Ozito PRG-621V User manual

PLUNGE ROUTER
6.35mm
OPERATING INSTRUCTIONS
Always Wear Eye, Face & Ear Protection www.ozito.com.au
PRG-621V manual 23/3/04 5:40 PM Page 1

1. Variable Speed Control
2. Plunge Lock Lever
3. Handles
4. Straight Guide Fence
5. Centering Pin
6. Spanners
7. 6.35mm & 8mm Collets
8. Template Guide
9. Dust Extraction Adaptor
10. 7 Tier Depth Stop
11. Collet Nut
12. Depth rod
13. On/off Switch
SPECIFICATIONS - MODEL NO. MSH-115
2
Motor Size: 650W
Input: 230V ~ 50Hz
No Load Speed: 11500 – 32000 rpm
Collet Size: 6.35mm (1/4”) & 8mm
Features: Variable Speed
Plunge Action
7 Tier Depth Stop
Dust Extraction Facility
SPECIFICATIONS - MODEL NO. PRG-621V
10
9
7 6 5
3
13
1
12
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11
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2
8
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Congratulations on purchasing an Ozito Plunge Router.
We aim to provide quality tools at an affordable price.
We hope you will enjoy using this tool for many years.
Your Ozito Router PRG-621V has been designed for
routing wood and wood products and is intended for
DIY use only.
SAFETY INSTRUCTIONS
ELECTRICAL SAFETY
INTRODUCTION
Warning! When using mains-powered tools, basic safety precautions including
the following should always be followed to reduce risk of fire, electric shock,
personal injury and material damage.
Read the whole manual carefully and make sure you know how to switch the tool off,
in an emergency, before operating the tool.
Save these instructions and other documents supplied with this machine for future reference.
The electric motor has been designed for one voltage only. Always check that the
power supply corresponds to the voltage on the rating plate.
Note: 230V and 240V supply and Ozito tools are interchangeable for Australia and
New Zealand.
This tool is double insulated in accordance with EN 50144; therefore no earth
wire is required.
If the supply cord is damaged, it must be replaced by the manufacturer or an
authorised Ozito Service Centre in order to avoid a hazard.
Note: Double insulation does not take the place of normal safety precautions when
operating this tool. The insulation system is for added protection against injury resulting
from a possible electrical insulation failure within the tool.
Using an Extension Lead
Always use an approved extension lead suitable for the power input of this tool. Before
use, inspect the extension lead for signs of damage,
wear and ageing. Replace the extension lead if damaged or defective.
When using an extension lead on a reel, always unwind the lead completely. Use of an
extension lead not suitable for the power input of the tool or which is damaged or
defective may result in a risk of fire and electric shock. Do not use extremely long
extension cords. These create additional resistance for the power to travel and can also
damage your tool.
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GENERAL
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1. Keep work areas clean. Cluttered work areas and benches can cause accidents.
2. Consider work area environment. Keep the work area well lit. Do not use
your tool where there is a risk of causing fire or explosion, e.g. in the presence
of flammable liquids and gases.
3. Keep children away. Do not allow children, visitors or animals to come near
the work area or to touch the tool or power lead.
4. Dress appropriately. Do not wear loose clothing or jewellery, as these can be
caught in moving parts. Preferably wear non-slip footwear when working
outdoors. Wear protective hair covering to keep long hair out of the way.
5. Head protection. Always use safety glasses. Use a face or dust mask whenever
the operations may produce dust or flying particles. Wear ear protection
whenever the sound level seems uncomfortable.
6. Guard against electric shock. Prevent body contact with earthed or grounded
surfaces (e.g. pipes, radiators, cookers and refrigerators). Electric safety can be
further improved by using a high sensitivity (30 mA / 30 mS) residual current
device (RCD).
7. Do not overreach. Keep proper footing and balance at all times.
8. Stay alert. Watch what you are doing. Use common sense. Do not operate the
tool when you are tired.
9. Secure work piece. Use clamps or a vice to hold the work piece; it is safer as it
frees both hands to operate the tool.
10. Remove adjusting keys and wrenches. Always check that adjusting keys and
wrenches are removed from the tool before operating the tool.
11. Extension leads. Before use inspect the extension leads and replace if
damaged. When using the tool outdoors, only use extension leads intended for
outdoor use and marked accordingly.
12. Use appropriate tool. The intended use is described in this instruction
manual. Do not force small tools or attachments to do the job of a heavy duty
tool. The tool will do the job better and safer at the rate for which it was
intended. Do not force the tool.
Warning! The use of any accessory or attachment, or performance of any
operation with this tool other than those recommended in this instruction
manual may present a risk of personal injury.
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13. Check for damaged parts. Before use carefully check the tool and power lead for
damage. Check for misalignment and seizure of moving parts, breakage of parts,
damage to guards and switches and any other conditions that may affect its
operation. Ensure that the tool will operate properly and perform its intended
function. Do not use the tool if any parts are damaged or defective. Do not use the
tool if the switch does not turn it on and off. Have any damaged or defective parts
repaired or replaced by an Ozito Authorised Service Agent. Never attempt any
repairs yourself.
14. Unplug the tool. Shut off the power and wait for the tool to come to a complete
standstill before leaving it unattended. Unplug the tool when it is not in use, before
changing any parts of the tool, accessories or attachments and before servicing.
15. Avoid unintentional starting. Do not carry the tool with a finger on the on / off
switch. Make sure the tool is switched off when plugging in.
16. Do not abuse the cord. Never carry the tool by its cord or pull it to disconnect
from the socket. Keep the cord away from heat, oil and
sharp edges
17. Connect dust extraction equipment. If devices are provided for the connection of
dust extraction and collection facilities, ensure that these are connected and
properly used.
18. Store idle tools. When not in use, tools should be stored in a dry, locked up or
high place, out of reach of children.
19. Maintain tools with care. Keep tools clean and in good condition for better and
safer performance. Follow the instructions for maintenance and changing
accessories. Keep handles and switches dry, clean and free from oil and grease.
20. Have your tool repaired by an authorised OZITO SERVICE AGENT.
This power tool complies with relevant safety requirements. To avoid danger,
electrical appliances must only be repaired by qualified technicians using original
spare parts; otherwise this may result in considerable danger to the user.
21. Users. This appliance is not intended for use by young children or infirmed
persons without supervision. Young children should be supervised to ensure that
they do not play with this appliance.
22. Replacement of the supply cord. If the supply cord is damaged, it must be
replaced by the manufacturer or an authorised Ozito Service Agent in order to
avoid a hazard.
GENERAL (cont.)
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• Wear safety glasses or goggles when operating this tool.
• Only use router bits with a shank diameter equal to the size of the collet
installed in the tool.
• Only use router bits suitable for the no-load speed of the tool.
• Do not use the tool in an inverted position.
• Do not attempt to use the tool in a stationary mode.
• Take special care when routing MDF or surfaces coated with lead-based paint:
Wear a dust mask specifically designed for protection against lead paint
dust and fumes and ensure that persons within or entering the work area
are also protected.
Do not let children or pregnant women enter the work area.
Do not eat, drink or smoke in the work area.
Dispose of dust particles and any other debris safely.
• This appliance is not intended for use by young or infirmed persons without
supervision. Children must be supervised to ensure they do not play with
the appliance.
• If the supply cord is damaged, it must be replaced by the manufacturer or an
authorised Ozito Service Centre in order to avoid a hazard.
Before attempting any of the following operations, make sure that the
tool is switched off and unplugged and that the spindle has stopped.
Fitting a Router Bit
• Use the 11mm spindle lock spanner to hold the spindle in place.
• Use the other spanner to loosen the collet nut, rotating it counter clockwise.
Keep the spring and collet in the spindle.
• Insert the shank of the router bit through the collet nut and into the larger end
of the collet. Make sure that the shank protrudes at least 3mm from the collet.
• Fasten the collet nut to the spindle using the spindle lock spanner to hold the
spindle, and the other spanner to rotate the collet nut clockwise.
• Do not over tighten.
• Ensure you remove the spanners then plug the tool in and turn it on. Check for
any undue vibration or wobbling which may indicate the bit is damaged or not
installed correctly.
ADDITIONAL SAFETY INSTRUCTIONS FOR ROUTERS
ASSEMBLY
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ASSEMBLY (cont.)
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Fitting the Straight Guide Fence
The straight guide fence helps to guide the tool parallel to the edge.
• Insert the bars into the router base.
• Set the guide fence to the required distance.
• Tighten the two fixing knobs.
Fitting the Dust Extraction Adaptor
The dust extraction adaptor allows you to connect a vacuum cleaner or dust extractor
to the tool.
• Loosen the motor clamp knob which is located right next to the plunge lock lever.
• Remove the router motor.
• Fit the dust extraction adaptor into the base and secure with the two screws provided.
• Refit the motor back to the base and ensure you secure it by tightening the motor
clamp knob.
Warning! Ensure the motor clamp knob is properly tightened and motor is
secured within the base. Failure to do so could cause material damage and
bodily harm if the motor comes out of the base while in operation.
Fitting the Template Guide
• Fit the template guide to the bottom of the router so that the raised side would be
facing the bottom (work piece side).
• Feed the screws supplied through the template and base of the router towards the
motor and secure with the two nuts supplied.
Fitting the Centring Pin
• Remove one of the guide bars from the fence if already assembled.
• Remove the screw, spring washer and washer from the guide bar.
• Attach the centring pin to one end of the guide bar. Fasten the centring pin to the
guide bar by tightening the wing-nut.
• Insert the guide bar into the router base and fasten at the required length.
PRG-621V manual 23/3/04 5:40 PM Page 7

Plunge Lock Lever
The plunge lock lever must first be pulled down in order to then change the
position of plunge up or down. Once the plunge depth is set in the required
position release the lever and it will automatically lock the plunge depth in place.
The plunge lock lever itself is adjustable. To place the lever in a position with which
you are more comfortable; remove the screw, pull the lever out and then replace it
in the preferred position. Retighten the screw.
Setting the Speed
Your router is provided with a variable speed control to greatly increase the versatility
of the tool. This can be used to adjust the rotational speed of the bit to its size and
the material being worked on. The control is located on the top face of the machine.
Use higher speeds for small diameter router bits and lower speeds for larger
diameter router bits.
Note: Do not run the tool at low speeds for extended periods without occasionally
running at high speed with no load. At lower speeds the fan (within the motor) does
not cool the motor as effectively as it does at higher speeds and the motor may
over heat.
Using a Batten as a Guide
When it is not possible to use the straight guide fence, for example when routing
grooves in the back panel of a bookcase to support shelves, proceed as follows:
• Place a batten onto the work piece.
• Move the batten until it is in the correct position to guide the tool.
• Securely clamp the batten to the work piece.
Using the Template Guide
The template guide can be used to make a cut-out shape from a template, for
instance a letter. You will need to purchase or make a template.
• Secure the template over the work piece with double-sided tape
or “G” clamps.
• The router bit must extend below the flange of the template guide to cut the
work piece in the shape of the template.
Using the Centring Pin
The centring pin can be used to cut out circular patterns.
• Drill a hole for the point of the centring pin in the centre of the circle to be cut.
• Place the router on the work piece with the point of the centring pin in the drilled hole.
• Adjust the radius of the circle with the bar of the straight guide fence.
• The router can now be moved over the work piece to cut out the circle.
Switching On and Off
Your router starts and stops by depressing the On / Off slide switch located on the
body of the tool. Push the switch down to start down router; it will lock into place,
allowing you to remove your finger while the router remains in operation. Always
ensure you are holding the router tightly before turning it on. To turn the router off,
simply push the rear of the switch and it will return to the off position.
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OPERATION
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Let the tool work at its own pace. Do not overload.
• Carefully guide the power cord in order to avoid accidentally cutting it.
Adjusting the Depth of Cut
The depth of cut is the distance X between the depth rod and the 7 tier depth stop.
The depth of cut can be set in two different ways as described below.
Adjusting the depth of cut using a piece of wood
• Fit the router bit as previously described.
• Loosen the depth rod adjustment knob.
• Pull the plunge lock lever down. Plunge the router down until the router bit
touches the work piece.
• Release the plunge lock lever, locking the router down.
• Pull the depth rod up.
• Place a piece of wood with a thickness equal to the desired depth of cut between
the 7 tier depth stop and the depth rod.
• Tighten the depth rod adjustment knob.
• Remove the piece of wood.
• Pull the plunge lock lever down and let the router return to its original position.
Release the plunge lock lever.
• After switching the router on, plunge it down and make the desired cut.
Adjusting the depth of cut using the scale
• Fit the router bit as previously described.
• Loosen the depth rod adjustment knob.
• Pull the plunge lock lever down.
• Plunge the router down until the router bit touches the work piece.
• Release the plunge lock lever, locking the router down.
• Read the starting position from the scale.
• Add the desired depth of cut to the starting position.
• Move the depth rod to the calculated position on the scale.
• Tighten the depth rod adjustment knob.
• Pull the plunge lock lever down and let the router return to its original position.
• After switching the router on, plunge it down and make the desired cut.
OPERATION (cont.)
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Hints for Optimum Use
• When working on outside edges, move the tool counter clockwise.
When working on inside edges, move the tool clockwise.
• You can use the tool without a guide. This is useful for signwriting and creative
work. Only make shallow cuts.
Your Ozito Router has been designed to operate over a long period of time with a
minimum of maintenance. Continuous satisfactory operation depends upon proper
tool care and regular cleaning.
Before performing any maintenance, switch off and unplug the tool.
• Regularly clean the ventilation slots on your router using a soft brush or dry cloth.
• After each use, blow air through the router to ensure it is free from all dust
particles that may build up. Build up of dust particles may cause the tool to
overheat and fail.
• Regularly clean the motor housing using a damp cloth. Do not use any abrasive
or solvent-based cleaner.
• When the carbon brushes wear out the tool will spark and/or stop. This
situation can damage your tool so to avoid this happening the brushes should
be replaced prior to wearing out fully. Brushes will wear out after many uses
but before they do take the tool to an Authorised Ozito Service Agent for quick
and low cost replacement.
Note: Ozito Industries will not be held responsible for any damage or injuries
caused by the repair of the tool by an unauthorised person or by mishandling of
the tool.
OPERATION (cont.)
MAINTENANCE
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CONTENTS
OZITO INDUSTRIES PTY LTD
OZITO AUTHORISED SERVICE AGENTS
1 x Router PRG-621V
2 x Collets (6.35mm and 8mm)
2 x Spanners
1 x Straight Guide Fence
1 x Dust Extraction Adaptor
1 x Spare Set of Brushes
1 x Centring Pin
1 x Template Guide
2 x Nuts & Screws
1 x Instruction Manual
AUSTRALIA (Head Office)
5 Chestnut Crt, Dingley, Victoria, Australia, 3172
Telephone:[phone]
Facsimile: 03 9558 0583
www.ozito.com.au
NSW/ACT
Panther Power Tools
Unit 1, 10 Eddie Road
Minchinbury NSW 2770
Ph: 02 9625 0266
QLD
Logan Park Electrical
Unit 18, 22 - 26 Allgas Street
Slacks Creek QLD 4127
Ph: 07 3209 3705
SA
Prestige Power Tool Repairs
Unit 3, 937 Marion Road
Mitchell Park SA 5043
Ph: 08 8358 5772
TAS
Ozito Industries
5 Chestnut Court
Dingley VIC 3172
Ph: 03 9558 3999
VIC
Tool Centre McKinnon
254 McKinnon Road
McKinnon VIC 3204
Ph: 03 9578 2022
NT
Mr. Vac
18 Menmuir Street
Winnellie NT 0821
Ph: 08 8947 1898
WA
Cloverdale Hardware
17 Love Street
Cloverdale WA 6105
Ph: 08 9479 4383
NEW ZEALAND
Network Product Distribution
34 Ben Lomond Crescent
Pakuranga Auckland
Ph: 9576 2730
PRG-621V manual 23/3/04 5:40 PM Page 11

WARRANTY
THIS WARRANTY FORM AND CONFIRMED BUNNINGS REGISTER RECEIPT SHOULD
BE
RETAINED BY THE CUSTOMER AT ALL TIMES
The warranty is only made available by returning the product to your nearest
Bunnings Building Supplies with a confirmed Bunnings register receipt.
PURCHASED FROM:________________________________________________
DATE PURCHASED: ________________________________________________
3 YEAR REPLACEMENT WARRANTY
Your Ozito tool is guaranteed for a period of 36 months from the ORIGINAL date of
purchase under the following conditions: Professional, industrial or high frequency
use will VOID this warranty.
WARNING
The following actions will result in the warranty being void.
• If the tool has been operated on a supply voltage other than that specified on
the unit.
• If the tool shows signs of damage or defects caused by or resulting from abuse
accidents or alterations.
• If the tool has been disassembled or tampered with in any way.
Note: Warranty excludes consumable parts such as brushes, batteries, sanding
pads, blades, discs, drill bits, collets and router bits.
YOUR WARRANTY FORM SHOULD BE RETAINED
BY YOU AT ALL TIMES.
SHOULD YOU HAVE ANY QUESTIONS PRIOR TO
RETURNING YOUR PRODUCT FOR WARRANTY OR
REPAIR PLEASE TELEPHONE OUR CUSTOMER
SERVICE HELPLINE:
Australia 1800 069 486
New Zealand 0508 069 486
TO ENSURE A SPEEDY RESPONSE PLEASE HAVE THE MODEL NUMBER
AND DATE OF PURCHASE AVAILABLE. AN OZITO CUSTOMER SERVICE
REPRESENTATIVE WILL TAKE YOUR CALL AND ANSWER ANY QUESTIONS
YOU MAY HAVE RELATING TO THE WARRANTY POLICY OR PROCEDURE.