the mitre fence to the runner with the
handle bolt and washer.
Slide the runner into the table slot from the end.
There are adjustable preset stops for setting the
mitre fence at 90 degrees and 45 degrees left &
right
45 Degrees Right
90 Degrees
45 Degrees left
Attaching the Router to the Table
Consider removing the faceplate cover from the
router base. Doing so will increase the maximum
plunge depth by an amount equal to the
baseplate thickness.
The router table is supplied with our unique
centring jig to speed up accurate mounting of
1/2” collet routers.
Fully plunge the router and lock the 1/2”
diameter shaft of the Centring Jig into the
routers collet.
Ensure the body of the shaft projects from the
base plate by approximately 30mm.
Offer the router up to the underside of the table
with the shaft passing through the cutter
aperture.
Holding the router in position, place the centring
disc over the threaded shaft and then use the
thumb screw to secure it.
Ensuring that the centring disc is correctly
seated in the aperture, release the router plunge
lock and the router will then be held in place
against the underside of the table.
Lock the plunge mechanism again.
Rotate the router body to the most convenient
position for access to the depth and speed
controls. It might subsequently be necessary to
adjust this position slightly to allow the four
clamps to be positioned on convenient parts of
the baseplate.
Base + 13mm
Adjust the rear bolt and locknut on each of the
four mounting clamps as shown.
The distance shown should be equal to the
thickness of your router base plus 13mm.
Mounting Clamp
Add the clamp lock, locking nut, washer and bolt
as shown.
Bolt
Washer
Locking nut
Clamp Lock
Slide both bolt heads into a slot in the underside
of the table and position the mounting clamp on
a convenient part of the router baseplate.
The clamps should be spaced as equally as
possible in order to provide maximum support to
the router.
With the mounting clamp pushed up against the
router base plate, Slide the Clamp Lock and its
bolt away from the router, until it is at the end of
the slot in the mounting clamp.
Next, tighten the locking nut against the
underside of the table, using a 10mm spanner.
Now clamp the router to the table by tightening
the 4 Clamp Locks, using a 14mm spanner.
Increase the plunge depth slightly, unlock the
router collet and remove the centring jig.
The router is now mounted, ready for use.
In future, only the 4 Clamp Locks need to be
undone to remove or remount the same router.
To remove the router, loosen the 4 Clamp Locks
and slide the 4 clamps out, away from the
router.
For safe and accurate routing, three feather
boards have been supplied and these should be
used whenever possible.
Two feather boards should be fitted vertically to
the fence.
One feather board should be attached to the
table in the horizontal plane. There are two sets
of holes in the table to accommodate different
sizes of work piece.
Optional Accessories
CE12 Collet Extension
A collet extension is available to extend the
plunge depth of your router. It can be used with
1/2” shank router bits and extends the collet by
65mm.
100/63RC 100mm Diameter Extraction
Adapter
This connector can be used to convert the
extraction outlet for use with a 100mm diameter
hose.
W026 NVR Safety Switch
We strongly recommend the use of a secondary
switch to start and stop the router without
reaching under the table.
Mounting holes for this item are provided in the
front upper brace.
Basic Operating Instructions
1) EDGING AND PROFILING
One of the most common operations undertaken using a router is Edging or Profiling, i.e.
running a shaped cutter along the edge of the work piece. In many instance this is for
decorative purposes but it can also be to make a joint or fitting such as a raised panel.
Using a router table for this type of work vastly reduces the setting up time required and
does away with many awkward clamping devices. Router table users soon find that having
both hands free to control the work piece, rather than holding a machine, makes the task far
more comfortable and generally a lot safer.
SET THE CUTTER HEIGHT:- First fit a suitable cutter after making sure the router is
unplugged. It is often easier to do this by lifting the mounting plate and router from the table.
Draw a profile of the required cut onto the edge of the work piece and adjust the cutter
height to match. Adjusting the cutter height is made much easier if a fine height adjuster is
fitted to the router. With many models this now comes as standard, but on others it is
available as an accessory produced by the router manufacturer. Having set the cutter height
fit the router back into the table.
SET THE FENCE:- The next step is to set the fence in a position to give the desired width of
cut. Use the profile drawn on the end of the work piece to set the fence and lock into
position. There are two scales set into the table to assist in rapid fence setting. Make a note
of the fence position if you are likely to run the same job again.
When using a cutter fitted with a guide bearing the fence should be set in line or just in front
of the edge of the bearing so that the work piece runs on the face of the bearing. The
distance between the two fence faces can be adjusted by undoing the plastic handles at the
rear and sliding the fence face along. The fence faces should be set so that the edges just
clear the cutter. This provides the maximum amount of support to the work piece during the
cut.
SET THE FEATHERBOARDS:- Adjust the Feather boards so that they provide a positive
pressure against the fence or against the table. Set them somewhere between 2mm & 5mm
less than the dimension of the work piece. This will hold the work piece securely up against
the cutter and prevent 'kick-back' during the cut. When the feather boards are correctly set,
the operator merely has to push the work piece across the table from right to left. It is still
recommended to use a push stick for small work pieces. Please Note: Some work pieces
may be too big to fit underneath the feather boards and they can simply be removed from
the router table. The function of the feather boards is twofold; to hold the work piece securely
against the cutter and to keep the hands well away from it. When using larger work pieces
the increased weight will help to keep it against the cutter and the danger of hands being too
near the cutter is greatly reduced.
SET THE CUTTER GUARD:- Adjust the cutter guard so that it just clears the top of either
the cutter or the work piece. It will deflect any chips or dust which are thrown upwards. If
possible, connect a dust collector or vacuum extractor to the dust outlet before commencing
the cut.
To test the settings you have made, make a cut with a scrap piece of wood before using the
work piece. Mistakes cannot usually be rectified afterwards.
2) GROOVING
Grooving and Trenching operations are often carried out to form joints such as slot dovetails
or to make fittings such as draw runner grooves.
SET THE FENCE:- The table is set up in the same manner except the fence will be set
further back away from the cutter. The cutter guard can be removed and the 2 fence faces
can be moved closer together so they are touching.
SET THE CUTTER HEIGHT:- For this kind of operation the work piece will be run directly
over the top of the cutter. Set the cutter height carefully and ensure enough material is left at
the bottom of the trench to avoid break out.
3) USING THE MITRE GUIDE
For some operations it is not possible to use the fence as a guide, for example cutting
across the grain, trenching at an angle or cutting a tenon. To do these jobs the sliding mitre
fence is used which runs in the T-slot across the front of the table
SET THE BACK FENCE:- Undo the two plastic knobs and move it back to a position where it
will not interfere with the cut.
SET THE ANGLE:- To change the angle of the mitre fence, undo the locking knob and read
off the engraved scale on the casting. There are preset angles at 90 degrees and 45
degrees each way. Tighten the knob to lock the fence at the required angle.
SACRIFICIAL FENCE:- The mitre fence can be enhanced by adding a longer wooden
sacrificial fence to the front of the sliding fence. The sacrificial fence can run all the way up to
the cutter and can be used to prevent breakout on the back edge of the work piece.
4) REMOVING A COMPLETE EDGE
If the complete edge is to be removed you may need to step the outfeed fence out to
correctly support the work piece during the cut. To achieve this undo the two locking knobs
on the back of the outfeed fence and insert one or more of the metal shims between the
aluminium support and the wooden fence. There are a set of 4 shims provided with the table.
The shims vary in thickness and the set consists of 1 x 0.5mm, 2 x 1mm, 1 x 2mm. By using
a combination of the shims, anything up to 4.5mm in 0.5mm increments can be set.
Charnwood W020 Parts Drawing
Charnwood W020 Parts List
No.
Description
No.
Description
12
Flat Washer
13
Mitre Gauge Handle
14
Hex Nut
15
Pozi Screw
16
Mitre Gauge Body
17
Sliding Block
18
Screw
19
Guide Bar
20
Locating Plate
21
Pointer
22
Set Screw
23
Roll Pin
24
Table Top
25
Table Frame
26
Hex Bolt
27
Lock Washer
28
Flat Washer
29
Table Insert 60mm
30
Table Insert 29mm
31
Table Left Support
32
Table Right Support
33
Hex Bolt
34
Flat Washer
35
Hex Nut
36
Hex Nut
38
Bumper
39
Left 45 degree Positioning Piece
40
Right 45 degree Positioning Piece
41
Positioning Piece
42
Round Head Screw
43
Flat Washer
44
Mounting Clamp
45
Clamp Lock
46
Hex Bolt
47
Hex Bolt
48
Hex Nut
49
Hex Lock Nut
50
Hex Bolt
51
Floor Stand Leg
53
Upper Left Angle Plate
54
Upper Right Angle Plate
55
Front Upper Brace
56
Front Lower Brace
57
Rear Lower Brace
58
Lower Side Brace
59
Left Bracket
60
Right Bracket
61
Carriage Bolt
62
Flat Washer
63
Lock Washer
64
Hex Nut
65
Rubber Feet
78
Arched Handle
79
Hex Socket Head Screw M6 x 20
80
Fence Measuring Scale
81
Set of Fence Shims
82
Centring Jig
Charnwood W020 Fence Parts Drawing
No.
Description
B01
Aluminium Fence Support
B02
Black, Castellated Knobs
B03
Captive Bolt
B04
Pozi Head Screw
B05
Optional -Dust Port
B06
Black, Tri-wing Knob
B07
T-track
B08
Hex-head Bolt
B11
Countersunk Screw
B12
Fence
B13
Cutter Guard
B15
Black Castellated Knob
B17
Washer
B18
Feather board assembly
B19
Yellow Plastic Knob
B20
Washer
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