Harbor Freight Tools 37793 User's Manual
Contents
1. sharpened bits Ifthe bit stops abruptly or the bit becomes blocked remove the Router from the workpiece and shut it off Never start the Router while the bit is in contact with workpiece Allow the tool to reach its normal operating speed before applying the bit to the workpiece Maintain labels and nameplates on the Router These carry important information If unreadable or missing contact Harbor Freight Tools for a replacement Always wear ANSl approved safety impact eye glasses full face shield and heavy duty work gloves when using the Router Using personal safety devices reduce the risk for injury Safety impact eye goggles and heavy work gloves are available from Harbor Freight Tools Maintain a safe working environment Keep the work area well lit Make sure there is adequate surrounding workspace Always keep the work area free of obstructions grease oil trash and other debris Do not use a power tool in areas near flammable chemicals dusts and vapors Do not use this tool in a damp or wet locations Avoid unintentional starting Make sure you are prepared to begin work before turning on the Router SKU 37793 For technical questions please call 1 800 444 3353 Page 5 20 21 22 29 24 25 26 Do not force the Router This tool will do the work better and safer at the speed and capacity for which it was designed Always unplug the Router from its electrical outlet before performing any inspection2. well lit Cluttered benches and dark areas invite accidents 2 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 3 Keep bystanders children and visitors away while operating a power tool Distractions can cause you to lose control Protect others in the work area from debris such as chips and sparks Provide barriers or shields as needed 4 Use tool in a well ventilated area ELECTRICAL SAFETY 1 Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances Never remove the grounding prong or modify the plug in any way Do not use any adapter plugs Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded If the SKU 37793 For technical questions please call 1 800 444 3353 Page 2 tools should electrically malfunction or break down grounding provides a low resistance path to carry electricity away from the user Double insulated tools are equipped with a polarized plug one blade is wider than the other This plug will fit in a polarized outlet only one way If the plug does not fit fully in the outlet reverse the plug If it still does not fit contact a qualified electrician to install a polarized outlet Do not change the plug in any way Double insulation o eliminates the need for the three wire gr
3. 3353 Page 16 ACCESSORIES PARTS LIST Templet Guide Dimensions A 37 64 B 5 8 C 33 64 Collet Sleeve Straight Guide Guide Holder ACCESSORIES PARTS 1A 4A 3A S 6A SKU 37793 For technical questions please call 1 800 444 3353 Page 17 LIMITED 1 YEAR 90 DAY WARRANTY Harbor Freight Tools Co makes every effort to assure that its products meet high quality and durability standards and warrants to the original purchaser that for a period of ninety days from date of purchase that the engine motor the belts if so equipped and the blades if so equipped are free of defects in materials and workmanship Harbor Freight Tools also warrants to the original purchaser for a period of one year from date of purchase that all other parts and components of the product are free from defects in materials and workmanship 90 days if used by a professional contractor or if used as rental equipment This warranty does not apply to damage due directly or indirectly to misuse abuse negligence or accidents repairs or alterations outside our facilities normal wear and tear or to lack of maintenance We shall in no event be liable for death injuries to persons or property or for incidental contingent special or consequential damages arising from the use of our product Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation of exclusion may not apply to you T
4. CHICAGO JCal Power Tools PLUNGE ROUTER LLI 37793 SET UP AND OPERATING INSTRUCTIONS Diagrams within this manual may not be drawn proportionally Due to continuing improvements actual product may differ slightly from the product described herein Distributed exclusively by Harbor Freight Tools 3491 Mission Oaks Blvd Camarillo CA 93011 Visit our website at http www harborfreight com Read this material before using this product Failure to do so can result in serious injury SAVE THIS MANUAL Copyright 2005 by Harbor Freight Tools All rights reserved No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools For technical questions or replacement parts please call 1 800 444 3353 REV 07 SPECIFICATIONS reese SAVE THIS MANUAL You will need this manual for the safety warnings and precautions assembly operating inspection maintenance and cleaning procedures parts list and assembly diagram Keep your invoice with this manual Write the invoice number on the inside of the front cover Keep this manual and invoice in a safe and dry place for future reference GENERAL SAFETY RULES AWARNING READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions listed below may result in electric shock fire and or serious injury SAVE THESE INSTRUCTIONS WORK AREA Ts Keep your work area clean and
5. DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO SKU 37793 For technical questions please call 1 800 444 3353 Page 14 PARTS LIST Pan Head Screw M5x20 wiwasher 2 Rearcowr e MotorHousing e Nanerae Sid o fe e ianea 2 Bal Bearing 0202RS zreo 1 10 insuatonwesner 1 11 Armature Assembly w tems 012 1 z fras dC Ca fe ooo 14 Bal Bearing 6008 2RSiearareen 1 i fkos id 16 Motor racket SSS dt 17 compression Spingi0 __ Pie rane Sid se JeasePate Cr fso s frenan Cso hereon r 60 Compression srno 2 1 Cor Fathead Screws ez reena o es hexeonmsao dt Cea reena id 65 hexeonmsas e6 compression sping 2 ee kno eo Compression Spro 2 C7 namos Cid Pr Pawee Sid 72 fremra i _ Note Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts Q e ee ee ee ee ee ee ee e eaea ea SKU 37793 For technical questions please call 1 800 444 3353 Page 15 ASSEMBLY DRAWING SKU 37793 For technical questions please call 1 800 444
6. HIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS To take advantage of this warranty the product or part must be returned to us with transportation charges prepaid Proof of purchase date and an explanation of the complaint must accompany the merchandise If our inspection verifies the defect we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement We will return repaired products at our expense but if we determine there is no defect or that the defect resulted from causes not within the scope of our warranty then you must bear the cost of returning the product This warranty gives you specific legal rights and you may also have other rights which vary from state to state 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 800 444 3353 REV 07 SKU 37793 For technical questions please call 1 800 444 3353 Page 18
7. ada to indicate it is acceptable for outdoor use T Make sure the extension cord is properly wired and in good electrical condition Always replace a damaged extension cord or have it repaired by a qualified electrician before using it 8 Protect the extension cords from sharp objects excessive heat and damp or wet areas RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS 120 240 VOLT NAMEPLATE EXTENSION CORD LENGTH AMPERES usd 25Feet 50Feet 75Feet 100Feet 150 Feet 121 160 4 2 J wo fJ gt o o 161 200 12 Tt TABLE A Based on limiting the line voltage drop to five volts at 150 of the rated amperes Double Insulated Volts Alternating Current Underwriters Laboratories Inc pe Revolutions per Minute SKU 37793 For technical questions please call 1 800 444 3353 Page 8 UNPACKING When unpacking check to make sure the following parts are included Refer to the Assembly Section and the Assembly Drawing and Parts List at the end of this manual If any parts are missing or broken please call Harbor Freight Tools at the number on the cover of this manual as soon as possible OPERATING INSTRUCTIONS Installing Bits Caution Turn router power Off and unplug Bits are sharp Handle with care Check the bit for cracks or damage before using Use only router bits Lock Lever 26 er g Screw 32 Stopper i Pole Half Nut 18 Collet Nut 20 Loosen to left Tighten to ri
8. ast moving parts Misuse can cause severe injury Follow the safety instructions SKU 37793 For technical questions please call 1 800 444 3353 Page 4 10 11 12 13 14 15 16 17 Under no circumstance is the Router base ever to be removed from the Router in order to use bits that are too large to use with the base assembly attached Removal of the Router base and using the Router free hand can lead to serious bodily injury Never touch the bit collet or any other moving parts while the Router is in operation Never lay the Router down until it has stopped rotating completely Hold the Router firmly when starting as startup rotation creates significant torque Never hold workpiece by hand Secure the workpiece by clamping or with other holding devices Make sure the workpiece is free of nails and other obstacles These can interfere with the cutting process and possibly cause damage and injury Hold the tool firmly while cutting The action of the bit against the workpiece can cause it to kick out jumping rapidly away from the workpiece This can be caused by an improper type or dull bit being used Do not handle the Router bit immediately after cutting It may be very hot potentially causing burns or injury Avoid overloading the tool If the speed drops abnormally decrease the pressure on the bit immediately Do not apply excessive pressure to the router while cutting Always use
9. d or broken parts damaged electrical wiring and any other condition that may affect its safe operation If abnormal noise or vibration occurs have the problem corrected before further use Do not use damaged equipment Periodically recheck all nuts bolts and screws for tightness Store in a clean and dry location Keep air vents clean of dirt and debris at all times If any cracks appear on the Chip Deflector 53 replace immediately o Oo N Keep clean and free of grease at all times Brush Replacement Remove and check the carbon brushes regularly Replace when they wear down to the limit mark Keep the carbon brushes clean and free to slip in the holders Both brushes should be replaced at the same time 1 Set Power Switch to the Off position and unplug router from the electrical outlet 2 Remove Knob 68 to allow access to Brush Holder Caps 35 3 Using a screwdriver remove the Brush Holder Caps 4 Remove brush from Brush Holder Cap and replace with new one 5 Insert brush and screw Brush Holder Cap back in PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR
10. er limit adjustment should be set so that the bit clears the stock material by approximately 1 2 inch 1 Turn the Knob 68 to the correct upper limit and clamp in place using the Lock Lever 26 2 Screw the Nut 70 down the screw shaft until it seats firmly against the motor housing 5 3 Loosen the Lock Lever Using the Straight Guide The Straight Guide 4A and Guide Holder 6A are used for chamfering or grooving cuts Wing Nut C Wing Nut C Guide Holder 6A Fine Adjustment Screw A PARAE Guide 4A 1 Place the Straight Guide on the Guide Holder with the Wing Nut B 2 Insert Guide Holder into the holes in the router base SKU 37793 For technical questions please call 1 800 444 3353 Page 10 3 Adjust the Straight Guide by turning the Fine Adjustment Screw A to the desired distance from the bit 4 Tighten wing nuts C 5 When cutting move the router with the Straight Guide flat against the side of the material to be chamfered or grooved See figure Note Standoffs can be mounted to the Straight Guide to widen its operation This also prevents larger bits from striking the Straight Guide Using the Trimmer Guide The Trimmer Guide 3A is used to make cuts on curved material The guide roller rides the curve of the material Fine Adjustment Screw A Wing Nut B Trimmer Guide 3A 1 Place the Trimmer Guide 3A on the Guide Holder with t
11. ght Hex Bolt 65 Bit Stopper 57 1 Push down on the shaft Lock Lever 26 to keep the shaft stationary See photo above 2 Using Wrench 5A loosen the Collet Nut 20 3 Insert the bit all the way into the Collet Cone 21 When using smaller shank bits insert the Collet Sleeve 2A into the Collet Cone then the bit through the Cone 4 Securely tighten Collet Nut 20 Do not tighten the Collet Nut without inserting a bit or Collet Cone with bit Damage can occur 5 Pull up the Lock Lever 26 to free the shaft Cutting Depth Adjustment 1 Place the router on a flat surface 2 Loosen the Lock Lever 26 3 Lower router body until the bit just touches the flat surface SKU 37793 For technical questions please call 1 800 444 3353 Page 9 4 Tighten the Lock Lever 5 Turn Stopper 57 turret to select the desired Hex Bolt 65 height D Lower the Screw 32 stopper pole until it touches the adjustable Hex Bolt 65 Press and hold the Half Nut 18 fast feed button to lower stopper pole rapidly Raise the Screw 32 stopper pole in fine increments to desired depth of cut Zz N iD The depth of cut is equal to the distance between the end of the Screw 32 and the top of the Hex Bolt 65 8 Loosen Lock Lever 26 and lower router body until Screw 32 stopper pole makes contact with the Hex Bolt 65 The depth of cut can now be seen Upper Limit Adjustment The upp
12. he wing nut N Insert Guide Holder into the holes in the router base w Adjust the Trimmer Guide by turning the Fine Adjustment Screw A to the desired distance from the bit 4 Tighten Wing Nut B SKU 37793 For technical questions please call 1 800 444 3353 Page 11 9 When cutting move the router with the Trimmer Guide flat against the side of the material to be chamfered or grooved Using the Templet Guide The Templet Guide 1A enables the router to follow templet patterns when making cuts Screw Templet Guide 1A i Lay the router on its side Loosen the screws on the router base Insert the Templet Guide and retighten screws Secure the templet to the work surface Place the router Templet Guide inside the templet oP oe amp S Begin cutting sliding the router along the templet E Bit Templet Guide 1A Distance Z L Templet Guide 1A Outside Diameter Note The cut size may be slightly different from that of the templet Allow for the distance Z between the router bit and the outside of the Templet Guide by subtracting the bit diameter size from the Templet Guide outside diameter then divide that by 2 SKU 37793 For technical questions please call 1 800 444 3353 Page 12 OPERATION Before operating the router read these safety tips e Wear ANSI approved impact safety goggles e Avoid cutting nails e Hold router handles firmly with both hands e Keep hand
13. maintenance or cleaning procedures Never leave the Router unattended while running Turn power off if you have to leave the Router Before each use check all nuts bolts and screws for tightness Vibration during mixing may cause these to loosen Keep extension cord off the ground and away from water Always connect the Line Cord or extension cord to a Ground Fault Circuit Interrupter GFCI protected electrical outlet If this Plunge Router is to be mounted on a router table it must be an approved router table and must have all appropriate holding devices and safety shields Never use a router table which is not specifically designed for use with this Plunge Router People with pacemakers should consult their physician s before use Electromagnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure 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 or other masonry products 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 chemicals work in a well ventilated area and work with app
14. n the hands of untrained users 6 Maintain tools with care Keep cutting tools sharp and clean Properly maintained tools with a sharp cutting edge are less likely to bind and are easier to control Do not use a damaged tool Tag damaged tools Do not use until repaired T Check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the tool s operation If damaged have the tool serviced before using Many accidents are caused by poorly maintained tools 8 Use only accessories that are recommended by the manufacturer for your model Accessories that may be suitable for one tool may become hazardous when used on another tool SERVICE 1 Tool service must be performed only by qualified repair personnel Service or maintenance performed by unqualified personnel could result in a risk of injury 2 When servicing a tool use only identical replacement parts Follow instructions in the Inspection Maintenance And Cleaning section of this manual Use of unauthorized parts or failure to follow maintenance instructions may create a risk of electric shock or injury SPECIFIC SAFETY RULES FOR THE PLUNGE ROUTER 1 Hold tool by the insulated gripping handles when performing an operation where the cutting tool may contact hidden wiring or its own cord Contact with live wire will make exposed metal parts of the tool live and shock the operator 2 This Router has sharp f
15. ounded power cord and grounded power supply system Avoid body contact with grounded surfaces such as pipes radiators ranges and refrigerators There is an increased risk of electric shock if your body is grounded Do not expose power tools to rain or wet conditions Water entering a power tool will increase the risk of electric shock Do not abuse the Power Cord Never use the Power Cord to carry the tools or pull the Plug from an outlet Keep the Power Cord away from heat oil sharp edges or moving parts Replace damaged Power Cords immediately Damaged Power Cords increase the risk of electric shock When operating a power tool outside use an outdoor extension cord marked W A or W These extension cords are rated for outdoor use and reduce the risk of electric shock PERSONAL SAFETY Stay alert Watch what you are doing and use common sense when operating a power tool Do not use a power tool while tired or under the influence of drugs alcohol or medication A moment of inattention while operating power tools may result in serious personal injury Dress properly Do not wear loose clothing or jewelry Contain long hair Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts Avoid accidental starting Be sure the Power Switch is off before plugging in Carrying power tools with your finger on the Power Switch or plugging in power tools with
16. roved safety equipment such as those dust masks that are specially designed to filter out microscopic particles California Health amp Safety Code 25249 5 et seq GROUNDING Improperly connecting the grounding wire can result in electric AWARNING rroPery one a shock Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded Do not modify the power cord plug provided with the tool Never remove the grounding prong from the plug Do not use the tool if the SKU 37793 For technical questions please call 1 800 444 3353 Page 6 power cord or plug is damaged If damaged have it repaired by a service facility before use If the plug will not fit the outlet have a proper outlet installed by a qualified electrician Grounded Tools Tools with Three Prong Plugs Note This product has a line cord with a 3 prong grounded plug 1 Tools marked with Grounding Required have a three wire cord and three prong grounding plug The plug must be connected to a properly grounded outlet If the tool should electrically malfunction or break down grounding provides a low resistance path to carry electricity away from the user reducing the risk of electric O shock See 3 Prong Plug and Outlet The grounding prong in the plug is connected through the green wire inside the cord to the grounding system in the tool The green wire in the cord must be the only wire connected to
17. s away from rotating bit Wait until is stops before making adjustments e Don t touch bit right after cutting It becomes very hot e Before cutting material turn router On Watch and feel for vibration that could indicate an improperly installed bit e Turn router Off when not actually cutting Do not leave running 1 Secure material to be routed 2 Set router on material to be cut Verify there are no obstructions in the cutting path 3 Verify Lock Lever 26 is loose 4 Press the Power Switch 46 to the On position Hold firmly Router may try to twist from the torque of turning it on 5 Hold router with both hands when cutting 6 Allow bit to come to full speed slowly engage material Do not attempt to cut more than 5 8 inch in a single pass The router bit should always be fed into the stock from left to right so as to match the clockwise rotation of the router T When finished turn Power Switch to the Off position Do not set the router down until the bit has stopped turning SKU 37793 For technical questions please call 1 800 444 3353 Page 13 MAINTENANCE WARNING Make sure the Power Switch of the Plunge Router is in its OFF position and that the tool is unplugged from its electrical outlet before performing any inspection maintenance or cleaning procedures 1 Before each use inspect the general condition of the Plunge Router Check for loose screws misalignment or binding of moving parts cracke
18. the Power Switch on invites accidents Remove adjusting keys or wrenches before turning the power tool on A wrench or a key that is left attached to a rotating part of the power tool may result in personal injury Do not overreach Keep proper footing and balance at all times Proper footing and balance enables better control of the power tool in unexpected situations Use safety equipment Always wear eye protection Dust mask non skid safety shoes hard hat or hearing protection must be used for appropriate conditions SKU 37793 For technical questions please call 1 800 444 3353 Page 3 TOOL USE AND CARE lis Use clamps not included or other practical ways to secure and support the workpiece to a stable platform Holding the work by hand or against your body is unstable and may lead to loss of control 2 Do not force the tool Use the correct tool for your application The correct tool will do the job better and safer at the rate for which it is designed 3 Do not use the power tool if the Power Switch does not turn it on or off Any tool that cannot be controlled with the Power Switch is dangerous and must be replaced 4 Disconnect the Power Cord Plug from the power source before making any adjustments changing accessories or storing the tool Such preventive safety measures reduce the risk of starting the tool accidentally 5 Store idle tools out of reach of children and other untrained persons Tools are dangerous i
19. the tool s grounding system and must never be attached to an electrically live terminal See 3 Prong Plug and Outlet 3 Prong Plug and Outlet The tool must be plugged into an appropriate outlet properly installed and grounded in accordance with all codes and ordinances The plug and outlet should look like those in the following illustration See 3 Prong Plug and Outlet Extension Cords Grounded tools require a three wire extension cord Double Insulated tools can use either a two or three wire extension cord As the distance from the supply outlet increases you must use a heavier gauge extension cord Using extension cords with inadequately sized wire causes a serious drop in voltage resulting in loss of power and possible tool damage See Table A The smaller the gauge number of the wire the greater the capacity of the cord For example a 14 gauge cord can carry a higher current than a 16 gauge cord See Table A When using more than one extension cord to make up the total length make sure each cord contains at least the minimum wire size required See Table A SKU 37793 For technical questions please call 1 800 444 3353 Page 7 5 If you are using one extension cord for more than one tool add the nameplate amperes and use the sum to determine the required minimum cord size See Table A 6 If you are using an extension cord outdoors make sure it is marked with the suffix W A W in Can
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