Ozito PRR-1200 User manual

Motor: 1200W
Input: 230-240V ~ 50Hz
No load speed: 10,000-28,000/min
Collet Size: 6.35mm (1/4”)
Plunge Depth: 40mm
Weight (tool only): 3.75kgs
Know Your Product
1. Soft Grip Handles
2. Variable Speed Dial
3. Micro Depth Adjuster Knob
4. On/Off Trigger Switch
5. Lock-on Button
6. Depth Lock Lever
7. Parallel Guide Fence
8. Guide Fence Rods
9. Dust Extraction Adaptor
10. Template Guide
11. Spanner
12. Circular Template Guide
13. Parallel Guide Locking Knob
14. Spindle Lock Button
15. Collet Nut
16. Adjustable Turret Depth Stop
17. Micro Depth Gauge
18. Micro Depth Locking Knob
2
7
6
2
SPECIFICATIONS MODEL NO. PRR-1200
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10
18
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17
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5
Front Back
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TABLE OF CONTENTS
SPECIFICATIONS………………………………………….
TABLE OF CONTENTS……………………………………
INTRODUCTION…………………………………………..
GENERAL SAFETY INSTRUCTIONS……………………..
GENERAL SAFETY RULES………………………………..
ADDITIONAL SAFETY INSTRUCTIONS FOR ROUTERS……
ASSEMBLY.…………………………………………………
OPERATION…………………………………………………
MAINTENANCE……………………………………………
TROUBLE SHOOTING……………………………………
SPARE PARTS………………………………………………
DESCRIPTION OF SYMBOLS…………………………….
CONTENTS…………………………………………………
WARRANTY…………………………………………………
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Page 11
Page 15
Page 16
Page 16
Page 17
Page 18
Page 19

INTRODUCTION
4
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 Plunge Router PRR-1200 has been designed for
routing wood and wood products and is intended for
DIY use only.
Warning! When using mains-powered equipment, basic safety precautions,
including the following, should always be followed to reduce risk of fire, electric
shock, personal injury and material damage.
Read and understand the manual prior to operating this tool.
Save these instructions and other documents supplied with this tool for future reference.
The electric motor has been designed for 230V and 240V only. Always check that
the power supply corresponds to the voltage on the rating plate.
Note: The supply of 230V and 240V on Ozito tools are interchangeable for
Australia and New Zealand.
This tool is double insulated in accordance with AS/NZS 60745; therefore
no earth wire is required.
If the supply cord is damaged, it must be replaced by a qualified electrician or a
power tool repairer 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.
It is recommended that the extension lead is a maximum of 25m in length. Do Not
use multiple extension leads.
ELECTRICAL SAFETY
GENERAL SAFETY INSTRUCTIONS

5
GENERAL SAFETY RULES
Warning! Read all instructions. Failure to follow all instructions listed below may
result in electric shock, fire and/or serious injury. The term "power tool" in all of the
warnings listed below refers to your mains-operated (corded) power tool or
battery-operated (cordless) power tool.
Save these instructions
1) Work area
a) Keep work area clean and well lit. Cluttered and dark areas invite accidents.
b) Do not operate power tools in explosive atmospheres, such as in the
presence of flammable liquids, gases or dust. Power tools create sparks which
may ignite the dust or fumes.
c) Keep children and bystanders away while operating a power tool. Distractions
can cause you to lose control.
2) Electrical safety
a) 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
b) 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.
c) Do not expose power tools to rain or wet conditions. Water entering a power
tool will increase the risk of electric shock.
d) 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.
e) 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.
3) Personal safety
a) 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 influence
of drugs, alcohol or medication. A moment of inattention while operating power
tools may result in serious personal injury.
b) Use safety equipment. Always wear eye protection. Safety equipment such as
dust mask, non-skid safety shoes, hard hat, or hearing protection used for
appropriate conditions will reduce personal injuries.
c) Avoid accidental starting. Ensure the switch is in the off-position before
plugging in. Carrying power tools with your finger on the switch or plugging in
power tools that have the switch on invites accidents.
d) 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.

6
GENERAL SAFETY RULES (cont.)
e) Do not overreach. Keep proper footing and balance at all times. This enables
better control of the power tool in unexpected situations.
f) 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.
g) If devices are provided for the connection of dust extraction and collection
facilities, ensure these are connected and properly used. Use of these
devices can reduce dust-related hazards.
4) Power tool use and care
a) Do not force the power tool. Use the correct power tool for your
application. The correct power tool will do the job better and safer at the rate
for which it was designed.
b) 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.
c) Disconnect the plug from the power supply 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.
d) 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.
e) Maintain power tools. Check for misalignment or binding of moving parts,
breakage of parts and any other condition that may affect the power tools
operation. If damaged, have the power tool repaired before use. Many
accidents are caused by poorly maintained power tools.
f) Keep cutting tools sharp and clean. Properly maintained cutting tools with
sharp cutting edges are less likely to bind and are easier to control.
g) Use the power tool, accessories and tool bits etc. in accordance with these
instructions and in the manner intended for the particular type of power
tool, 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.
5) Service
a) Have your power tool serviced by a qualified repair person using only
identical replacement parts. This will ensure that the safety of the power tool
is maintained.
b) If the supply cord is damaged, it must be replaced by the manufacturer, its
service agent or similarly qualified persons in order to avoid a hazard.

ADDITIONAL SAFETY INSTRUCTIONS FOR ROUTERS
7
This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, unless
they have been given supervision or instruction concerning use of the appliance by a
person responsible for their safety.
Recommendations for the use of a residual current device with a rated residual
current of 30mA or less.
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.
It is recommended that the extension lead is a maximum of 25m in length. Do Not use
multiple extension leads.
• 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.

Assembly of the Parallel Guide Fence
1. Remove the two Phillips screws from the end of
the guide fence rods (8) by rotating them anti-
clockwise (Fig.A).
2. Fix the two guide fence rods (8) onto the parallel
guide fence (7) by inserting the Phillips screws
through the holes in the guide fence (7) as shown
in (Fig.B).
3. Tighten the two Phillips screws by rotating them
clockwise.
Assembly of the Circular Template Guide
1. Slide the circular
template guide (12)
onto one of the
guide fence rods (8).
(Fig.C).
2. Secure by
tightening the wing
nut clockwise (Fig.D).
Installing and Removing Collets
CAUTION: Always ensure that the router is switched
off and unplugged from the mains supply before
installing or removing a collet or router bits.
1. The router is fitted with a 6.35mm (1/4”) collet
(Fig.1).
Note: It is recommended that you turn the router
upside down and rest it on a table or bench when
changing the router bits. This will assist when
changing the router bits. Rest the upside down router
on the support lugs located on the top of the router assembly.
ASSEMBLY
8
Fig. A
Fig. B
Fig. C Fig. D
Fig. 1

9
ASSEMBLY (cont.)
2. Depress and hold the spindle lock button (14) to stop
the spindle from turning.
3. Whilst holding the spindle lock button (14), loosen the
collet nut (15) by rotating it clockwise using the
spanner (11) provided.
4. Remove the collet nut (15), followed by the collet (Fig.3).
5. Install the new collet into the assembly.
6. Install the collet nut (15) and tighten by hand, turning
anti-clockwise.
Warning! Do not tighten the collet nut without a bit in
place or you may break the collet.
Installing and Removing Router Bits
1. Ensure the correct collet size diameter is installed for
the router bit shaft diameter you are using.
2. Loosen the collet nut (15) by depressing and holding
the spindle lock button (14) and then rotating the
collet nut (15) clockwise (Fig.4).
3. Insert a router bit into the collet, ensuring that the
shaft of the bit is inserted all the way into the collet
and then raise the bit approx 2mm (Fig.5).
4. Tighten the collet nut (5) by depressing and holding
the spindle lock button (14) and then tightening the
collet nut (15) anti-clockwise (Fig.6).
CAUTION: Ensure the bit is firmly secured before
commencing operation.
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6

10
Adjusting the Cutting Depth
CAUTION: Always ensure that the router is switched off and unplugged from the
mains supply before adjusting the cutting depth.
1. The router has an
adjustable turret
depth stop (16).
This turret stop (16)
enables the router
to have 5 preset
depth of cut
settings (Fig.7).
Turn the adjustable
turret depth stop (16) until the highest depth stop position, or 0mm, is facing
the front of the router (Fig.8).
2. Place the router on a flat surface and loosen the
micro depth locking knob (18) by rotating it
anti-clockwise (Fig.9).
3. Loosen the depth lock lever (6) by pushing the
lever down and lowering the body of the router
until the router bit just touches the flat surface
(Fig.10).
4. Lower the micro depth gauge (17) allowing it to
just make contact with the adjustable turret
depth stop (16).
5. The adjustable turret depth stop (16) has five
steps. By rotating the adjustable turret depth stop
it is possible to quickly and easily set the depth at five different cutting depths.
This procedure is particularly useful when you
wish to make a deep cut in a number of stages.
6. Use the micro depth adjuster knob (3) for precise
setting of cutting depth. This will allow you to
finely adjust the cutting depth to suit your
requirements. Rotate the micro depth adjuster
knob (3) clockwise to raise the router bit or anti-
clockwise to lower or increase the cutting depth
of the router bit (Fig.11).
Once you have made the required cutting depth
adjustments, simply lower the depth lock lever (6)
and then lower the router until the micro depth
gauge (17) touches the adjustable turret depth stop
(16). Release the depth lock lever (6) to lock the
cutting depth.
ASSEMBLY (cont.)
Fig. 9
Fig. 10
Fig. 11
Fig. 7 Fig. 8
0mm
Router bit touching
the flat surface.

Switching On and Off
CAUTION: Before plugging in the router, always check that the on/off trigger switch
engages and disengages properly.
1. Press the on/off trigger switch (4) to turn on the
router (Fig.12).
2. To turn off the router, release the on/off trigger switch (4).
3. If you require the router to run continually without
having to continue applying pressure to the on/off
trigger switch, press the on/off trigger switch (4) and
then depress the lock-on button (5) to lock the
switch on (Fig.13).
4. The router will now run in the “locked-on” condition.
5. If the switch is in the lock-on position, depress the
on/ off trigger switch (4) to disengage the lock-on
button (5) and then release the on /off switch (4) and
the router will stop.
Variable Speed Control
The variable speed dial (2) is located in the left soft grip
handle (1), depending on what direction the router is
facing, for convenient speed adjustment and improved
safety (Fig.14).
1. Adjust the variable speed dial (2) to suit different
working materials. The tool cuts quicker and
smoother at varying speeds when working in
different timber materials or in plastic.
2. Turn the variable speed dial (2) to a higher number, or Max for faster speed. Turn
the dial to a lower number, or Min for slower speed.
3. Determine the optimum speed by making a trial cut in a scrap piece of material.
NOTE: Using the correct speed for the job increases the life of the bit.
CAUTION: Always use two hands to hold the router.
CAUTION: Where possible, clamp the work piece to the bench.
CAUTION: Moving the machine too fast may cause a poor quality of cut and can
damage the bit or the motor. Moving the machine too slowly may burn or mar the cut.
The proper feed rate will depend on the bit size, the type of material being cut and
the cutting depth. Practice first on a scrap piece of material to gauge the correct feed
rate and cut dimensions.
Making a Cut
Your router can be used to make specialty cuts and shapes in the surface and on the
edge of wood. It accepts a wide range of bits that are each designed for a specific cut
or shape.
1. Make all your adjustments as described in the previous sections. 11
OPERATION
Fig. 12
Fig. 13
Fig. 14

OPERATION (cont.)
12
2. Insert and secure your router bit.
3. Adjust the cutting depth as required for the application.
4. Ensure that the materials you are working on are fastened to the workbench or
secured correctly.
5. Place the base plate on the work piece, ensuring that the bit is not in contact
with the material to be cut.
6. Connect the router to the power supply.
7. Turn the router on. Ensure you have a firm grip on both handles. Wait for the
bit to come to full speed.
8. Lower the router body and lock it in position at the desired cutting depth.
9. Follow the guide below to assist you when routing your workpiece.
10. Keep the cutting pressure constant, taking care not to overload the router,
causing the motor to slow excessively.
11. On very hard woods or problem materials it may be necessary to make more
than one pass at progressive cutting depths until the desired cutting depth is
achieved.
12. To turn the router off, release the on/off trigger switch (4) or press and release
the on/off trigger switch if in the “lock-on” position.
Warning! When using this router to cut flat panels such as kitchen work
surfaces, before joining please ensure that you use an appropriate jig together
with the correct guide bush. DO NOT use the curved part of the router base
against a simple guide piece.
Using the Parallel Guide Fence
The parallel guide fence (7) is an effective aid to
cutting in a straight line when chamfering or grooving.
1. Loosen the parallel guide locking knobs (13)
by rotating them anti-clockwise (Fig.15).
Direction of the router travel
When routering the outside of
your workpiece
When routering the inside of
your workpiece
Fig. 15

13
OPERATION (cont.)
2. Feed the two bars on the parallel guide fence (7)
through the holes in the router base, located on the
right hand side of the router in the feed direction.
This will assist in keeping the guide flush with the
side of the work piece (Fig 16).
3. Adjust the distance between the router bit and
parallel guide fence (7) by moving the guide until it
is at the correct distance from the router bit and the
cut you are making.
4. Tighten the parallel guide locking knobs (13) by rotating clockwise, to hold the
parallel guide fence (7) in position.
Note: If the distance between the side of the work piece and the cutting position is
too wide, or the side of the work piece is not straight, firmly clamp a straight board to
the work piece and use this as a guide against the flat of the router base.
Using the Dust Extraction Adaptor
The dust extraction adaptor (9) will accept most standard
vacuum cleaner nozzles allowing the dust to be
efficiently removed when the tool is in use.
Fit the dust extraction adaptor (9) into the base as shown
in Fig.17.
Ensure that the suction hose that will be used is a
reinforced hose such as a garden hose or a wire
reinforced hose. If you use a non-reinforced hose, the hose can collapse and reduce
the suction therefore limiting the extraction of debris and dust.
Using the Copy Template Guide
The copy template guide (10) can be used in various ways:
• Producing duplicates of a particular design of an original shape.
• In conjunction with a template, producing decorative features.
• Repetitive shape cutting.
1. To attach the template guide (10) turn the router upside down and remove the
two fixing screws by rotating them anti-clockwise. These screws also hold the dust
extraction shroud in place. The dust extraction shroud is the clear shroud located
on the underside of the router base (Fig.8).
2. Insert the template guide (10) into the base of the
router with the raised collar facing up or out from
the base plate of the router (Fig.18).
3. You will need to hold the dust extraction shroud in
it's position with your other hand prior to screwing
the template guide (10) into position.
Fig. 17
Fig. 16
Fig. 18

14
4. Secure the template guide (10) using the two
fixing screws that you just removed by rotating
them clockwise (Fig.19).
If you wish to make your own templates, it is best to
use a hardwood such as plywood. Use a piece that is
just thicker than the depth of the copy template
guide (10). Allow for the thickness of the guide in
your template to ensure that the work piece is cut to
the correct size.
Consult woodworking forums or woodworking magazines for assistance in the use
of circular or round template guide attachments .
Using the Circular Template Guide
1. To use the circular template guide (12), insert
a guide fence rod (8) with the circular template
guide (12) attached into the holes, either side of
the base plate of the router (Fig.20).
2. Secure the guide fence rod (8) to the router at
the required length be rotating the parallel guide
locking knob (13) clockwise (Fig.21).
OPERATION (cont.)
Fig. 20
Fig. 21
Fig. 19

15
MAINTENANCE
Warning! Always ensure that the tool is switched off and the plug is removed from
the power point before making any adjustments or maintenance procedures. Always
wear sturdy gloves when handling or changing bits as they can be very sharp.
• Keep the ventilation vents of the tool clean at all times, if possible, prevent foreign
matter from entering the vents.
• After each use, blow air through the tool housing to ensure it is free from all dust
particles which may build up. Build up of dust particles may cause the tool to
overheat and fail.
• If the enclosure of the tool requires cleaning, do not use solvents but a moist soft
cloth only. Never let any liquid get inside the tool; never immerse any part of the
tool into a liquid.
Carbon Brushes
When the carbon brushes wear out, the tool will spark and/or
stop. Discontinue use as soon as this happens. They should
be replaced prior to recommencing use of the tool. Carbon
brushes are a wearing component of the tool therefore not
covered under warranty. Continuing to use the tool when
carbon brushes need to be replaced may cause permanent
damage to the tool. Carbon brushes will wear out after many
uses but when the carbon brushes need to be replaced, take the tool to an electrician
or a power tool repairer for a quick and low cost replacement. Always replace both
carbon brushes at the same time.
Note: Ozito Industries will not be responsible for any damage or injuries caused by the
repair of the tool by an unauthorised person or by mishandling of the tool.
Carbon brushes

16
Limited spare parts are available subject to availability. Please contact your local
Bunnings Special Orders Desk to order the required spare parts.
Most common spare parts listed below
Spare Part Part No.
Brush Holder SPPRR1200-06
Carbon Brushes (set) SPPRR1200-07
Variable Speed Switch SPPRR1200-16
On/Off Switch SPPRR1200-26
Collet Spring SPPRR1200-31
Collet 6.35mm (1/4”) SPPRR1200-38
Collet Nut SPPRR1200-39
Depth Lock Lever SPPRR1200-50A
TROUBLE SHOOTING
SPARE PARTS
SYMPTOM POSSIBLE CAUSE REMEDY
Router will not operate.
Router runs slowly.
Excessive vibration.
Heavy sparking occurs
inside motor housing.
No supply of power.
Blunt or damaged
router bits.
Variable speed set low.
Motor is overloaded.
Bent router bit shaft.
Brushes not moving freely.
Check that power is
available at source.
Re-sharpen or replace
router bits.
Increase variable
speed setting.
Reduce excessive load
or force on router.
Replace router bit.
Disconnect power,
remove brushes, clean
or replace.

17
VVolts Hz Hertz
~Alternating current WWatts
ø Diameter n oNo load speed
/min Revolutions or
reciprocation per minute Double insulated
Regulator compliance mark
Warning
Read instruction manual
DESCRIPTION OF SYMBOLS
CARING FOR THE ENVIRONMENT
Power tools that are no longer usable should not be
disposed of with household waste but in an environmentally
friendly way. Please recycle where facilities exist. Check with
your local council authority for recycling advice.
Recycling packaging reduces the need for landfill and raw
materials. Reuse of recycled material decreases pollution in
the environment. Please recycle packaging where facilities
exist. Check with your local council authority for recycling
advice.

18
OZITO INDUSTRIES PTY LTD
AUSTRALIA (Head Office)
1 - 23 Letcon Drive, Bangholme, Victoria, Australia 3175
Telephone: [phone]
Facsimile: [phone]
Website: www.ozito.com.au
Email: [email protected]
1 x Plunge Router (PRR-1200)
1 x Collet 6.35mm (1/4”)
1 x Spanner
1 x Parallel Guide Fence
1 x Dust Extraction Adaptor
1 x Template Guide
1 x Circular Template Guide
1 x Assembly Nuts & Screws
1 x Instruction Manual
CONTENTS

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 Warehouse 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 and is intended for DIY (Do it yourself) use only.
WARNING
The following actions will result in the warranty being void.
• Trade, Industrial or high frequency use.
•If the tool has been operated on a supply voltage other than that specified on
the tool.
•If the tool shows signs of damage or defects caused by or resulting from abuse,
accidents or alterations.
• If the tool is disassembled or tampered with in any way.
Note: Warranty excludes consumable parts such as carbon brushes, grinding or
cutting wheels/discs, diamond wheels, paper washers, allen keys, pin
spanners and other accessories.
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.