MasterCraft 054-6938-6 User manual

INSTRUCTION MANUAL
ROUTER TABLE
054-6938-6

ROUTER TABLE - 054-6938-6
If any parts are
missing or damaged,
or if you have any
questions, please call
our toll-free helpline
at 1-800-689-9928.
Read and understand this instruction manual
thoroughly before using the product. It contains
important information for your safety as well as
operating and maintenance advice.
Keep this instruction manual for future use. Should
this product be passed on to a third party, then this
instruction manual must be included.

ROUTER TABLE - 054-6938-6
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TABLE OF CONTENTS
TECHNICAL SPECIFICATIONS 3
SAFETY GUIDELINES 4–11
DESCRIPTION 12
OPERATING INSTRUCTIONS 13–21
MAINTENANCE 22
TROUBLESHOOTING 23
PARTS LIST 24–25
WARRANTY 26–27

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FIXED-BASE ROUTER
MOTOR 120 V ~ 60 Hz, 9.5A
HORSEPOWER 1 3/4 HP
NO-LOAD SPEED 25,000 RPM
COLLET CAPACITY 1/4" & 1/2"
WEIGHT 9 lb 14 oz (4.5 kg )
ROUTER TABLE
TABLETOP 23 5/8 x 14 1/4" (60 x 36 cm)
TABLE HEIGHT 12 1/2" (31.8 cm)
RATING 120 V AC, 60 Hz only
TECHNICAL SPECIFICATIONS

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WARNING!
Safety symbols in this Instruction Manual are used to flag possible dangers. The safety
symbols and their explanations require your full understanding. The safety warnings do
not, by themselves, eliminate any danger, nor are they substitutes for proper accident
prevention measures.
WARNING!
This Safety Alert Symbol indicates caution, warning, or danger. Failure to obey a safety
warning can result in serious injury to yourself or others. To reduce the risk of injury, fire, or
electric shock, always follow the safety precautions.
Know your tool
To operate this tool, carefully read this Instruction Manual and all labels affixed to the Router Table
before using. Keep this Instruction Manual available for future reference.
Important
This tool should only be serviced by a qualified service technician. For more information, call the toll-
free helpline at 1-800-689-9928.
Read all instructions thoroughly
Save these instructions
General power tool safety warnings
WARNING!
Read all safety warnings and 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.
SAFETY GUIDELINES

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General safety rules for bench tools
WARNING!
Read and understand all instructions. Failure to follow all instructions listed below may
result in electric shock, fire and/or serious personal injury.
• Keep guards in place and in working order.
• Remove adjusting keys and wrenches. Form a habit of checking to see that keys and adjusting
wrenches are removed from the tool before turning it on.
• Keep the work area clean. Cluttered areas and benches invite accidents.
• Don’t use in a dangerous environment. Don’t use power tools in damp or wet locations or
expose them to rain. Keep the work area well lighted.
• Keep children away. All visitors should be kept a safe distance from the work area.
• Make the workshop childproof with padlocks and master switches, or by removing
starter keys.
• Don’t force the tool. It will do the job better and more safely when used at the rate that it was
designed to work at.
• Use the right tool. Don’t force a tool or attachment to do a job that it was not designed to do.
• Use the proper extension cord. Make sure your extension cord is in good condition. When using an
extension cord, be sure to use one that is heavy enough to carry the current that your product will draw.
An undersized cord will cause a drop in line voltage, resulting in loss of power and overheating. Table 1
shows the correct size to use, depending on cord length and nameplate ampere rating. If in doubt, use
the next heavier gage. The smaller the gage number, the heavier the cord.
Table 1: Recommended size of extension cords
Amperage rating of the tool (120
V circuit only)
Total length of the extension cord
25' (7.6 m) 50' (15.2 m) 100' (30.4 m) 150' (45.7 m)
More than Not more than Minimum Gauge for the extension cord (AWG)
0 6 18 16 16 14
6 10 18 16 14 12
10 12 16 16 14 12
12 16 14 12 Not recommended
SAFETY GUIDELINES

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• Wear proper apparel do not wear loose clothing, gloves, neckties, rings, bracelets, or other
jewellery that can get caught in moving parts. Non-slip footwear is recommended. Wear protective
hair covering to contain long hair.
• Always use safety glasses. Also use a facemask or dust mask if the cutting operation is dusty.
Everyday eyeglasses only have impact resistant lenses. They are not safety glasses.
• Secure the workpiece. Use clamps or a vise to hold the workpiece when practical. It’s safer than
using your hand and it frees both hands to operate the tool.
• Don’t overreach. Keep proper footing and balance at all times.
• Maintain tools with care. Keep tools sharp and clean for the best and safest performance. Follow
instructions for lubricating and changing accessories.
• Disconnect tools before servicing and when changing accessories, such as blades, bits,
cutters, and the like.
• Reduce the risk of unintentional starting. Make sure the switch is in the off position before
plugging the tool into an electrical outlet.
• Use recommended accessories. Consult the instruction manual for recommended accessories.
The use of improper accessories may cause a risk of injury to persons.
• Never stand on the tool. Serious injury could occur if the tool is tipped or if the cutting tool is
contacted unintentionally.
• Check damaged parts. Before further use of the tool, a guard or other part that is damaged should
be carefully checked to determine whether it will operate properly and perform its intended function.
Check for misalignment or binding of moving parts, broken parts or mountings, and any other
condition that may affect the operation of the tool. A guard or other part that is damaged should be
properly repaired or replaced.
• Direction of feed: always feed work into a blade or cutter against the direction of rotation
of the blade or cutter.
• Never leave a tool running unattended. Turn the power off. Don’t leave the tool until it comes to
a complete stop.
Grounding instruction
• In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric
current to reduce the risk of electric shock. This router table is equipped with an electrical cord with
an equipment-grounding conductor and a grounding plug. The plug must be plugged into a matching
outlet that is properly installed and grounded in accordance with all local codes and ordinances
• Do not modify the plug provided. If it will not fit into the outlet, have the proper outlet installed by
a qualified electrician.
SAFETY GUIDELINES

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• Improper connection of the equipment-grounding conductor can result in a risk of
electric shock.
• The conductor with a green-coloured outer insulation cover, with or without yellow
stripes, is the equipment-grounding conductor. If repair or replacement is necessary, do not
connect the equipment-grounding conductor to a live terminal.
• Check with a qualified electrician or service personnel if the grounding instructions are
not completely understood, or if in doubt as to whether the tool is properly grounded.
• Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole
receptacles that accept the tool’s plug.
• Repair or replace damaged or worn cord immediately.
• This tool is intended for use on a circuit that has an outlet that looks like the one
illustrated in Sketch A in the figure below. The tool has a grounding plug that looks like the
plug illustrated in sketch A in the figure below. A temporary adapter, which looks like the adapter
illustrated in Sketches B and C, may be used to connect this plug to a 2-pole receptacle as shown in
Sketch B if a properly grounded outlet is not available. The temporary adapter should be used only
until a properly grounded outlet can be installed by a qualified electrician. The green-coloured rigid
ear, lug, and the like, extending from the adapter must be connected to a permanent ground, such as
a properly grounded outlet box.
A.
B.
C.
Grounding Pin
Adapter
Grounding Means
Cover of Grounded
Outlet Box
Metal
Screw
SAFETY GUIDELINES

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Guidelines for extension cords
• When operating a power tool outdoors, use an outdoor extension cord that is marked W-A
or W. These cords are rated for outdoor use, and reduce the risk of electric shock. Replace damaged
cords immediately. Using a damaged cord can cause shocks, burns, or electrocution.
• Use a proper extension cord. Make sure that extension cords are in good condition. When using
an extension cord, be sure to use a cord that is heavy enough to carry the drawn current needed by
the router and accessories. An undersized cord will cause a drop in line voltage, resulting in loss of
power and overheating. The table below shows the correct size to use, depending on the cord length
and nameplate amperage rating. If in doubt, use the next heavier gauge. The smaller the gauge
number, the heavier the cord.
• Be sure that extension cords are properly wired and in good condition. Always replace
a damaged extension cord or have it repaired by a qualified technician before using it. Protect
extension cords from sharp objects, excessive heat, and damp or wet areas.
• Use a separate electrical circuit for power tools. This circuit must not be less than #6 wire,
and should be protected with a time-delayed fuse. Before connecting the tool to the power line,
make sure the switch is in the OFF position and the electric current is rated the same as the current
stamped on the motor’s nameplate. Running at a lower voltage will damage the motor.
WARNING!
Ensure that the power supply outlet in question is properly grounded. If not sure, have a
licensed electrician check the outlet.
WARNING!
To avoid electrical hazards, fire hazards, or damage to the tool, use proper circuit
protection.
Specific safety rules for the router table
WARNING!
Read all instructions. Failure to comply with all of the following instructions may result in
electric shock, fire and/or serious injury.
• Read and understand all instructions and warnings in the Instruction Manual for the
router table and the router used with this table. Failure to follow all instructions and warnings
may result in serious personal injury.
• Fully assemble and tighten all fasteners required for this table and for mounting the
router to the table. Do not use the router table until all assembly and installation steps have been
completed.
SAFETY GUIDELINES

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• Before each use, check the router and the table to ensure that all fasteners are still tight.
A loose table is unstable, and may shift during use.
• Unplug the router before installing it into the table.
• Turn off the router-table safety switch that controls power to the router or unplug the
router before making adjustments or changing accessories, such as bits or cutters.
• Always wear a dust mask and ear protection when using this power tool.
• Only use cutters that are designed for the particular router in use.
• Only use sharp cutters that are not chipped or cracked. Blunt cutters will cause stalling.
• Secure small pieces of wood firmly before working. Never hold a workpiece by hand.
• Secure the workpiece using clamping equipment.
• Before starting the router, check that the cutter bit is firmly positioned and secured in the collet.
• Do not exceed the maximum indicated rotation speed of the cutter bit.
• Routing operations must always be performed against the direction of rotation of the
cutter bit (cutter rotation).
• Note that the direction of rotation is reversed when the router is installed in the router
table: when installed in the router table, the cutter rotates counter-clockwise.
• The cutter bit must be running at full speed before it is lowered to the workpiece.
• When operating the router, always hold the handles firmly with both hands. Always ensure
that footing is secure when working.
• Be prepared for the reaction torque of the router, particularly if the cutter bit becomes
jammed in the workpiece.
• Become familiar with the working area, and be alert for possible hazards that cannot be
heard due to the noise of the router.
• Never slow the router down with your hands.
• Do not touch the cutter immediately after operation. It may be extremely hot, and could burn.
• Never stop the router by applying lateral pressure to the cutter.
• Do not force the router. It will do a better job if it is allowed to work at its intended speed.
• Avoid cutting nails and screws. Inspect timber before cutting, and remove all nails and screws.
• In the event of an electrical or mechanical malfunction, switch the router off immediately, and
disconnect the power cord from the outlet.
SAFETY GUIDELINES

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• The label on your tool may include the following symbols. The symbols and their
definitionsare as follows:
V ..................... Volts
A ..................... Amperes
Hz ................... Hertz
W .................... Watts
min ................. Minutes
............... Alternating current
............. Direct current
n0 ................... No load speed
............... Class II Construction
…/min ........... Revolutions per minute
............... Grounding terminal
BPM ............... Beats per minute
.............. WARNING – To reduce the risk of injury, user must read instruction manual.
Unpacking
WARNING!
If any parts are missing, DO NOT attempt to assemble, install, or use the router table until
the missing parts have been found or replaced and the router table has been properly and
correctly assembled according to this Instruction Manual.
To simplify handling and to minimize any damage that may occur during shipping, the router table
comes partially assembled.
Separate all parts from the packaging materials, and check each part against Contents below to ensure
that all parts have been included. Do this before discarding any of the packaging material.
SAFETY GUIDELINES

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Contents:
Key No. Description Quantity
1Router table surface assembly 1
2Table leg 2
3Fence assembly 1
4Mitre-gauge assembly 1
5Clamping knob 3
6Short round-head square-neck
bolts 2
7Long pan-head screw 4
8Short pan-head screw 4
9Flat-head screw 3
10 Small nut 8
11 Plain washer 2
12 Small washer 16
13 Spring washers 8
SAFETY GUIDELINES

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Know the router table
1
8
2
5
11
10
6
3
4
7
9
No. Description No. Description
1 Router table 7 Mitre-gauge
2 Integrated safety switch 8 Fastening holes
3 Extended fence 9 Switch box
4 In-feed fence 10 Dust collection and guard
5 Out-feed fence 11 Above-the-table height adjust hole
6 Vacuum adaptor
The router table has a precision-built electric switch box, and it should only be connected to a 120 V
AC, 60 Hz power supply (normal household current). DO NOT operate on direct current (DC). The large
voltage drop would cause a loss of power, and the motor would overheat. If the router table does not
operate when plugged into correct 120 V AC, 60 Hz outlet ONLY, check the power supply. The router
table comes with an 6' (1.8 m) power cord (no adaptor needed).
DESCRIPTION

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Assembly
Attaching the legs to the table top
1. Place the router table surface on a flat, level
surface, with the underside of the table
facing up.
2. Position the legs against the router table
surface, as shown in fig 1.
3. Position one short end of the table so that it
extends beyond the edge of the work surface
far enough to gain access to the four holes in
that end of the top of the router table.
4. Align the two outermost holes on the tabletop
with the holes in the leg bracket.
5. Place a small washer (12) onto each of two
short pan-head screws (8). Insert the short
pan-head screws up through the holes in the
table and through the holes in the leg bracket.
Place a small washer (12), a spring washer
(13), and a small nut (10) on the threads of the
screw. Loosely tighten the nuts (fig 1).
6. Place a small washer (12) onto each of two
long pan-head screws (7). Insert the long pan-
head screws up through the other two holes
on the tabletop and through the corresponding
holes in the leg. Place a small washer (12), a
spring washer (13), and a small nut (10) on
the threads of the screw (fig 2).
7. Tighten all fasteners securely.
8. Repeat with the other leg.
OPERATING INSTRUCTIONS
fig 1
fig 2

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Attaching the router to the table
WARNING!
Unplug the router before attaching the router to the table. Attach the router to the router
table after assembling the table.
1. Place the router table upright, with the front edge closest to the operator.
2. Be sure that the table is stable, and that it rests on both legs.
3. Remove the sub-base from the fixed-based router.
4. Hold the router upside down and align the
three holes in the centre of the table with the
holes in the router, as shown in fig 3. Position
the router so that the screw holes used for the
attachment are not directly above either of the
router handles.
5. Insert a flat-head screw through each of the
three holes in the router table and into the
holes in the router.
6. Hold the router with one hand, and use the
other hand to tighten each flat-head screw (9)
securely.
If a different router is installed (one that is not
included with the table), ensure that the diameter
of the router sub-base does not exceed
6 7/8" (17.5 cm). There are six mounting holes for
the router located in the centre of the table; the
distance between two opposite holes is
5 3/8" (13.7 cm). Select three appropriate holes to
mount the router to the table (fig4).
The adjusting hole in the table, as shown in fig 4, is
for adjusting the cutting height of the router that is
included (Model No. 054-6908-8) or CTC Model No.
054-6810-8.
OPERATING INSTRUCTIONS
fig 3
fig 4 6-7/8"
5-3/8"
2"
Adjusting Hole

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Attaching the fence to the
table (fig 5)
WARNING!
Always unplug the router before
attaching or removing the fence.
The fence is shipped completely
assembled.
1. Place the fence assembly on the table, with
the four wing nuts facing toward the operator.
2. Align the two holes on the bottom of the fence
assembly with the two channels on the router
table.
3. Secure the fence to the table using two
clamping knobs (5), two plain washers (11), and
two short round-head square-neck bolts (6).
Attaching the mitre
gauge (fig 6)
1. The mitre gauge is shipped completely
assembled.
2. Attach the mitre gauge to the table by placing
the mitre-gauge bar in the slot on the table.
OPERATING INSTRUCTIONS
fig 5
fig 6

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Mounting the table to a work
surface (fig 7)
1. Place the router table upright on a sturdy
surface, such as a work stand, workbench, or
countertop.
2. While holding the router table in place, mark
the location of the two mounting holes
(11/32" [8.7 mm] diam.) in each of the legs on
the work surface.
3. Remove the router table.
4. Drill a hole at each of the marked locations.
5. Place the router table on the work surface, and align the holes in the table legs with the holes in
the work surface.
6. Secure the router table to the work surface using four screws (not included).
7. Tighten the screws securely.
Using the switch
The switch has a safety key to help avoid accidentally switching the router ON and unauthorized and
possibly hazardous use by others.
The safety key must be completely inserted into the switch before the switch can be turned ON.
OPERATING INSTRUCTIONS
fig 7

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OPERATING INSTRUCTIONS
To operate the switch
1. Insert the safety key into the switch (fig8).
2. To turn the router ON, pull the ON/OFF switch
up (fig 9).
3. To turn the router OFF, push the ON/OFF
switch down (fig 10).
WARNING!
Never leave the router unattended
while it is running or before it comes
to a complete stop.
4. To lock switch in the OFF position, push the
ON/OFF switch down to turn the switch OFF,
and then remove the safety key from the
switch.
Two receptacles are located at the back of the
switch assembly (fig 11). Use one for plugging
in the router. The other may be used to plug in a
vacuum or a light (not included). Two dust shields
are designed to protect the receptacles.
WARNING!
To ensure safety and reliability, when
one receptacle is used for the router,
the capacity of the other receptacle is
limited to 5 A. The total current drawn by
the two devices must not exceed 15 A.
NOTE: The vacuum adaptor in the fence assembly
is 2-1/2" (6.4 cm) in diameter. Select the vacuum
accordingly.
fig 9
fig 10
fig 8
Safety key
fig 11
Dust Shield

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Adjustments
Adjusting the fence
The fence supports and guides the workpiece.
To adjust the extended fence
forward and backward (fig 12)
1. Unplug the router table.
2. Loosen the two clamping knobs (5).
3. Move the fence forward or backward along
the slots to the desired position.
4. Tighten the clamping knobs. The fence can be
moved forward and backward 3-3/4" (9.5 cm).
To adjust the in-feed and out-
feed fences laterally
The in-feed and out-feed fence can each be
adjusted 2" (5 cm) laterally to lengthen the fences.
1. Turn off the safety switch on the table.
2. Loosen the four wing nuts.
3. Move the fence facings to the right or left, to
the desired position (fig 13).
4. Tighten the wing nuts.
OPERATING INSTRUCTIONS
fig 12
fig 13

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To adjust the out-feed fence for
joining (fig 14)
For joining operations, the out-feed fence can be
adjusted up to 9/16" (14.3 mm) in front of the in-
feed fence to support the workpiece after it passes
across the router bit.
1. Turn off the safety switch on the table.
2. Loosen the two clamping knobs on the out-
feed fence.
3. Move the out-feed fence in front of the in-feed fence to a distance equal to the width of material to
be removed from the workpiece. Tighten the clamping knobs.
4. Move and clamp the entire extended fence so that the out-feed fence is aligned with the cutting
edge of the bit.
Adjusting the mitre
gauge (fig 15)
1. Loosen the mitre gauge knob.
2. Rotate the mitre gauge to the desired angle.
3. Tighten the mitre gauge knob.
OPERATING INSTRUCTIONS
fig 14
fig 15