MasterCraft 054-6841-4 User manual

IMPORTANT:
Read and understand this instruction manual
thoroughly before using the product.
INSTRUCTION
MANUAL
ROUTER TABLE
054-6841-4

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TABLE OF CONTENTS
Technical Specifications 4
Safety Guidelines 5
Key Parts Diagram 13
Operating Instructions 14
Maintenance 26
Troubleshooting 27
Parts List 28
Warranty 30
TABLE OF CONTENTS
NOTE:
If any parts are missing or damaged, or if you have any questions,
please call our toll-free helpline at 1-800-689-9928.
SAVE THESE INSTRUCTIONS
• This manual contains important safety and operating instructions. Read all
instructions and follow them with use of this product.

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TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
Model 054-6841-4
Table size (approximate) 14 1/8" × 23 5/8"
Table height 12 1/2"
Switch rating 120V 60Hz 15A
Cord length 6'
Weight 14 lb 11 oz (6.65 kg)
Max. load capacity 50 lb (22.7 kg)

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SAFETY GUIDELINES
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
Read this Instruction Manual and all of the labels affixed to the router table carefully before operating
this tool. Keep this 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.
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.
SAFETY GUIDELINES

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• 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
• 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.
SAFETY GUIDELINES

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• 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.
• 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.
SAFETY GUIDELINES

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• 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
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.
SAFETY GUIDELINES

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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.
• 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.
SAFETY GUIDELINES

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• 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.
• Do not expose to rain or use in damp location.
• 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 or reciprocation per minute
............... Grounding terminal
BPM ............... Beats per minute
.............. WARNING – To reduce the risk of injury, user must read instruction manual.
.............. WARNING – To reduce the risk of injury always wear eye protection.
.............. WARNING – To reduce the risk of injury always wear ear protection.
SAFETY GUIDELINES

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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 on the following
page to ensure that all parts have been included. Do this before discarding any of the packaging
material.
CONTENTS:
Key No. Description Quantity
1Router table (with universal router mounting
plate) 1
2Table leg 2
3Fence assembly 1
4Mitre-gauge assembly 1
5Feather board 3
6Wing nut 6
SAFETY GUIDELINES

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7 Plain washer 8
8Round-head square-neck bolt M6x26 1
9Round-head square-neck bolts M6x35 6
10 Round-head square-neck bolt M6x40 1
11 Flat-head screw 3
12 Short pan-head screw 4
13 Long pan-head screw 4
14 Clamping knob 2
15 Starter pin 1
16 Level screws 4
17 Small nut 8
18 Spring washer 8
19 Small washer 16
20 Ellipse-shaped washer 2
21 Tabletop insert w/ 1 1/4" Dia. Hole 1
22 Tabletop insert w/ 1 7/8" Dia. Hole 1
23 Tabletop insert w/ 2 1/8" Dia. Hole 1
SAFETY GUIDELINES

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KEY PARTS DIAGRAM
4
3
2
18
9
10
4
7
5 6
1112
No. Description No. Description
1 Tabletop surface 7 Fastening holes
2 Out-feed fence 8 Mitre-gauge
3 Extended fence 9 Above-table height adjust hole
4 Feather board 10 In-feed fence
5 Integrated safety switch 11 Vacuum adaptor
6 Switch box 12 Dust collection and guard
The router table has a precision-built electric switch box, and it should only be connected to a 120V
AC, 60Hz 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 120V AC, 60Hz outlet ONLY, check the power supply. The router table
comes with a 6’ (1.8m) power cord (no adaptor needed).
KEY PARTS DIAGRAM
WARNING!
• Do not allow familiarity with the router table to cause a lack of alertness. A fraction of a second of carelessness
is enough to cause severe injury.
FPO

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ASSEMBLY AND ADJUSTMENT
ATTACHING THE LEGS TO THE TABLETOP
1. Place the tabletop on a flat, level surface, with the
underside of the table facing up.
2. Position the legs against the underside of the
tabletop 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(19) onto each of two short pan-
head screws(12). 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 (19), a spring
washer (18), and a small nut (17) on the threads of
each screw. Loosely tighten the nuts (fig 1).
6. Place a small washer(19) onto each of two long pan-
head screws(13). 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 (19), a spring washer (18), and a small
nut (17) on the threads of each 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 ROUTER TABLE (fig 3)
The holes on the router mounting plate can fit most popular routers: Mastercraft®, MAXIMUM®, Bosch®,
Porter Cable®, DeWALT®, Ryobi®.
AA
A
B
B
B
C
C
C
D
D
D
fig 3
ROUTER BRAND Router Model Hole Pattern
Mastercraft®54-6908-8, 054-6908-8, 054-6902-0, 054-6988-6,
54-7010-6, 054-7010-6, 054-6821-2 Hole A
MAXIMUM®54-6810-8, 054-6810-8, 054-2433-0 Hole A
Skil®1825 Hole A
Bosch®1617EVSPK (plunge base only) Hole B
Bosch®1617EVSPK( fixed base only) Hole C
Porter Cable®694VK, 893, 1001-T2 Hole C
Dewalt®DW616 Hole C
Ryobi®RE1803BK Hole D
SKIL®is a registered trademark of Chervon (China)Trading Co.,Ltd.. BOSCH®is a registered trademark
of Robert Bosch GmbH. Porter Cable®is a registered trademark of the Porter Cable Corporation.
DEWALT®is a registered trademark of DEWALT Industrial Tool Co. Ryobi®is a registered trademark of
Ryobi Limited and is used by One World pursuant to a license granted by Ryobi Limited.
OPERATING INSTRUCTIONS

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NOTE: Failure to make sure the router mounting plate is flush with the tabletop surface can result in poor routing performance.
Slide a square-cut board from right to left across the router mounting plate to be sure that the board moves smoothly.
ATTACHING THE ROUTER TO THE ROUTER TABLE
1. Unplug the router and the router table.
2. Remove the plastic sub-base from the router base
(fig 4).
3. Loosen the screws and remove the universal router
mounting plate from the router table.
4. Put the router upside down, and align the three holes
in the centre of the universal router mounting plate
with the holes in the router, as shown in fig 3.
5. Insert a flat-head screw (11) through each of the
three holes in the universal router mounting plate
and into the holes in the router base, and then
tighten each flat-head screw securely (fig 5).
6. Re-install the router mounting plate to the router
table (fig 6a). Install the four levelling screws into the
four holes around the mounting plate opening. Adjust
the mounting plate height so that it is flush with the
table (fig 6b). A turn to the right raises the mounting
plate and a turn to the left lowers the plate. Using a
straight edge, check to be certain that the surface of
the router mounting plate is flush with the tabletop
surface.
7. To hold the mounting plate in position, tighten the
four screws in Step 3. Recheck to make sure that the
surface of the router mounting plate is flush with the
tabletop surface. If not, repeat Step 6.
OPERATING INSTRUCTIONS
fig 4
fig 5
fig 6a
fig 6b

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ATTACHING THE FENCE TO THE TABLE (fig 7)
1. Place the fence assembly on the tabletop surface,
and align the two holes on the bottom of the fence
assembly with the two slots on the router table.
2. From underneath, slide a long round-head square-neck
bolt (10) through the left hole and a round-head square-
neck bolt (8) through the right hole. Slide a plain washer
(7) onto each bolt.
3. Put the clamping knobs (14) on the bolts. Secure
the fence to the tabletop surface by tightening the
clamping knobs.
4. To prepare the table for transportation and storage,
loosen the clamping knobs, push the fence back and
remove the fence from the table.
INSTALLING TABLETOP INSERTS (fig 8)
This router table includes three tabletop inserts, each with
openings of different diameters: insert with 1-1/4” Diameter
Hole (21), insert with 1-7/8” Diameter Hole (22), insert with
2-1/8” Diameter Hole (23).
1. Position the tabletop insert over the insert opening in
the router table.
2. Press the insert into the insert opening in the router
table.
3. Press down evenly over the tabs until the insert locks
in place.
4. To remove, pull up gently until the tabs disengage.
When not in use, store tabletop inserts in a convenient place.
OPERATING INSTRUCTIONS
WARNING!
• Always unplug the router before attaching or removing the fence. The fence is shipped completely assembled.
• Always attach the fence to the table when you use the router table.
• Always unplug the router before attaching or removing the fence. The fence is shipped completely assembled.
• DO NOT attempt to remove tabletop inserts from the insert opening unless the router is unplugged.
• DO NOT use bits that have a cutting diameter that exceeds the clearance hole in the table inserts. Select a table
insert that has a clearance hole 2mm larger than the diameter of the bit being used.
FPO
fig 7
fig 8

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ATTACHING THE MITRE
GAUGE (fig 9)
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.
3. To adjust the mitre gauge, loosen the mitre gauge
knob, rotate the mitre gauge to the desired angle and
tighten the knob again.
ATTACHING THE TABLE TO A WORK
SURFACE (fig 10)
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 into the work surface 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 with four
bolts and nuts (not included).
7. Tighten the bolts securely.
OPERATING INSTRUCTIONS
fig 9
fig 10

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ATTACHING THE FEATHERBOARDS (fig 11)
ATTACH THE FEATHER BOARD TO THE FENCE
1. Place the feather board on the fence as shown in fig 11.
2. Insert the long round-head square-neck bolt (9)
through the holes in the fence and the slot in the
feather boards.
3. Slide a plain washer (7) onto the bolt.
4. Tighten the wing nut (6) to secure the fence and
feather board.
ATTACH THE FEATHER BOARD TO THE TABLETOP
SURFACE
1. Place the feather board on the tabletop surface.
2. Place an ellipse-shaped washer (20) onto the long round-head square-neck bolts (9). Insert the bolt
through the holes in the tabletop surface and the slot in the feather boards.
3. Slide a plain washer (7) onto the bolt.
4. Tighten the wing nut (6) to secure the fence and feather board
ROUTING WITH FEATHER BOARDS
Feather boards are helpful in controlling the workpiece while routing and assist in keeping the
workpiece flat on the tabletop. The tabletop feather board, combined with the fence feather board, help
to keep the workpiece pressed against the fence and tabletop. The best location for the feather boards
varies according to your application, workpiece size, and other factors.
1. Loosely install the featherboard(s) as described above.
2. Place the workpiece on the router table so that it is squarely against the fence.
3. Position the featherboards snugly against the workpiece and tighten the clamping knobs.
4. The workpiece should move with some resistance but without requiring a great effort.
5. For wider workpieces, the tabletop featherboard cannot be used.
OPERATING INSTRUCTIONS
NOTE: The front and back side of each feather board is marked to indicate proper feed direction.
WARNING!
• Always unplug the router before attaching or removing the feather boards.
FPO
fig 11

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OPERATING INSTRUCTIONS
ADJUSTING THE FENCE (fig 12-14)
The fence supports and guides the workpiece. To
provide the best support during routing operations,
the fence facings should be as close to the bit as
possible without contacting the bit (typically about
1/4” from the bit is a suitable distance).
TO ADJUST THE EXTENDED FENCE FORWARD AND
BACKWARD (fig 12)
1. Loosen the two clamping knobs (14).
2. Move the fence forward or backward along the slots
to the desired position.
3. 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 FENCE
LATERALLY
(fig 13)
The in-feed and out-feed fence can each be adjusted
2” (5 cm) laterally to lengthen the fence.
1. Loosen the four wing nuts.
2. Move the fence facings to the right or left, to the
desired position.
3. Tighten the wing nuts.
TO ADJUST THE OUT-FEED FENCE FOR JOINING
(fig 14)
For joining operations, the out-feed fence can be
adjusted up to 1/2” (12.7 mm) forward of the in-feed
fence to support the workpiece after it passes across
the router bit.
1. Loosen the clamping knob (14) on the out-feed
fence.
2. Move the out-feed fence forward of the in-feed fence to a distance equal to the width of material to be
removed from the workpiece. Tighten the clamping knobs.
3. Move and clamp the entire extended fence so that the out-feed fence is aligned with the cutting edge of
the bit.
fig 12
fig 13
fig 14