Ryobi RTR400 User manual

RTR400
TRIM ROUTER
OWNER’S OPERATING MANUAL
ORIGINAL INSTRUCTIONS
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1. On / Off switch
2. Base
3. External brush cap
4. Motor housing
5. Collet
6. Collet nut
7. Depth of cut scale
8. Wing bolt
9. Cutter
10. Wrench on collet nut
11. Wrench on spindle flats
12. Locking screw
13. Fence
14. Wing nut
15. Washer
16. Center hole
17. connector
18. Bolt
19. Nail (not included)
20. Bolt A (Locking screw)
21. Bolt C
22. Bolt B
23. Bit
24. Workpiece
25. Guide
26. Depth of cut
27. Width of cut
28. 1st pass
29. 2nd pass
30. Trimmer feed direction
31. Trim end grains first
32. Brush assembly
33. Bit/cutter guard
34. Height adjust knob
35. Adjusting guide
DESCRIPTION
Fig. 1
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Fig. 4
Fig. 6
Fig. 8
Fig. 5
Fig. 7
Fig. 9
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Fig. 12 Fig. 13
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Fig. 10 Fig. 11
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28 29 28
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Important!
It is essential that you read the instructions in this manual before operating this
machine.
Subject to technical modifications.

1
GENERAL POWER TOOL SAFETY WARNINGS
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.
1. WORK AREA SAFETY
a. Keep work area clean and well lit. Cluttered or
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
adaptor 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.
f. If operating power tools in a damp location
is unavoidable, use a residual current device
(RCD) protected supply. Use of an RCD 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 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.
c. 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.
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.
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. Looseclothes,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
dust collection 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 can not be
controlled with the switch is dangerous and must
be repaired.
c. 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.
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

2
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
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.
TRIM ROUTER SAFETY WARNINGS
Hold power tool by insulated gripping surfaces,
because the cutter may contact its own cord.
Cutting a “live” wire may make exposed metal parts of
the power tool “live” and shock the operator.
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.
It is recommended that the product be always supplied
via a residual current device with a rated residual
current of 30mA or less.
WARNING
This product 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 product by a person
responsible for their safety.
Children should be supervised to ensure that they do
not play with the product.
SPECIFICATIONS
Voltage 220 V - 240 V 50/60 Hz
No-load speed 29,000 min-1 (+10% / -15%)
Input power 400 W
Max. cutter diameter 6.35 mm
Weight 1.68 kg
INTENDED USE
Cabinet making, trimming counter tops and finishing
work.
Trimming wood and plastics.
ASSEMBLY
WARNING
Your trim router should never be connected to a
power supply when you are assembling parts, making
adjustments, installing or removing cutters, or when
not in use. Disconnecting your trim router will prevent
accidental starting that could cause serious injury.
WARNING
Do not use cutters with undersized shanks. Undersized
shanks will not tighten properly and could be thrown
from tool causing injury.
WARNING
Do not use cutters that are larger in diameter than the
opening in trim router base. Use of such cutters will
come in contact with the trim router base and damage
both the cutter and trim router base, cause possible
loss of control or create other hazardous conditions that
could cause possible serious personal injury.
INSTALLING/REMOVING CUTTERS
See figure 2
WARNING
Failure to unplug your trim router could result in
accidental starting causing serious injury.
Unplug your trim router.
Place your trim router upside down on a workbench in
order to gain easy access to the spindle and collet nut.
Placethe smallend ofone ofthewrenches providedon
the spindle flats. This will hold the spindle stationary.
Place the large end of the other wrench provided onto
the collet nut. Rotate wrench counterclockwise to
loosen collet nut.
WARNING
If you are changing a cutter immediately after use, be
careful not to touch the cutter or collet with your hands
or fingers. They may get burnt due to the heat buildup
from cutting. Always use the wrench provided.
If installing a cutter for the first time, it can be installed
once the collet nut is loose. If changing cutters, cutter
will easily slip from collet after loosening collet nut.
The collet is machined to precision tolerances to fit
cutters with 6.35 mm diameter shanks.

3
With your trim router still upside down on a workbench,
insert shank of cutter into collet. The shank of your
cutter should be close to but not touching the bottom
of the collet. This allows for expansion when the cutter
gets hot.
Tighten the collet nut securely by turning clockwise
with the wrench provided.
WARNING
If collet nut is not tightened securely, cutter may come
out during use, causing serious personal injury.
WARNING
Avoid open area of trim router base. Serious personal
injury will result from contact with a rotating cutter.
TO SET THE DEPTH OF CUT
See figure 3
WARNING
Failure to unplug your trim router could result in
accidental starting causing serious injury.
Unplug your trim router.
Loosen the wing bolt and turn the height adjusting
knob until the tip of cutter touches the work surface.
The depth of cut is zero at this point.
Position your trim router so that the cutter can extend
below the sub base for desired depth of cut setting.
Turn the height adjusting knob to obtain the desired
depth of cut. The distance the cutter moves will be
indicated on the depth of cut scale. The cut scale is
dual measure. Each mark indicates a change of 1/16”
per division on one scale and 1mm on the other.
Securely tighten the wing bolt.
OPERATION
WARNING
Always wear safety goggles or safety glasses with side
shields when using your trim router. Failure to do so
could result in dust, shavings, chips, loose particles or
foreign objects being thrown into your eyes resulting in
possible serious injury. If the operation is dusty, also
wear a face or dust mask.
WARNING
When turing your trim router ON, be prepared for
start-up torque. Always have a firm grasp of your trim
router before starting. Because of the high cutter speed
rotation your trim router has a tendency to twist, jerk, or
grab in your hands during start-up. If not prepared, this
can cause a loss of control resulting in possible serious
injury.
STRAIGHT FENCE
See figure 4
It is helpful to use the straight fence when trimming the
straight edge or engraving a groove.
Tighten the screw to install straight fence. Loosen the wing
nut to adjust the required distance between bit and fence.
Then tighten the wing nut, keep the fence even with the
workpiece edge when cutting and moving the tool.
CIRCUMFERENCE CUTTING
See figure 5 - 6
By installing the straight fence and connector you can
make a circumference cut. Available radius cuts, shown
from bit to central hole.
Minimum radius: 70mm
Maximum radius: 220mm
Attention: The straight fence is unable to cut a radius
between 172mm and 186mm.
Correctly align the fence central hole to the required
circle’s center. Pushing a nail, with a diameter no more
than 6mm into the hole, to firmly fix the fence. Move the
tool around the nail in a clockwise direction.
ADJUSTING THE GUIDE
See figure 7 - 10
It is much easier to use the adjusting guide for curve
cutting and trimming. Move the guide along the curved
edge.
Tighten the screw to install the adjusting guide on the
tool base plate. Loosen the wing bolt to adjust the guide.
Then tighten the screw firmly to fix the adjusting guide at
a required distance.
Install the guide into the base by bolt A. Adjust the distance
between the bit and base by bolt B, then fasten by bolt C.
When using the tool, please keep the guide mounted on
the workpiece edge.
A bit/cutter guard is attached to protect users from
contacting the bit/cutter when adjusting the fence.
DEPTH OF CUT
See figure 11
As previously mentioned, the depth of cut is important
because it affects the rate of feed which, in turn, affects
the quality of a cut (and also, the possibility of damage

4
to your trim router motor and cutter). A deep cut requires
a slower feed than a shallow cut and a too deep cut will
cause you to slow the feed so much that the cutter is no
longer cutting.
Making a deep cut is never advisable. The smaller cutters
especially those only 1.6 mm in diameter are easily broken
when subjected to too much side thrust. A large cutter
may not break, but if the cut is too deep a rough cut will
result and it may be very difficult to guide and control the
cutter as desired. For these reasons, we recommend that
you do not exceed 3 mm depth of cut in a single pass,
regardless of the cutter size or the softness or condition
of the workpiece. This will result in a higher quality cut.
To make deeper cuts it is therefore necessary to make as
many successive passes as required, lowering the cutter
3 mm for each new pass. In order to save time, do all the
cutting necessary at one depth setting, before lowering the
cutter for the next pass. This will also ensure a uniform
depth when the final pass is completed.
WARNING
If desired depth of cut is greater than it can be safely cut
in one pass, make cuts in two or more passes.
DIRECTION OF FEED AND THRUST
See figure 12
The trim router motor and cutter revolve in a clockwise
direction. This gives the tool a slight tendency to twist (in
your hands) in a counterclockwise direction, especially
when the motor starts.
Because of the extremely high speed of cutter rotation
during “proper feeding” operation, there is very little
kickback under normal conditions. However, should the
cutter strike a knot, hard grain, foreign object etc, that
would affect the normal progress of the cutting action,
there will be a slight kickback — sufficient to spoil the
trueness of your cut if you are not prepared. Such a
kickback is always in the direction opposite to the direction
of cutter rotation.
To guard against such kickback, plan your setup and
direction of feed so that you will always be thrusting the
tool to hold it against whatever you are using to guide the
cut in the same direction that the leading edge of the cutter
is moving. In short, the thrust should be in a direction that
keeps the sharp edges of the cutter continuously biting
straight into new (uncut) timber.
MAINTENANCE
WARNING
When servicing use only identical replacement parts.
Use of any other parts may create a hazard or cause
product damage.
BRUSH REPLACEMENT
See figure 13
Your trim router has externally accessible brush
assemblies that should periodically be checked for wear.
Proceed as follows when replacement is required:
Unplug your trim router.
WARNING
Failure to unplug your trim router could result in
accidental starting causing serious injury.
Remove the brush cap with a flat blade screwdriver.
Brush assembly is spring loaded and will pop out when
you remove the brush cap.
Remove the brush assembly (brush and spring).
Check for wear. If worn, always replace in pairs. Do
not replace one side without replacing the other.
Reassemble using new brush assemblies. Make sure
curvature of brush matches curvature of motor and
that the brush moves freely in the brush tube.
Make sure the brush cap is oriented correctly (straight)
and replace.
Tighten the brush cap securely. Do not over tighten.
PROPER CARE OF CUTTERS
Get faster, more accurate cutting results by keeping
cutters clean and sharp. Remove all accumulated pitch
and gum from cutters after each use. When sharpening
cutters, sharpen only the inside of the cutting edge. Never
grind the outer diameter. Be sure when sharpening the
end of a cutter to grind the clearance angle the same as
originally ground.
PROPER CARE OF COLLET
From time to time, it also becomes necessary to clean
your collet and collet nut. To do so, simply remove collet
nut from the collet and clean the dust and chips that have
collected. Then return the collet nut to its original position.
GENERAL
Avoid using solvents when cleaning plastic parts. Most
plastics are susceptible to damage from various types of
commercial solvents and may be damaged by their use.
If the power supply cord is damaged, it must be replaced
only by the manufacturer or by an authorized service

5
center to avoid risk. Contact authorized service center.
WARNING
Do not at anytime let brake fluids, fuel, petroleum-
based products, penetrating oils, etc. come in contact
with plastic parts. They contain chemicals that can
damage, weaken or destroy plastic.
Use clean cloths to remove dirt, carbon dust, etc. When
electric tools are used on fibreglass boats, sports cars,
wallboard, spackling compounds or plaster, it has been
found that they are subject to accelerated wear and
possible premature failure, as the fiberglass chips and
grindings are highly abrasive to bearings, brushes,
commutators, etc. Consequently it is not recommended
that this tool be used for extended work on any fiberglass
material, wallboard, spackling compounds or plaster.
During any use on these materials, it is extremely
important that the tool is cleaned frequently by blowing
with an air jet.
WARNING
Always wear safety goggles or safety glasses with side
shields during power tool operation or when blowing
dust. If operation is dusty, also wear a dust mask.
LUBRICATION
All of the bearings in this tool are lubricated with a
sufficient amount of high grade lubricant for the life of
the unit under normal operating conditions. Therefore, no
further lubrication is required.
ENVIRONMENTAL PROTECTION
Recycle raw materials instead of disposing
of as waste. The machine, accessories
and packaging should be sorted for
environmental-friendly recycling.
SYMBOLS
Safety Alert
V Volts
Hz Hertz
Alternating Current
WWatts
noNo-load speed
min-1Revolutions or reciprocations per minute
Regulatory Compliance Mark (RCM). Product
meets applicable regulatory requirements.
Class II tool, double insulation
Wear ear protection
Wear eye protection
Read the instructions carefully before starting
the machine.
Waste electrical products should not be
disposed of with household waste. Please
recycle where facilities exist. Check with your
Local Authority or retailer for recycling advice.

20141017
Techtronic Industries (Australia) Pty. Ltd.
Level 1, 660 Doncaster Road
Doncaster, VIC 3108, Australia
Techtronic Industries New Zealand Ltd.
18-26 Amelia Earhart Avenue
Mangere, Auckland 2022, New Zealand