MasterForce 241-0835 User manual

241-0835
ROUTER
For questions / comments, technical assistance or repair parts –
Please Call Toll Free: 1-866-917-4374. (M-F 8:30am-5:00pm Est.)
OPERATOR’S MANUAL
CAUTION: To Reduce The Risk Of Injury, User Must Read And
Understand Operator’s Manual. Save These Instructions For Future
Reference.

TABLE OF CONTENTS
Safety Symbols......................................................... Page 2
Safety Instructions ...................................................... Page 3
Overview/Specifications ................................................. Page 7
Assembly ............................................................. Page 8
Operation ............................................................ Page 13
Maintenance .......................................................... Page 25
Troubleshooting ....................................................... Page 26
Warranty ............................................................. Page 30

Page 2
SAFETY SYMBOLS
Some of these following symbols may be used on this tool. Please study them and learn their
meaning. Proper interpretation of these symbols will allow you to operate the tool better and
more safely.
WARNING: To ensure safety and reliability, all repairs should be performed by a
qualied service technician.
Symbol Name Designation / Explanation
V Volts Voltage
A Amperes Current
Hz Hertz Frequency (cycles per second)
W Watts Power
∿Alternating current Type of current
�Direct current Type or characteristic of current
noNo-load speed Rotational speed at no load
lbs Pounds Weight
Class II construction Double insulated construction
.../min Per minute Revolutions, strokes, surface speed
orbits, etc., per minute
Wear safety goggles WARNING: The operation of any
power tool can result in foreign objects
being thrown into your eyes, which can
result in severe eye damage. Before
beginning power tool operation, always
wear safety goggles or safety glasses
with side shields and a full-face shield
when needed. We recommend a Wide
Vision Safety Mask for use over eye-
glasses or standard safety glasses with
side shields. Always use eye protection
which is marked to comply with
ANSI Z87.1.

Page 3
The purpose of safety symbols is to attract your attention to possible dangers. The
safety symbols, and the explanations with them, deserve your careful attention and
understanding. The symbol warnings do not, by themselves, eliminate any danger. The
instructions and warnings they give are no substitutes for proper accident prevention
measures.
WARNING: Be sure to read and understand all safety instructions in this manual,
including all safety alert symbols such as “DANGER,” “WARNING,” and “CAUTION”
before using this tool. Failure to following all instructions listed below may result in
electric shock, re, and/or serious personal injury.
SYMBOL MEANING
SAFETY ALERT SYMBOL: Indicates DANGER, WARNING, OR CAUTION.
May be used in conjunction with other symbols or pictographs.
DANGER: Indicates an imminently hazardous situation, which, if not avoided,
will result in death or serious injury.
WARNING: Indicates a potentially hazardous situation, which, if not avoided,
could result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation, which, if not avoided,
could result in minor or moderate injury.
NOTICE:
(Without Safety Alert Symbol) Indicates a situation that may result in property
damage.
SAVE THESE INSTRUCTIONS!
SAFETY INSTRUCTIONS

Page 4
GENERAL POWER TOOL SAFETY WARN-
INGS
WARNING: Read all safety
warnings and all 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.
WORK AREA SAFETY
1. Keep work area clean and well lit.
Cluttered and dark areas invite accidents.
2. Do not operate power tools in explosive
atmospheres, such as in the presence of
ammable liquids, gases or dust. Power
tools create sparks which may ignite the
dust or fumes.
3. Keep children and bystanders away
while operating a power tool. Distractions
can cause you to lose control
ELECTRICAL SAFETY
1. Power tool plugs must match the
outlet. Never modify the plug in any way.
Do not use any adapter plugs with earthed
(grounded) power tools. Unmodified plugs
and matching outlets will reduce risk of
electric shock.
2. Avoid body contact with earthed
or grounded surfaces, such as pipes,
radiators, ranges and refrigerators. There
is an increased risk of electric shock if your
body is earthed or grounded.
3. Do not expose power tools to rain or
wet conditions. Water entering a power tool
will increase the risk of electric shock.
4. Do not abuse the cord. Never use the
cord for carrying, pulling or unplugging the
power tool. Keep cord away from heat, oil,
sharp edges or moving parts. Damaged or
entangled cords increase the risk of electric
shock.
5. When operating a power tool outdoors,
use an extension cord suitable for outdoor
use. Use of a cord suitable for outdoor use
reduces the risk of electric shock.
6. If operating a power tool in a damp
location is unavoidable, use a ground-fault
circuit interrupter (GFCI) protected supply.
Use of a GFCI reduces the risk of electric
shock.
PERSONAL SAFETY
1. Stay alert, watch what you are doing
and use common sense when operating a
power tool. Do not use a power tool while
you are tired or under the inuence of
drugs, alcohol or medication. A moment of
inattention while operating power tools may
result in serious personal injury.
2. Use personal protective equipment.
Always wear eye protection. Protective
equipment such as dust mask, non-skid
safety shoes, hard hat, or hearing protection
used for appropriate conditions will reduce
personal injuries.
3. Prevent unintentional starting. Ensure
the switch is in the off-position before
connecting to power source and/or battery
pack, picking up or carrying the tool.
Carrying power tools with your finger on the
switch or energising power tools that have
the switch on invites accidents.
4. Remove any adjusting key or wrench
before turning the power tool on. A wrench
or a key left attached to a rotating part of the
power tool may result in personal injury.
5. Do not overreach. Keep proper footing
and balance at all times. This enables better
control of the power tool in unexpected
situations.
6. Dress properly. Do not wear loose
clothing or jewellery. Keep your hair,
clothing and gloves away from moving
parts. Loose clothes, jewellery or long hair
can be caught in moving parts.
7. If devices are provided for the
connection of dust extraction and
collection facilities, ensure that these are
connected and properly used. Use of these
devices can reduce dust-related hazards.
SAFETY INSTRUCTIONS

Page 5
SAFETY INSTRUCTIONS
POWER TOOL USE AND CARE
1. Do not force the power tool. Use the
correct power tool for your application.
The correct power tool will do the job better
and more safely at the rate for which it was
designed.
2. Do not use the power tool if the switch
does not turn it on and off. Any power tool
that cannot be controlled with the switch is
dangerous and must be repaired.
3. Disconnect the plug from the power
source and/or the battery pack from the
power tool before making any adjustments,
changing accessories, or storing power
tools. Such preventive safety measures
reduce the risk of starting the power tool
accidentally.
4. Store idle power tools out of the reach
of children and do not allow persons
unfamiliar with the power tool or these
instructions to operate the power tool.
Power tools are dangerous in the hands of
untrained users.
5. Maintain power tools. Check for
misalignment or binding of moving parts,
breakage of parts and any other condition
that may affect the power tool’s operation.
If damaged, have the power tool repaired
before use. Many accidents are caused by
poorly maintained power tools.
6. Keep cutting tools sharp and clean.
Properly maintained cutting tools with sharp
cutting edges are less likely to bind and are
easier to control.
7. Use the power tool, accessories,
tool bits, etc. in accordance with these
instructions, taking into account the
working conditions and the work to be
performed. Use of the power tool for
operations different from those intended
could result in a hazardous situation.
SERVICE
1. Have your power tool serviced by a
qualied repair person using only identical
replacement parts. This will ensure that the
safety of the power tool is maintained.
SAFETY GUIDELINES FOR
ROUTERS
1. Hold the power tool by insulated
gripping surfaces only, because the cutter
may contact its own cord. Cutting a “live”
wire may make exposed metal parts of the
power tool “live” and could give the operator
an electric shock.
2. Use clamps or another practical way
to secure and support the workpiece to a
stable platform. Holding the work by your
hand or against the body leaves it unstable
and may lead to loss of control.
ADDITIONAL SAFETY GUIDE-
LINES FOR ROUTERS
1. Always make sure the work surface is
free from nails and other foreign objects.
Cutting into a nail can cause the bit and the
tool to jump and damage the bit.
2. Never hold the workpiece in one hand
and the tool in the other hand when in use.
Never place hands near or below cutting
surface. Clamping the material and guiding
the tool with both hands is safer.
3. Never lay workpiece on top of hard
surfaces, like concrete, stone, etc...
Protruding cutting bit may cause tool to
jump.
4. Always wear safety goggles and dust
mask. Use only in well ventilated area.
Using personal safety devices and working
in safe environment reduces risk of injury.
5. Keep handles dry, clean and free from
oil and grease. Slippery hands cannot safely
control the power tool.
6. After changing the bits or making any
adjustments, make sure the collet and
any other adjustment devices are securely
tightened. Loose adjustment device can
unexpectedly shift, causing loss of control,
loose rotating components will be violently
thrown.
7. Never start the tool when the bit is
engaged in the material. The bit cutting
edge may grab the material causing loss of
control of the cutter.
8. Always hold the tool with two hands
during start-up. The reaction torque of the
motor can cause the tool to twist.

Page 6
SAFETY INSTRUCTIONS
9. The direction of feeding the bit into
the material is very important and it
relates to the direction of bit rotation.
When viewing the tool from the top, the
bit rotates clockwise. Feed direction of
cutting must be counter-clockwise. NOTE:
inside and outside cuts will require different
feed direction, refer to section on feeding
the router. Feeding the tool in the wrong
direction, causes the cutting edge of the bit
to climb out of the work and pull the tool in
the direction of this feed.
10. Never use dull or damaged bits. Sharp
bits must be handled with care. Damaged
bits can snap during use. Dull bits require
more force to push the tool, possibly
causing the bit to break.
11. Never touch the bit during or
immediately after the use. After use the bit
is too hot to be touched by bare hands.
12. Never lay the tool down until the motor
has come to a complete standstill. The
spinning bit can grab the surface and pull
the tool out of your control.
13. Never use bits that have a cutting
diameter greater than the opening in the
base.
WARNING: Some dust created by
power sanding, sawing, grinding, drilling
and other construction activities contains
chemicals known to the state of California
to cause cancer, birth defects or other
reproductive harm. Some examples of
these chemicals are:
• Lead from lead-based paints
• Crystalline silica from bricks and
cement and other masonry products,
and
• Arsenic and chromium from chemically-
treated lumber.
Your risk from these exposures varies,
depending on how often you do this type
of work. To reduce your exposure to these
chemical: work in a well ventilated area,
and work with approved safety equipment,
such as those dust masks that are specially
designed to filter out microscopic particles.
14. Your router can also be used in the
router tables listed as below. Carefully
read the Instruction Manuals for the
router tables before operation.
Router Router table
241-0835
(MASTERFORCE
router)
KOBALT: 857432
SKIL: RAS900
BOSCH: 2429294,
2429295
CRAFTSMAN:
37599, 39595,
37610, 37596
PERFORMAX:
2411462
MASTERFORCE:
2410833

Page 7
OVERVIEW
0
3/64
1/64
Handle
ON/OFF
switch
Fine-
adjustment dial
Depth-indicator
ring
Coarse-
adjustment
button
Dust-extraction
adaptors
Collet wrench
Straight-edge guide
Screws
1/4” collet
sleeve
Hex wrench
Lock nut
Electronic keyboard LED display
screen
Power
indicator
Motor
clamp
Dust-
extraction
adaptor
Spindle
lock
Chip shield
Plunge-depth locking lever
Depth-stop
nut
Depth-stop
rod
Depth-stop turret Base plate
Chip shield
Lock
nut
Fine-adjustment dial
Handle
Base
plate LED worklight
1/2”
collet
Pattern guide

Page 8
SPECIFICATIONS
Rated voltage 120 V~ 60 Hz
Rated power Input 14 A
Max HP 2.5 HP
Speed 10,000–25,000 RPM
Collet capacity 1/4” & 1/2”
Fixed-base range 1-3/4”
Plunge stroke 2”
Base dimension Fixed base 6”; Plunge base 6-11/16”
Inside base diameter 2”
Micro-fine depth 1/64”
Weight 12 lb. 12 oz. (5.8 kg)
ASSEMBLY
WARNING: If any part is broken
or missing, DO NOT attempt to plug in the
power cord or operate the tool until the
broken or missing part is replaced. Failure to
do so could result in possible serious injury.
WARNING: Do not attempt to
modify this tool or create accessories not
recommended for use with this tool. Any
such alteration or modication is misuse
and could result in a hazardous condition
leading to possible serious injury.
WARNING: Your tool should
never be connected to the power source
when you are assembling parts, making
adjustments, installing or removing
blades, cleaning, or when it is not in
use. Disconnecting the tool will prevent
accidental starting, which could cause
serious personal injury.
CONTENTS
Fixed base router, plunge base, 1/2” collet,
1/4” collet sleeve, collet wrench, hex
wrench, straight-edge guide, pattern guide,
(2) dust-extraction adaptors and instruction
manual.
UNPACKING
1. Carefully remove the tool and any
accessories from the carton. Make sure
that all items listed in the packing list are
included.
2. Inspect the tool carefully to make sure
that no breakage or damage occurred
during shipping.
3. Do not discard the packing material
until you have carefully inspected and
satisfactorily operated the tool.

Page 9
ASSEMBLY
SELECTING THE CUTTER BIT
This router comes with 1/2”collet and 1/4”
collet sleeve that accept cutter bits with
1/2” and 1/4” shanks, respectively. The 1/2”
collet is equipped on the tool, the 1/4” collet
sleeve can be installed inside the 1/2” collet.
INSTALLING THE 1/4” COLLET
SLEEVE (FIG. 1-2)
1. Disconnect the plug from the power
supply.
2. Remove the router motor from the
base; refer to the section “REMOVING
MOTOR FROM BASE”.
3. Set the router motor upside down on its
top cap with the collet pointing up.
4. Press the spindle-lock button to engage
and lock the spindle shaft and 1/2”
collet (FIG. 1).
FIG. 1 1/2” collet
Spindle-lock
button
5. Place the wrench (included) on the 1/2”
collet and turn it counterclockwise to
loosen the collet slightly to accept the
cutter bit shank.
6. Insert the 1/4” collet sleeve into the 1/2”
collet assembly as far as it will go (FIG. 2).
FIG. 2
1/4” collet
sleeve
7. With the 1/4” collet sleeve inserted and
the spindle-lock button pressed in to
engage the shaft, place the wrench on
the 1/2” collet and turn it clockwise until
the 1/4” collet sleeve is tightened in it.
REPLACING THE CUTTER BIT
CAUTION: Always ensure that
the tool is switched OFF and unplugged
from the power supply before installing or
removing bits or accessories.
INSTALLING THE CUTTER BIT
(FIG. 3)
1. Disconnect the plug from the power
supply.
2. Remove the router motor from the
base; refer to the section “REMOVING
MOTOR FROM BASE”.
3. Set the router motor upside down on its
top cap, with the collet pointing up.
4. Press the spindle-lock button to engage
and lock the spindle shaft and collet.
5. Place the wrench on the collet and turn
it counterclockwise to loosen the collet
slightly to accept the cutter bit shank.
6. Insert the cutter bit shank into the
collet assembly as far as it will go, then
back the shank out until the cutters are
approximately 1/8” to 1/4” away from
the face of the collet (FIG. 3).

Page 10
ASSEMBLY
FIG. 3 Cutter
Bit shank
Spindle-lock
button
7. With the cutter bit inserted and the
spindle-lock button pressed in to
engage the shaft, place the wrench on
the collet and turn it clockwise until the
cutter bit is firmly tightened in the collet.
NOTICE: To ensure proper gripping of the
cutter bit shank and minimize run-out, the
shank of the cutter bit must be inserted
into the collet at least 5/8”.
WARNING: Tighten the collet
securely to prevent the cutter bit from
slipping. If the collet is not securely
tightened, the cutter bit may detach
during use, causing serious personal
injury.
REMOVING THE CUTTER BIT
1. Disconnect the plug from the power
supply.
2. Remove the router motor from the
base; refer to the section “REMOVING
MOTOR FROM BASE”.
3. Set the motor upside down on its top
cap, with the collet pointing up.
4. Press the spindle-lock button to engage
and lock the spindle shaft and collet.
5. Place the wrench on the collet and turn
it counterclockwise to loosen the collet
slightly.
6. Remove the cutter bit shank.
INSTALLING MOTOR IN FIXED
BASE (FIG. 4)
FIG. 4
Coarse-
adjustment
button Arrow
Motor
clamp
WARNING: Never use the router
motor without rst properly installing it
into an approved base. Failure to do so
could result in serious personal injury and
damage to motor.
NOTICE: Before installing the motor
housing in the xed base, have the collet
and router cutter bit installed on the motor
housing; refer to the section “REPLACING
THE CUTTER BIT”.
CAUTION: Always ensure that
the tool is switched OFF and unplugged
from the power supply before installing or
removing bits or accessories.
1. Disconnect the plug from the power
supply.
2. Place the fixed base on a flat surface.
3. With the back of the fixed base facing
you, open the motor clamp.
4. Press in the coarse-adjustment button
while you align the motor to the fixed
base so that the arrows align.
5. Slide the motor down into the fixed base.
6. The router motor will now slide up or
down to when the coarse-adjustment
button is pressed in.
7. After all adjustments are made (see
“DEPTH ADJUSTMENT WITH FIXED
BASE”), close the router clamp securely.

Page 11
INSTALLING MOTOR IN PLUNGE
BASE (FIG. 5)
FIG. 5
Arrow
Lock
lever
Motor
clamp
1. Disconnect the plug from the power
supply.
2. Place the plunge base on a flat surface.
3. With the back of the plunge base facing
you, open the motor clamp and make
sure that the plunge action is in the
“DOWN” position, with the plunge-lock
lever locked.
4. With the arrows aligned, lower the motor
housing into the plunge base.
5. Slide the motor into the base as far as it
will go.
6. Close the motor clamp securely.
REMOVING MOTOR FROM THE
FIXED BASE (FIG. 4)
1. Disconnect the plug from the power
supply.
2. Place the router on a flat surface.
3. With the back of the router facing you,
open the router motor clamp.
4. Push in the coarse-adjustment button
while you lift the router motor out of the
fixed base.
5. Set the motor upside down on its top
cap with the collet pointing up and
remove the cutter bit.
REMOVING MOTOR FROM THE
PLUNGE BASE (FIG. 5)
1. Disconnect the plug from the power
supply.
2. Place the router on a flat surface.
3. With the back of the plunge base facing
you, open the motor clamp and make
sure that the plunge action is in the
“DOWN” position with the plunge-lock
lever locked.
4. Lift the motor straight up out of the
base.
5. Set the motor upside down on its top
cap with the collet pointing up and
remove the cutter bit.
ASSEMBLY

Page 12
INSTALLING THE DUST-EXTRAC-
TION ADAPTORS (FIG. 6)
0
3/64
1/64
FIG. 6a
Dust-extraction
adaptor
Fixed
base
FIG. 6b
Dust-extraction
adaptor
Plunge base
To attach the dust-extraction adaptor onto
the fixed base, insert the dust-extraction
adaptor into the adaptor slot on the back of
the fixed base. Rotate the adaptor until it is
secured on the base; as shown in fig. 6a.
To attach the dust-extraction adaptor onto
the plunge base, position and secure it to
the base with the two screws (included), as
shown in fig. 6b.
HEAVY-DUTY EDGE GUIDE (FIG. 7)
FIG. 7
Lock nut
Edge-guide
adjustment button
The router combo kit comes with a heavy-
duty edge guide. This edge guide can
be used as an aid in routing applications
such as decorative edging, straight-edge
planning and trimming, grooving, dadoing
and slotting.
To attach the edge guide to the fixed or
plunge base, simply insert the edge-guide
rods into the edge-guide mounting slots
either from the left or the right. Adjust the
edge guide to the desired position, and then
secure the edge guide by turning the lock
nuts clockwise.
To adjust the edge guide, with the edge
guide adjustment buttons pressed in, slide
the edge guide.
ASSEMBLY

Page 13
NOTICE: All depth adjustments on the
xed base must be made with the motor
clamp open.
NOTICE: For xed base routers, the cutter
bit depth equals the amount of the cutter
that is exposed below the surface of the
sub-base.
The fixed base is designed with a fine
adjustment system. When the bit is lowered
to the approximate position desired (coarse
setting), the system can then be micro-
adjusted to the precise depth.
COARSE ADJUSTMENT:
Depressing the coarse-adjustment button
allows you to quickly lower or raise the
cutter bit to an approximate depth setting.
FINE ADJUSTMENTS:
The depth-indicator ring located on the
fine-adjustment dial is marked in 1/64”
increments. Turning the fine-adjustment dial
clockwise 180º (1/2 turn), lowers the cutter
bit 1/32”. One full turn clockwise 360° (zero
“0” to zero “0”) lowers the bit 1/16”.
The depth-indicator ring may be reset to zero
“0” without moving the fine-adjustment dial.
This allows the user to begin adjustments
from any chosen reference point.
ADJUSTING DEPTH (FIG. 10)
1. Disconnect the plug from the power
supply.
2. Place the router on a flat surface with
the back of the fixed base facing you.
Open the motor clamp.
3. With the cutter bit already installed, press
in the coarse-adjustment button and lower
the motor into the base until the cutter bit
is close to the flat surface on which the
base is sitting. Turn the fine-adjustment
dial until the cutter bit “just” touches the
flat surface on which the base is sitting.
Then lock the motor clamp.
4. Place the router on two level pieces of
wood, positioned so that the cutter bit
can be lowered below the sub-base
(FIG. 10).
INSTALLING THE PATTERN
GUIDE (FIG. 8)
To attach the pattern guide onto either the
fixed or plunge base, position and secure it
to the base with the screws (included); as
shown in fig. 8.
FIG. 8
Pattern
guide
ADJUSTING THE DEPTH OF CUT
WARNING: Your router should
never be turned on or be connected to the
power source when you are assembling
parts, making adjustments, installing or
removing collets and cutter bits, cleaning
or when it is not in use. Disconnecting
the router will prevent accidental starting,
which could cause serious personal injury.
DEPTH ADJUSTMENT WITH
FIXED BASE (FIG. 9)
0
3/
FIG. 9
Fine-adjustment
dial
Depth-indicator
ring
OPERATION

Page 14
0
3/64
1/64
FIG. 10
5. Turn the fine-adjustment dial clockwise
to lower the bit to the desired depth of
cut. Turn the dial counterclockwise to
raise the cutter bit.
6. Once the depth of cut is set, close the
motor clamp securely.
DEEP CUTS
The proper cutting depth for each pass,
is always determined by the material, the
cutter bit size and type, and the power of
the motor.
Always make several progressively deeper
cuts by starting at one depth and then
making several passes, each time increasing
the cutting depth until your desired depth is
reached.
Making a cut that is too deep will stress the
motor and the cutter bit, and it may burn the
workpiece and dull the cutter bit. It could
also “grab” too much of the workpiece
and cause you to lose control of the router,
causing a serious accident.
To be certain that your depth settings are
correct, always make test cuts in scrap
material similar to your workpiece before
beginning your final cutting.
Remember, knowing the right depth for each
cut comes with routing experience.
DEPTH ADJUSTMENT WITH THE
PLUNGE BASE
PLUNGING ACTION (FIG. 11)
FIG. 11
The plunge base feature simplifies the depth
adjustments and allows the cutter bit to be
accurately lowered down into the workpiece
for more precise set-ups.
To lower the cutter bit, release the plunge-
lock lever by moving it “Up” to the unlocked
position.
Use both hands to apply an even downward
pressure on the plunge action until the
cutter bit reaches the desired depth, then
move the plunge-lock lever “Down” to the
locked position.
To raise the bit and the plunge action, unlock
the plunge-lock lever and the cutter bit and the
plunge action will automatically retract from the
workpiece and return to the raised position.
Always have the plunge action in the raised
position and locked when the bit is not
cutting in the workpiece.
OPERATION

Page 15
PLUNGE ACTION WITH DEPTH-
STOP ROD AND DEPTH-STOP
TURRET (FIG. 12)
FIG. 12
Plunge-depth
locking lever
Depth-stop
rod
Depth-stop rod
locking knob
Depth scale
Plastic depth
indicator
Depth-stop turret
The depth-stop rod and the depth-stop
turret are used to control the plunge-action
cutting depth as follows:
1. Disconnect the plug from the power
supply.
2. Place the router on a flat surface.
3. With the cutting bit already installed,
lower the plunge action until the cutter
bit makes contact with the flat, level
surface on which the router is sitting.
Lock the plunge-depth locking lever. This
position is zero “0”: the point from which
further depth adjustments can be made.
4. To set a desired depth-of-cut, rotate the
depth-stop turret until the lowest step
of the turret is aligned directly under
the depth-stop rod (FIG. 12). Loosen
the depth-rod locking knob and lower
the depth-stop rod until it contacts the
lowest step on the turret.
5. Slide the clear plastic depth indicator
until the red line on the indicator is lined
up with ZERO – “0” marked in black on
the bottom of the depth scale. (This is
now the indicating point at which the bit
makes contact with the workpiece).
6. To set a desired cutting depth, slide the
depth-stop rod up until the red line on
the clear plastic depth indicator points
to your desired cutting depth on the
depth scale. Secure the depth-stop rod
at this position by tightening the depth-
rod locking knob.
7. Unlock the plunge depth-locking lever
to allow the bit to automatically retract
to the up position.
8. The desired depth-of-cut may now be
achieved by plunging the router down
until the depth-stop rod contacts the
selected step on the depth-stop turret.
NOTICE: When making depth adjustments
on the plunge base, the motor clamp
should always be closed securely.
USING THE DEPTH-STOP
TURRET TO SET UP DEEP CUTS
(FIG. 13)
FIG. 13
NOTICE: Making a single deep cut is
never advisable. Smaller diameter cutter
bits are easily broken by too much side
thrust and torque. Larger cutter bits will
cause a rough cut and be difcult to guide
and control. For these reasons, do not
exceed 1/8” depth of cut in a single pass.
To produce deep cuts, always make several
progressively deeper cuts by starting with the
highest step on the depth-stop turret, and,
after each cut, rotate the turret to the next
lower step until the lowest step is reached.
Each of the steps progresses by 1/4”
increments. The 4 steps represent a total of
“0” inch to 3/4” with a full 360º rotation of
the turret. Repeat this process if necessary.
OPERATION

Page 16
MICRO-ADJUSTMENTS WITH
THE DEPTH-STOP ROD AND
DEPTH-STOP TURRET
The depth-stop rod has a micro-adjustment
knob that turns a screw (inside the rod) either
clockwise or counterclockwise to lower or
raise the depth-stop rod on the turret for
micro-fine adjustments of the plunge depth.
Each complete revolution of the micro-
adjustment knob adjusts the plunging depth
by approximately 1/32”.
A reference indicator line is marked into the
depth-stop rod under the fine-adjustment
knob to set a reference point of “0”.
When adjusting the plunge depth, always
make sure that the micro-adjustment knob
has been turned down (clockwise) several
revolutions from the top before setting the
depth-stop rod and depth-stop turret.
Always set your micro-adjustments with the
plunge action locked in the raised (or up)
position.
To use the micro-adjustment knob after the
depth rod and turret have been set, check
the final depth setting and micro-adjust as
follows:
• To micro-increase the plunge depth,
raise the micro-adjustment screw by
turning the knob counterclockwise the
desired amount.
• To micro-reduce the plunge depth,
lower the micro-adjustment screw by
turning the knob clockwise the desired
amount.
OPERATION
TOGGLE “ON/OFF”
SWITCH (FIG. 14)
0
3/64
1/64
FIG. 14
Your router motor is turned “ON” and “OFF”
with the toggle switch located on the top
cap of the motor housing.
The left side of the toggle switch hood (as
you face it) is marked “I” and “ON” and the
right side (as you face it) is marked “O” and
“OFF.”
• To turn the motor “ON”, push the toggle
switch to the left side marked “I” and
“ON.”
• To turn the motor “OFF” push the
toggle switch to the right side marked
“O” and “OFF.”
Always hold the router and the cutter bit
away from the workpiece when turning
the toggle switch “On.” Only contact the
workpiece with the router and cutter bit
after the router has reached the full selected
speed. Only remove the router and cutter bit
from the workpiece after turning the router
motor “OFF” and after the cutter bit comes
to a complete stop.
SOFT START FEATURE
The soft start control minimizes torque
twist, customary in larger router motors, by
limiting the speed at which the motor starts.
This increases the motor’s life.

Page 17
LED WORKLIGHTS (FIG. 15)
FIG. 15
Your router motor has 3 built-in worklights
located around the collet to provide high
visibility of the workpiece when cutting.
These lights are always “On” when the
toggle switch is in the “ON” position.
“LIVE TOOL INDICATOR” LIGHT
(FIG. 16)
FIG. 16
Live tool
indicator
Your router also has a “live tool indicator”
green light, located on the motor housing
top cap where the power cord enters the
motor housing. This green light is always
on when the router motor is plugged into a
power source.
OPERATION
ELECTRONIC VARIABLE-SPEED
CONTROL (FIG. 17)
FIG. 17
The electronic-speed control feature allows
the motor speed to be matched to the
cutter size and the material hardness for an
improved finish and extended bit life.
Press “+” or “-” to choose the cutting speed
according various materials of workpieces.
Choose the applicable cutting speed
according the bit diameter and the material
being cut. The chart below and all of the
specifications that appear on the display of
the router are for your reference.
Bit Size
and Speed
Setting
Material
Hardness
0-1” 1.25-
2”
2.25-
2.5” 3-3.5”
Plastic 6 4 3 2
Softwood 6 4 2 1
Hardwood 5 3 2 1
The speed chart in the next column indicates
the relationship between the speed setting
and the cutting application. Exact settings
are determined through operator experience
and preference and by recommendations
from manufacturers of cutter bits.

Page 18
DIAL
SETTING RPM APPLICATION
1 10,000/11500 Hardwoods,
larger
diameter
cutter bits
2 13,000/14500
3 16,000/17500
4 19,000/20500 Softwoods,
plastics,
countertops,
smaller
diameter
cutter bits
5 22,000/23500
6 25,000
NOTICE: Reduce the speed when using
very large bits (1-inch or greater in cutting
diameter) or heavy cutting bits. Changing
the router rate of feed can also improve
the quality of the cut.
NOTICE: The speed may be changed while
the router is “ON”, but do not change the
speed if the cutter bit is in the workpiece.
WARNING: Before operating your
router, follow all safety instructions in this
manual. Failure to do so could result in
serious personal injury.
EDGE ROUTING OR
INTERNAL ROUTING (FIG. 18)
For ease of operation and to maintain
proper control, your router has two handles,
one on each side of the router base. When
operating the router, always hold it firmly
with both hands (FIG. 18).
0
3/64
1/64
FIG. 18
EDGE ROUTING (FIG. 19)
1. With the depth-of-cut set, place the
router on the edge of workpiece, making
sure that the cutter does not contact the
workpiece. (With the plunge base, lock
the plunge action in the DOWN position,
ready to cut).
2. Have an edge guide (or a board or a
metal straightedge) clamped in place to
help guide the router base when making
the edge cut (FIG. 19).
FIG. 19
3. Turn the router “ON”, and allow the
router motor to reach the selected
speed.
4. To begin the cut, gradually feed the
cutter bit into the edge of the workpiece.
5. When the cut is complete, turn the
router motor “OFF” and allow the cutter
bit come to a complete stop before
removing it from the workpiece.
OPERATION

Page 19
OPERATION
6. Unplug the router from the power
source, and inspect the finished cut.
WARNING: Always securely clamp
your workpiece and keep a rm grip on
the router base with both hands at all
times. Failure to do so could result in
loss of control causing possible serious
personal injury.
WARNING: Removing the cutter
bit from the workpiece while it is still
rotating could damage the workpiece and
result in loss of control, causing serious
personal injury.
INTERNAL ROUTING WITH FIXED
BASE (FIG. 20)
1. With the depth-of-cut set, tilt the router
and place it on the workpiece with the
leading edge of the sub-base contacting
the workpiece first (FIG. 20).
2. Turn the router motor “ON” and allow
the router motor to reach the selected
speed, being careful not to allow the
cutter bit to contact the workpiece.
3. To begin your cut, gradually lower the
cutter bit into the workpiece until the
sub-base is flush with the workpiece
(FIG. 20).
FIG. 20
4. When the cut is complete, turn the
router motor “OFF” and allow the cutter
bit come to a complete stop before
removing it from the workpiece.
5. Unplug the router from power source,
place the router upside down on the
worktable, and inspect the finished cut
in the workpiece.
WARNING: Always securely clamp
your workpiece and keep a rm grip on the
router base with both hands at all times.
Failure to do so could result in loss of
control causing possible serious personal
injury. If using a router table, large cutter
bits should be used for edging only.
WARNING: Removing the cutter bit
from workpiece while it is still rotating could
damage the workpiece and result in loss of
control, causing serious personal injury.
INTERNAL ROUTING WITH
PLUNGE BASE (FIG. 21)
1. With the depth-of-cut set, and the
plunge action locked in the raised (Up)
position, turn the motor “ON” and let the
motor build up to its full selected speed
(FIG. 21).
FIG. 21 Plunge up
Feed direction
2. To begin your cut, unlock the plunge-
lock lever and gently lower the plunge
action evenly into the workpiece.
3. When the desired depth-of-cut is
achieved, lock the plunge-lock lever
(Down) and proceed to make your cut.
4. When the cut is completed, turn the
motor “OFF” and let the cutter bit come
to a complete stop.