Performax 90239 Quick guide

Router/Table Combo
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Model 90239
Operating and Safety Instructions

Table of Contents
Technical data…………………………………………………………………….. 2
General safety rules………………………………………………………………. 3
Specific safety rules for router tables…………………………………………….. 5
Electrical information…………………………………………………………….. 7
Know your router table…………………………………………………………… 9
Assembly and adjustments……………………………………………………….. 10
Operation…………………………………………………………………………. 17
Maintenance………………………………………………………………………. 21
Replacement parts………………………………………………………………… 22
Warranty………………………………………………………………………….. 24
Technical data
Router/Table Combo Model 90239
Power source: 120 V AC, 60 Hz
Power cord: 6' (1.8 m), 2-prong, polarized
Double insulated: Yes
Net weight: 22 lb (10 kg)
2

General safety rules
Safety is a combination of common sense, staying alert and knowing how your router table works.
SAVE THESE SAFETY INSTRUCTIONS.
WARNING: To avoid mistakes that could cause serious injury, do not plug in the router
table until the following steps have been read and understood.
1. READ and become familiar with this entire instruction manual. LEARN the tool’s applications,
limitations, and possible hazards.
2. AVOID DANGEROUS CONDITIONS. Do not use power tools in wet or damp areas or expose
them to rain. Keep work areas well-lit.
3. DO NOT use power tools in the presence of flammable liquids or gases.
4. ALWAYS keep your work area clean, uncluttered, and well-lit. DO NOT work on floor
surfaces that are slippery with sawdust or wax.
5. KEEP BYSTANDERS AT A SAFE DISTANCE from the work area, especially when the tool
is operating. NEVER allow children or pets near the tool.
6. DO NOT FORCE THE TOOL to do a job for which it was not designed.
7. DRESS FOR SAFETY. Do not wear loose clothing, gloves, neckties, or jewelry (rings, watches,
etc.) when operating the tool. Inappropriate clothing and items can get caught in moving parts
and draw you in. ALWAYS wear non-slip footwear and tie back long hair.
8. WEAR A FACE MASK OR DUST MASK.
WARNING: Dust generated from certain materials can be hazardous to your health.
Always operate the router in a well-ventilated area and provide for proper dust removal. Use dust
collection systems whenever possible.
9. ALWAYS remove the power cord plug from the electric outlet when making adjustments,
changing parts, cleaning or working on the tool.
10. KEEP GUARDS IN PLACE AND IN WORKING ORDER.
11. AVOID ACCIDENTAL START-UPS. Make sure the power switch is in the OFF position
before plugging in the power cord.
12. REMOVE ADJUSTMENT TOOLS. Always make sure all adjustment tools are removed from
the router table before turning it ON.
3

General safety rules (continued)
13. NEVER LEAVE A RUNNING TOOL UNATTENDED. Turn the power switch to OFF. Do
not leave the tool until it has come to a complete stop.
14. NEVER STAND ON A TOOL. Serious injury could result if the tool tips or is accidentally hit.
DO NOT store anything above or near the tool.
15. DO NOT OVERREACH. Keep proper footing and balance at all times. Wear oil-resistant
rubber-soled footwear. Keep the floor clear of oil, scrap, and other debris.
16. MAINTAIN TOOLS PROPERLY. ALWAYS keep tools clean and in good working order.
Follow instructions for lubricating and changing accessories.
17. CHECK FOR DAMAGED PARTS. Check for alignment of moving parts, jamming, breakage,
improper mounting, or any other conditions that may affect the tool’s operation. Any part that is
damaged should be properly repaired or replaced before use.
18. MAKE THE WORKSHOP CHILDPROOF. Use padlocks and master switches and ALWAYS
remove starter keys.
19. DO NOT operate the tool if you are under the influence of drugs, alcohol, or medication that
could affect your ability to use the tool properly.
20. USE SAFETY GOGGLES AT ALL TIMES—that comply with
ANSI Z87.1. Normal safety glasses only have impact resistant
lenses and are not designed for safety. Wear a face or dust mask
when working in a dusty environment. Use ear protection, such
as plugs or muffs, during extended periods of operation.
4

Specific safety rules for router tables
1. Fully assemble and tighten all of the fasteners required for this table. Do not use the router table
until it is fully assembled. Check the table and the router to make sure the fasteners are still
tight before each use.
2. Make sure the router table is secured to a solid, flat, and level surface, and that it will not tip
during use.
3. Make sure the router is not plugged into a power outlet when installing it on the table, making
adjustments, or changing accessories. The router could start accidentally.
4. Make sure the router is fully and securely attached to the router table. Periodically check
connections for tightness. The router motor can vibrate loose during use and fall from table.
5. Do not use the router table without the guard. The guard aids in keeping hands from unintended
contact with the rotating bit.
6. Do not use the router dust collecting attachment when installing the router on the router table.
7. Ensure the collet, with the bit fully installed, is thoroughly tightened before operating the router.
8. Never place your fingers near a spinning bit or under the guard when the router is plugged in.
Never hold the workpiece on the out-feed side of a bit. Pressing the workpiece against the out-
feed side may cause material binding and possible kickback.
9. Use the router to cut and shape wood, wood-like products, and plastic or laminates. Do not cut
or shape metals. Make sure each workpiece is free of nails or other obstructions.
10. Install the bit according to the instructions in the router manual. Make sure the bit is securely
seated in the collet chuck before making any cuts. Do not use bits that have a cutting diameter
that exceeds the clearance hole in the table insert or router sub base.
11. Do not use dull or damaged bits. Dull bits may cause the bit to break or the material to kick
back. Damaged bits can snap during use.
12. Never start the tool when the bit is engaged in the material. The cutting edge may grab the
material and cause you to lose control of the workpiece.
5

Specific safety rules for router tables (continued)
13. Use the router table to cut flat, straight, and squared materials. Do not cut warped, wobbly, or
otherwise unstable material. If the material is slightly curved but otherwise stable, cut the
material with the concave side against the table or fence. Cutting the material with the concave
side up or away from the table may cause warped material to roll and kick back.
14. Feed the material against the rotation of the bit. The bit rotates counter-clockwise as viewed
from the top of the table. Feeding the work in the wrong direction will cause the workpiece to
“climb” up on the bit pulling the workpiece and possibly your hands into the rotating bit.
15. Guide the workpiece by the fence to maintain control. Do not place material between the router
bit and fence while routing the edge. This will cause the material to become wedged, making
kickback possible.
16. Use push sticks, vertical- and horizontally-mounted feather boards (spring sticks), and other jigs
to hold down the workpiece. Push sticks, feather boards and jigs eliminate the need to hold the
workpiece near the spinning bit.
17. Do not use the table as a workbench or work surface. Using it for purposes other than routing
may cause damage and make it unsafe to use for routing. Do not stand on the table.
6

Electrical information
WARNING: To avoid electrical hazards, fire hazards, or damage to the tool, use proper
circuit protection. The router table and router are wired at the factory for 115 V operation. Connect
to a 120 V, 15 A circuit and use a time delayed fuse or circuit breaker. If the power cord is worn,
cut, or damaged, replace it immediately.
Double insulated
This router table has a plug that looks like the one shown in Fig. A.
The router table is double insulated for additional user protection.
All exposed metal parts are isolated from the internal metal motor
components with protective insulation.
WARNING: Double insulation does not take the place of normal safety precautions when
operating this tool.
WARNING: To avoid electrocution:
Use only identical replacement parts when servicing a tool with double insulation. Servicing should
be performed by a qualified technician.
Do not use power tools in wet or damp areas or expose tools to rain.
Grounding instructions
In the event of a malfunction or breakdown, grounding provides the path of least resistance for
electric current and reduces the risk of electric shock. This tool is equipped with an electric cord
that has a polarized 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 in the outlet, have the proper
outlet installed by a licensed electrician.
7

Electrical information (continued)
Guidelines for using extension cords
WARNING: This router table is intended for indoor use only. Do not expose it to rain or
use in damp locations.
Make sure your extension cord is in good condition. When using an extension cord, be sure to use
one heavy enough to carry the current your product will draw. 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
be used according to cord length and nameplate ampere rating. If in doubt, use the next heavier
gauge. The smaller the gauge number, the heavier the cord.
Minimum Gauge for Extension Cords (AWG)
(When using 120 V only)
Ampere Rating Total Length of Cord in feet
More Than Not More Than 25 50 100 150
0 6 18 16 16 14
6 10 18 16 14 12
10 12 16 16 14 12
12 16 14 12 Not Recommended
Make sure your extension cord is properly wired and in good condition. Always replace a damaged
extension cord or have it repaired by a qualified person before using it.
Protect your extension cords from sharp objects, excessive heat and damp or wet areas.
Use a separate electric circuit for your tools. This circuit must not be less than a #12 wire and
should be protected with a 15 A time-delayed fuse. Before connecting the motor 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 nameplate. Running at a lower voltage will damage the motor.
WARNING: Although this tool is double insulated, the extension cord and receptacle
must still be grounded while in use to protect the operator from electric shock.
8

Know your router table
A Router table
B Router
C Switch with safety lock
D Guard
E Fence
F Miter gauge
WARNING: Do not use the router dust collecting attachment with the router table. When
using the router dust collecting attachment with the router, do not use router bits larger than 1-1/2”
(38 mm).
9

Assembly and adjustments
Carefully unpack the router table and all of its parts. Compare the parts against the list below. Do
not discard the carton or any packaging until the router table is completely assembled.
WARNING: If a part is missing or damaged, do not plug in the router table until you
have replaced the missing or damaged part.
1 Table top 16 Carriage bolts (1 large, 1 med, 4 small)
2 Table legs (3) 17 Flat washers for carriage bolts (6)
3 Power switch leg (1) 18 Lock knobs (2 large, 4 small)
4 Fence panels (2) 19 Socket head screws (16)
5 Fence (partially assembled) 20 Locking washers (16)
6 Switch box 21 Flat washers (16)
7 Guard 22 Screws (2)
8 Miter gauge 23 Machine screws (4)
9 Miter bar knob 24 Hex wrench (5 mm)
10 Miter bar 25 Router wrench
11 Table insert 1-1/4” (32 mm) 26 Router
12 Table insert 1-7/8” (47 mm) 27 Router dust collecting attachment*
13 Table insert 2 1/8” (55 mm) *Do not use when the router is installed
14 Starting pin on the router table.
15 Guard pin
10

Assembly and adjustments (continued)
Assembly
This router table must be assembled before use. The router is shipped assembled.
Attach the legs to the table (Fig. 2)
The right front leg has a rectangular cutout for the switch. The other three legs are identical and can
be placed in any position. When the table is assembled, the switch faces the front for easy
accessibility by the operator.
1. Place the router table upside down on a suitable work surface, so that the logo side (1) is closest
to you.
2. Place the leg with the cutout (2) over the four holes to your left and align the holes in the leg
over the threaded holes in the table.
3. Secure the leg with a flat washer (3), a locking washer (4), and a socket head screw (5) in each
of the four holes.
4. Align the four holes of each of the other legs with the corresponding threaded holes in the table.
5. Secure each leg to the table with four flat washers, locking washers, and socket head screws.
6. Make sure all of the screws are securely fastened.
7. Place the router table right-side up on the work surface.
11

Assembly and adjustments (continued)
WARNING: Do not plug the router table power cord into an outlet until the table is fully
assembled and the router is installed.
Attach the switch box to the front leg (Fig. 3 and 4)
The switch box fits into the rectangular cutout on the right front leg so that the switch is easily
accessible. The switch on the front of the switch box fits through the cutout in the leg. An electric
cord and a double-insulated electric outlet for the router are located on the rear of the switch box.
Note: If the cutout is not on the right front leg when the table is upright, reinstall the legs.
1. Place the switch box (1) through the cutout (2) on the front right leg.
2. Align the screw holes at the top and the bottom of the switch box with the 2 small openings
above and below the cutout on the leg.
3. Secure the switch box to the leg with the two small Phillips® head screws (3).
4. Flip the switch (4) up and down to make sure it moves freely.
Note: The switch has a safety lock that must be in place before you will be able to flip the switch
up or down.
Secure the table to a work base (optional)
Each table leg has an opening at the bottom for securing the assembled table to a suitable base. The
work base should be level and strong enough to support the weight of the table and the router. In
addition, the work base should be very stable to eliminate vibration and wobble when the router is
operating.
Select a suitable work base and use an appropriate fastener to secure each table leg to the work base.
12

Assembly and adjustments (continued)
Assemble the table accessories
The router table accessories include a moveable fence with a guard, a miter gauge, several table
inserts, and a safety pin.
Attach the fence to the table (Fig. 5)
The plastic fence is moveable and attaches to the table through the two channel openings on the
table. Two sliding panels and a guard attach to the fence.
1. Place the router table so that you are facing the rear of the table.
2. Align the fence (1) over the channel openings (2) in the table. The large round opening on the
fence (3) should face the rear of the table.
3. Place the longest carriage bolt (4) through the channel opening (2) on the table and through the
hole (5) on the right side of the fence. Secure the bolt with a flat washer (6) and a large lock
knob (7).
4. Place the shorter carriage bolt (8) through the channel opening on the left side of the table and
through the opening on the left side of the fence. Secure the bolt with a flat washer and a large
lock knob.
13

Assembly and adjustments (continued)
Attach the sliding panels to the fence (Fig. 6)
1. Place one sliding panel (1) along the front side of the fence (2) and align the channel openings
on the panel with the holes along the front of the fence.
2. Place a carriage bolt (3) through each of the two openings on the panel and secure each bolt
with a flat washer (4) and a small lock knob (5).
3. Repeat steps 1 and 2 to secure the second sliding panel to the fence.
Attach the guard to the fence (Fig. 7)
The guard protects the cutting edge of the router bit. A pin secures the guard to a support on the
fence. The guard will move freely when it is attached properly to the fence.
1. Place the arm of the guard (1) over the support base (2) on the fence.
2. Align the openings (3) on each side of the guard arm with the openings on the support base.
3. Slide the pin (4) through both sides of the guard arm and the support base on the fence. Tap
gently on the pin if needed to insert it through the support base.
14

Assembly and adjustments (continued)
Attach the router to the table (Fig. 8–11)
The plunge router attaches to the underside of the router table and is secured by four bolts. Once
installed, the router power cord plugs into an outlet on the switch box. When properly installed, the
router table switch turns the router on and off.
Note: See the Plunge Router Instruction Manual for additional information on assembling and
using the router.
1. Remove the four screws (1) that hold the plastic protective plate (2) to the router plate (3).
2. Make sure the dust collecting attachment is not installed on the router (Fig. 9).
WARNING: Do not use the router dust collecting attachment when installing the router on
the router table.
3. Place the router under the table and align the four openings (4) on the router plate with the four
openings (5) on the table. Make sure the front of the router faces the front side of the router
table (Fig. 10).
4. Secure the router to the table with four brass flat head Phillips® screws (6). Make sure the
router is securely attached to the table before continuing.
5. Make sure the switch on the front right leg is in the OFF (down) position.
6. Plug the router power cord into the outlet (7) on the rear of the switch box. Secure the router
power cord so that it will not interfere with the operation of the router (Fig. 11).
15

Assembly and adjustments (continued)
Install a table insert (Fig. 12)
Three table inserts, each with a different size opening, are supplied with the router table. Change
the table inserts as needed to accommodate the size of the router bit. The bit should not make
contact with the table insert.
WARNING: Do not use the router dust collecting attachment when installing the router
on the router table.
1. Select a table insert (1) that has a clearance hole (2) that is larger than the diameter of the bit
you will be using.
2. Align the table insert with the square depression (3) that surrounds the router opening in the
table.
3. Press gently and evenly on the table insert to secure it in the depression.
Assemble the miter gauge (Fig. 13–14)
The miter gauge pivots on the miter bar and is secured in position by a lock knob that fits into a
threaded opening on the bar. The small post on the bottom of the miter gauge fits into an
unthreaded opening on the bar.
1. Remove the lock knob (1) from the miter bar (2).
2. Slide the front of the miter gauge (3) under the pointer (4) on the miter bar.
3. Insert the small post (5) on the bottom of the miter gauge into the unthreaded hole (6) on the bar.
4. Insert and tighten the lock knob bolt through the miter gauge and into the threaded hole (7) on
the miter bar.
5. Place the assembled miter bar (8) into the channel (9) that runs the full length of the table. The
bar should move freely in this channel.
Adjust the miter gauge
To change the angle of the miter gauge, loosen the lock knob and move the gauge to the desired
angle. Tighten the lock knob to maintain the gauge at the selected position.
16

Operation
With the router properly installed on the router table, you will be able to operate the router using
the router table switch box. The switch on the router table has a switch lock safety feature. If the
lock is not in place, the router table switch will not operate. Push the switch lock into the switch or
pull on the switch lock to remove it from the switch.
Plug in the router (Fig. 15)
WARNING: Always wear safety goggles or safety glasses with side shields when
operating your router. Failure to do so could result in objects being thrown into your eyes, resulting
in serious injury.
1. Make sure the safety lock (1) is inserted in the router table switch and the switch is in the OFF
(down) position.
2. Make sure the router switch is in the OFF (O) position. 2
3. Plug the router into the outlet (2) on the rear of the switch box.
4. Secure the router power cord so that it does not interfere with the operation of the router.
5. Plug the router table power cord into an AC power outlet.
Turn on the router (Fig. 16)
Once the router is properly installed and connected to the router table, you will be able to use the
safety switch on the router table to turn the router on and off.
1. Make sure the safety lock is inserted in the router table switch and the router table switch is in
OFF (down) position.
2. Make sure the switch (1) on the router is in the OFF (O) position.
3. Make sure the router is plugged into the outlet on the router table switch box.
4. Make sure the router table power cord into an AC wall outlet.
5. Slide the router switch to the ON (I) position.
6. Flip the router table switch to the ON (up) position to turn on and operate the router.
7. Flip the router table switch to the OFF (down) position to turn off the router.
17

Operation (continued)
WARNING: Keep the router and the router table power cords away from the cutting area.
Turn the router table switch to the OFF position if either cord interferes with the cutting area.
Unplug the router and check the cords for damage. If there is no damage, re-position the cords to
prevent them from interfering with the workpiece again.
General Operating Instructions
The type of material you are using and the type of cut you want to make will determine which of
the router table features you will use. For example, small round pieces may require the use of a
starting pin. The fence should be used with larger pieces.
1. Determine which accessories you will need for the piece.
2. Put a bit into the router collet and adjust the height of the bit. Use the wrench to make sure the
bit is seated securely in the collet. See the Plunge Router Instruction Manual for more
information.
3. Attach or install the appropriate accessories (fence, starting pin, etc.) to the router table.
4. Adjust the fence to support the uncut workpiece and adjust the out-feed side of the fence so it
will support the workpiece after it is cut.
5. Double check all router and router table adjustments. Make sure the guard is in place.
6. Flip the router table switch (1) to the ON (up) position and feed the workpiece (2) from right to
left.
WARNING: Always feed the workpiece against the sharp edges of the bit and into the
rotation of the cutter. Failure to heed this warning can result in serious personal injury.
18

Operation (continued)
WARNING: Before operating the router, always install the appropriate router bit and
adjust the height of the bit. For your safety and to avoid damage, turn the router ON and OFF only
when the router bit is not in contact with the workpiece.
Adjust the bit height and depth of cut (Fig. 18)
The depth of cut affects the rate and quality of the cut. The recommended depth of cut for one pass
is 1/8" (3 mm) and the recommended depth for the final pass is no more than 1/16" (1.5 mm). The
plunge lock lever on the router holds the router at the desired height and depth of cut.
1. Make sure the router table switch is in the OFF position.
2. Release the plunge lever (1) on the router (Fig. 18).
3. Place your hand under the router and push up until the bit is at the desired height.
4. Move the lever to the locked position to set the depth of cut.
Note: See the Plunge Router Instruction manual for more information on working with bits.
Using the starting pin (Fig. 19)
The starting pin is used to pivot a small workpiece. The fence does not need to be used with the
starting pin.
The starting pin (1) fits into a threaded opening (2) on the top of the table near the table insert. Turn
the pin clockwise to insert it into the table. Turn the pin counterclockwise to remove it from the
table.
19

Operation (continued)
Adjust the Fence (Fig. 20–22)
The fence can be adjusted in various ways to accommodate the size and shape of a particular
workpiece. For example, you can:
•Loosen the lock knobs (1)
that secure the fence to the
table and slide the fence
toward the front or rear of
the table. This will set the
in-feed (left) side of the
fence to support the
workpiece (Fig. 20).
•Loosen the lock knobs (2)
on a fence panel and slide
the panel to the left or the
right (Fig. 21).
•Loosen the lock knob (3)
that moves the left side of
the fence forward or
backward. Set this panel to
support the workpiece after
it is cut (Fig. 22).
20