JessEm Tool 02101A Service manual

Operating Instruction
JessEm Tool Company, LTD
100 Caplan Ave., Unit 14 & 15
Barrie, ON L4N 9J2 Canada
705-726-8233
705-726-7519 Fax
1-866-272-7492
www.jessem.com
[e-mail]
Mast
-
R
-
Lift
Operating Instruction
s
and Parts Manual
Models: 02101A and 02102A
and Parts Manual
Revised: 6/25/09

Thank you for choosing this product from JessEm Tool Company. We appreciate your
support andhopethatour productservesyouwell. This product is designed to provide
many years of reliable service provided it is used as intended and taken care of.
This user manual will assist you in assembly and general operation of this product. It
is not our intent to teach you about woodworking. It is assumed that you are an
experienced woodworker with the basic skills andexperience necessary to use this
product safely. If after reading the following instructions, if you are unsure or
uncomfortable about safely using this product we urge you to seek additional
information through widely available woodworking books or classes.
As part of our Continuous Product Improvement Policy, JessEm products are
always advancing in design and function. Therefore theremay be differencesbetween
what is showninour catalogs, website or at retail display and what is sold at time of
purchase. We reserve the right to make positive changes to our products at our
discretion.
Model 02101A – Fits Table Opening 9-1/4” x 11-3/4”
Fits Porter Cable 7518/7519 Router Motor
Model 02102A – Fit Table Opening 8-1/4” x 11-3/4”
This unit is for non-JessEm Router Tables
Adapter Collars for Model 02101A
Model 02111 – Fits Porter Cable 690/890, Bosch 1617/1618, DeWalt
610/616/618
Model 02113 (3-1/4” diameter) – Fits Makita 1101
Model 02115 – Fits Hitachi M12VC and KM12VC
Model 02118 – Fits Milwaukee 5615/5616/5619
Shim Kit Model 02116 – Fits Milwaukee 5625
Important!!
Read and understand the contents of this manual
before assembly or operation of this product.

IMPORTANT SAFETY PRECAUTIONS
 Before operating any router, read and understand all safety instructions in the
owner’s manual that came with the router.
 If you do not have a manual, contact the manufacturer and obtain one before using
any power tool.
 Always wear eye protection in compliance with ANSI safety standards when operating
any power tool.
 Always use proper guards and safety deviceswhenoperatingpowertoolsand
machinery.
 Carefully check router bits before each use. Do not use if damage or defect is
suspected.
 DonotexceedtherecommendedRPM for any router bit.
 Do notwearloose clothingorjewelrythatmay catch on tools or equipment.
 Unplug thetool or machine when mounting or making any adjustments to mechanical
performance.
ROUTER SAFETY PRECAUTIONS
 Neverforcethe bitor overload therouter beyond the expectations of the tool.
 Be sure that at least 3/4 of the shank length is inserted securely in the router collet.
 Never bottom out the bit in the collet. Allow 1/8” clearance between shank and bottom
of collet.
 Always makesure the fenceon your routertable is locked into position before each
use.
 Always rout in two or more passes when large amounts of stock must be removed.
 Use reduced RPM speeds for large diameter bits.
DO NOT USE A CORDLESS DRILL T
O RAISE
AND LOWER THE LIFT CARRIAGE. THE
AMOUNT OF FRICTION WILL CAUSE
PREMATURE WEAR OF THE THREADS.
CALIFORNIA PROPOSITION 65 WARNING
This product contains lead known to the State of California to cause cancer or
reproductive harm. Components made of brass are known to contain lead. Wash hands
after using this product.

Suggested Router Bit Speeds
Bit Diameter Max. Speed
1” (25mm) 24,000 RPM
1-1/4”-2”(30-50mm) 18,000 RPM
2-1/4” - 2-1/2” (55-65mm) 16,000 RPM
3”-3-1/2”(75-90mm) 12,000 RPM
JessEm Tool Company Limited Warranty
All JessEm products are warranted to be free from defects in materialand
workmanship. JessEmwillrepair orreplaceanyproductwhichupon inspection
proves to be defective for a period of (1)year from dated receipt andproof of
purchase. All warranty claims should be made direct to JessEm Tool Company.
Contact JessEm for a warrantyclaim return authorization and instructions to
proceed. The consumer is responsible for shipping costs to return product to
JessEm Tool Company. We will repair or replace the product at our discretion
and JessEm Tool will return shipment to you at no charge.
Warranty Limitations
This warranty does not cover:
 Repairs or alterations made or attempted by anyone other than JessEm Tool
Companyoran authorized JessEmservice professional.
 Normal wear and tear
 Abuse, misuse or neglect.
 Improper care or maintenance.
 Continued use after partial failure.
 Products that have been modified in any way.
 Products used with improperaccessories.
 Premature thread wear due to adjusting height with electric or cordlessdrill
CONTENTS:
(1) Mast-R-Lift, (1) HeightAdjustment Handle, (1) Insert Ring,(1) InsertRingWrench, (1) Hex
Key, (1) Start Pin
TOOLSREQUIREDFORASSEMBLY: 6mm and8mm Hex Key
TOOLS REQUIREDFORADJUSTMENT: 10mm Wrench

Figure 1
Place the crank handle into the hex hole in the
lift’s dial on the top plate. Crank the lift carriage
up so that it just contacts the O-rings atthe top of
the carriage shafts. The carriage should beall
the way toward the top plate. With a 5/16” hex
wrench, loosen the cap screwonthecarriage
clamp toallowthe motor toslide into the carriage
assembly (Fig. 1). TheMast-R-Liftwill accept the
PorterCable 7518out of the box. If you are
using a smaller diameter router motor insert the
adapter collar intothe opening.
Installing the Router
(cont’d)
Rotate the router so that when the final
installation is made all router controls will
be positioned for convenient access. Then
back the motor off approx. 1/16” from
contacting the top plate and tighten the
cap screw on the carriage assembly.
Installing a JessEm Lift in a
Custom Router Table Application
A JessEm router lift is similar to us i ng a
router mountingplate.Yourtable topmust
h a ve aportmachined into the top. JessEm
offers so l id phenolic router tables tops with
pre-machined p orts for all JessEm router
lifts. If you are inst a lling this Lift in a custom
tableapplication youwillhave tofabricate
thisopeningyourself. Jes s Em offers a
separate template for this operation. See
your JessEm distributor for the proper
templa t e for your JessEm router lift.
Figure 2
Before installing the router motor, prop the
unit up on blocks of wood (Fig. 2) so the
router’s collet can extend through the center
hole in the top plate. The motor housing
must slide all the way through and contact
the inside back of the center hole on the
plate.
Now slide the router motor into the carriage
so the top of the motor housing just makes
contact with the inside surface of the center
hole in the top plate.
Installing the Router

Leveling the Lift to the Table Top
The Mast-R-
Lift features 8 drilled and tapped
holes around the perimeter of the insert plate
with adjustable set screws (Fig. 4
). Using the
hex wrench included with your
lift, turn the set
screws in the clockwise direction to raise the
insert plate orturnthe set screwsin the counter
clockwise directionto lower the insert plate until
the insert plate is level (flush) with the router table
surface. Start at one corner o
f the insert plate
and work your way around the perimeter of the
insert plate until all set screws have been
adjusted properlyso that the insert plate does not
rest above or below the table surface. Once the
insert plate has been leveled properly, please
figure 4 for adjusting the insert plate to the table.
Figure 4
Securing the Mast-R-
Lift to the Table
After adjusting the leveling screws and
getting the lift plate level and flush with the
table top, the Mast-R-Lift
can be secured
by inserting a bolt
through the top of the
then screwing the bolt into the
corresponding corner hole in the table
opening using a hexkey (Fig. 5
). This will
secure the lift or plate frommoving during
operation. Refer to the router lift or plate
manual for more detail
s on leveling the lift
or plate to the table.
Leveling the Lift to the Table Top
Lift features 8 drilled and tapped
holes around the perimeter of the insert plate
). Using the
lift, turn the set
screws in the clockwise direction to raise the
insert plate or turn the set screws in the counter
clockwise direction to lower the insert plate until
the insert plate is level (flush) with the router table
f the insert plate
and work your wayaround the perimeter of the
insert plate until all set screws have been
adjusted properly so that the insert plate does not
rest above or below the table surface. Once the
insert plate has been leveled properly, please
see
figure 4 for adjusting the insert plate to the table.
Tab
-
Loc Insert Rings
The Rout-R-
Lift FX comes with one insert
ring
with a pre
center hole.
Additional ring sets are
available with different diameter pre
holes and/or no pre
creating your own custom center hole
diameters. See your JessEm distributor for
these
and other accessories.
1.
Place the insert ring into the center
hole of
the Lift’s top plate (Fig. 6).
2.
With the insert wrench provided, insert
the
prongs of the wrench into the
corresponding
holes in the insert ring and
turn the insert ring
tighten.
3.
Turn the insert wrench clockwise to
loosen
and remove the ring. If the insert
ring becomes
too tight to loosen with hand
pressure, a tap
clockwise on the insert
wrench with a block of
Figure 4
Lift to the Table
After adjusting the leveling screws and
gettingthe lift plate level and flushwith the
can be secured
through the top of the
lift
corresponding corner hole in the table
). This will
secure the lift or plate from moving during
operation. Refer to the router lift or plate
s on leveling thelift
Loc Insert Rings
Lift FX comes with one insert
with a pre
-drilled 1-1/2” diameter
Additional ring sets are
available with different diameter pre
-drilled
holes and/or no pre
-drilled holes for
creating your own custom center hole
diameters. See your JessEm distributor for
and other accessories.
Figure 6
Place the insert ring into the center
the Lift’s top plate (Fig. 6).
With the insert wrench provided, insert
prongs of the wrench into the
holes in the insert ring and
turn the insert ring
counter clockwise to
Turn the insert wrench clockwise to
and remove the ring. If the insert
too tight to loosen with hand
clockwise on the insert
wrench with a block of
wood will loosen it.
Figure 5

Using the Mast
-
R
-
Lift
To raise your router, turn the height adjustment
handle clockwise. To lower, turn the handle
counter-clockwise. Keep in mind that one
complete revolution equals 1/16” of change.
When your adjustment is complete, remove the
handle and place somewhere off the work
surface for safety. Refer to the chart below for
fractional and decimal adjustments based on
amount of revolutions made.
Fraction
Decimal
Number of
Revolutions
1/64”
0.016”
1/4
1/32”
0.031”
1/2
1/16”
0.062”
1 Revolution
1/8”
0.125”
2
1/4”
0.250”
4
1/2” 0.500” 8
Re-Adjusting the Thread Tensioning
All JessEm Lifts feature our patented thread
tensioning design. This feature is why it is not
necessary to lock the router into position after
setting the cutting height. The design keeps
tension on the position wherever you set the
height. Thread tension is set at the factory and
depending on the amount of use you may have to
reset this adjustment periodically. If the bit height
ever begins to change (or drop) during use, the
thread tensioning likely needs to be reset.
1. TurntheLift upsidedownon atablewith the
threaded height adjustment rod facing you.
2. With an open end wrench, (Fig. 7) loosen
the hex nut that is located on the right side of
the brass post next to the threaded rod. Then
use a hexwrench to back out the set screw that
threads through the nut until the brass
tensioning collar can be turned.
Figure 7
Figure 8
3. Then route the brass tensioning
collar (Fig. 8) with vertical grooves, so
it tightens against the rubber washer.
Note: A drop of oil on the rubber
washer eases the rotation of the
brass collar.
4. Make certain the set screw seats
in one of the vertical grooves when
tightening the brass collar.
5. Tighten the nylon lock nut with the
open end wrench again and the
adjustment is complete.

02101A Mast-R-Lift Parts List
Item No. Part No. Description Qty Specification
1 02101A-001 Guide Tube Base 2
2 02101A-002 Shaft Mtg Block Bolt 9 M6X12
3 02101A-003 Rubber O-ring 2 M29.4X18.6X5.4
4 02101A-004 Bearing Tube 2
5 02101A-005 Rubber O-ring 2 M25.4X18.6X3.4
6 02101A-006 washer 2 M8.5X25X2.5
7 02101A-007 Screw 2 M8X16
8 02101A-008 Carriage Bolt long 6 M6X63
9 02101A-009 Carriage Tube Retainer 2
10 02101A-010 Guide Tube 2
11 02101A-011 Carriage Lock bolt 1 M10X60
12 02101A-012 Clamp pin 1
13 02101A-013 Carriage Adjusting Lock Nut 2 M10
14 02101A-014 Clamp pin 1
15 02101A-015 Down carriage plate 1
16 02101A-016 Carriage Spacer 10
17 02101A-017 Upper Carriage Plate 1
18 02101A-018 Retainer Bolt 2 M6X25
19 02101A-019 Carriage bolt short 4 M6X50
20 02101A-020 Retainer 1
21 02101A-021 Rubber O-ring 3 M32X25.2X3.4
22 02101A-022 Pin 1
23 02101A-023 Shaft Bushing 1
24 02101A-024 Backlash Lock Nut 1 M6
25 02101A-025 Backlash set screw 1 M6X25
26 02101A-026 Backlash Pin 1
27 02101A-027 Rubber Washer 1
28 02101A-028 Brass Backlash Nut 1
29 02101A-029 Lead Screw w/spring pin 1
30 02101A-030 Mtg Block Bolt 4 M6X18
31 02101A-031 Spindle Mounting Block 1
32 02101A-032 Brass Washer 1
33 02101A-033 Spring Washer 1
34 02101A-034 Rubber Washer 1
35 02101A-035 Height Dial 1
36 02101A-036 Top Plate 1
A 02101A-A 2" Insert Ring 1
B 02101A-B Hex Key 1 M6
C 02101A-C Hex Key 1 M8
D 02101A-D Starter Pin 1
E 02101A-E Leveling Screw 11 M6X8
F 02101A-F Crank Handle 1
G 02101A-G Wrench 1