Ryobi R163K Router User Manual
Contents
1. SUBBASE SIZE A DIFFERENCE WORKPIECE f Fig 24 OPERATION STRAIGHT GUIDE The straight guide is used as an edge guide that slides against the edge of a board to guide the cutter through the cut The straight guide can be used from either side of the router base TO INSTALL THE STRAIGHT GUIDE SUBBASE See Figures 25 and 26 B Unplug your router STRAIGHT GUIDE MOUNTING POSTS A WARNING Failure to unplug your router could result in accidental starting causing serious injury B Slide the two straight guide mounting posts into the holes in the side of the router base B Set the straight guide to a desired location E To secure the straight guide install the two knob screws into the tapped holes in the base of the router E Tighten both knob screws securely STRAIGHT GUIDE AGAINST EDGE OF WORKPIECE 22 MAINTENANCE A WARNING When servicing use only identical Ryobi replacement parts Use of any other parts may create a hazard or cause product damage 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 Use clean cloths to remove dirt carbon dust etc A WARNING Do not at any time let brake fluids gasoline petroleum based products penetrating oils etc come in contact with plastic parts They contain chemicals that can dam age w2. tion the cord so that it will not get caught on lumber tools or other obstructions while you are working with a power tool Failure to do so can result in serious personal injury A WARNING Check extension cords before each use If damaged re place immediately Never use tool with a damaged cord since touching the damaged area could cause electrical shock resulting in serious injury FEATURES SPECIFICATIONS Depth of Cut Plunge Base nete eine ee eee Fixed Base amp D Base see Before using this tool familiarize yourself with all operat ing features and safety requirements However do not let familiarity with the tool make you careless This new router is equipped with the following features See Figure 1 MOTOR The router kit has a powerful 10 amp motor with sufficient power to handle tough routing jobs It delivers 2 peak horsepower for heavy duty performance SWITCH The router has a conveniently located rocker switch SPINDLE LOCK The spindle lock secures the spindle so that you only need one wrench to loosen the collet nut and change cutters DEPTH ADJUSTING RING The depth adjusting ring allows you to adjust the depth of cut VARIABLE SPEED The router s advanced electronic feature allow you to adjust the motor speed to required job conditions The variable speed control is located on the front of the router and allows the router to develop a no load speed
3. non skid safety shoes hard hat or hearing protection must be used for appropriate conditions E Do not wear loose clothing or jewelry Contain long hair Loose clothes jewelry or long hair can be drawn into air vents E Do not use on a ladder or unstable support Stable footing on a solid surface enables better control of the tool in unexpected situations TOOL USE AND CARE E Use clamps or other practical way 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 E Do not force 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 E Do not use tool if switch does not turn it on or off Any tool that cannot be controlled with the switch is dangerous and must be repaired E Disconnect the plug from power source before making any adjustments changing accessories or storing the tool Such preventive safety measures reduce the risk of starting the tool accidentally E Store idle tools out of the reach of children and other untrained persons Tools are dangerous in the hands of untrained users B Maintain tools with care Keep cutting tools sharp and clean Properly maintained tools with sharp cutting edges are less likely to bind and are easier to control B Check for misalignment or binding of moving parts breakage of parts and any other condition
4. abuse the cord Never use the cord to carry the tools or pull the plug from an outlet Keep cord away from heat oil sharp edges or moving parts Replace damaged cords immediately Damaged cords increase the risk of electric shock When operating a power tool outside use an outdoor extension cord marked W A or W These cords are rated for outdoor use and reduce the risk of electric shock PERSONAL SAFETY Stay alert watch what you are doing and use com mon sense when operating a power tool Do not use 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 jew elry 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 E Avoid accidental starting Be sure switch is off before plugging in Carrying tools with your finger on the switch or plugging in tools that have the switch on invites accidents E Remove adjusting keys or wrenches before turning the tool on A wrench or a key that is left attached to a rotating part of the tool may result in personal injury E Do notoverreach Keep proper footing and balance at all times Proper footing and balance enables better control of the tool in unexpected situations E Use safety equipment Always wear eye protection Dust mask
5. is designed for making shallow cuts A router with a high horsepower rating can safely cut deeper Small cutters such as veining bits with 1 16 in 1 6 mm cutting diameters are designed to remove only small amounts of wood Large cutters such as straight flute bits are made to remove larger amounts of wood You can make deeper cuts in soft woods such as white pine than in hardwoods like oak or maple Based on these considerations choose a depth of cut that will not place excessive strain on the router motor If you find that extra force is needed or that the motor speed slows down considerably turn off the router and reduce the depth of cut Then make the cut in two or more passes When routing a groove that is too deep to safely cut in one pass it is best to make the cut in several passes We recommend that cuts be made at a depth not exceeding 1 8 in 3 2 mm and that several passes be made to reach deeper cuts Adjusting the depth of cut for the plunge router is different from adjusting the depth of cut for the fixed router TO ADJUST DEPTH OF CUT FOR FIXED BASE OR D BASE ROUTERS See Figures 9 and 10 Follow these steps to adjust depth of cut for fixed routers 1 Unplug the router ADJUSTMENT INDICATOR A WARNING Failure to unplug the tool could result in accidental starting causing serious injury INDICATOR RING 2 Place the router on a flat surface 3 Loosen the locking arm INDICATOR POINT 4
6. limitations as well as the specific potential hazards related to this tool Following this rule will reduce the risk of electric shock fire or serious injury Always wear safety glasses Everyday eyeglasses have only impact resistant lenses they are NOT safety glasses Following this rule will reduce the risk of serious personal injury Protect your lungs Wear a face or dust mask if the operation is dusty Following this rule will reduce the risk of serious personal injury Protect your hearing Wear hearing protection during extended periods of operation Following this rule will reduce the risk of serious personal injury Inspect tool cords periodically and if damaged have repaired at your nearest authorized service center Constantly stay aware of cord location Following this rule will reduce the risk of electric shock or fire Check damaged parts Before further use of the tool a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function Check for alignment of moving parts binding of moving parts breakage of parts mounting and any other condi tions that may affect its operation A guard or other part that is damaged should be properly repaired or replaced by an authorized service center Following this rule will reduce the risk of shock fire or serious injury Do not abuse cord Never carry the tool by the cord or yank it to disconnec
7. piloted cutters The pilot which extends below the cutter allows the cutter to turn while the pilot follows the edge of the workpiece Some pilots are solid extensions of the cutter Others are ball bearing guides that are fastened to the end of the cutter Arbor type bits with pilots are excellent for quick easy edge shaping They follow workpiece edges that are either straight or curved The pilot prevents the bit from making too deep a cut Holding the pilot firmly in contact with the workpiece edge throughout the cut prevents the cut from becoming too shallow Whenever the workpiece thickness together with the ROUTER desired depth of cut as adjusted by router depth setting are such that only the top part of the edge is to be shaped leaving at least a 1 16 inch 1 6 mm thick uncut portion at bottom the pilot can ride against the uncut portion which serves to guide it However if the workpiece is too thin or the bit is set so low that there will PILOT be no uncut edge to ride the pilot against an extra board must be placed under the workpiece to act as a guide This guide board must have exactly the same contour GUIDE straight or curved as the workpiece edge If the guide is positioned so that its edge is flush with the workpiece WHOLE EDGE SHAPING edge the bit will make a full cut in as far as the bit radius On the other hand if the guide is positioned as shown out from the workpiece edge the bit will make less
8. that may affect the tool s operation If damaged have the tool serviced before using Many accidents are caused by poorly maintained tools E 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 B Keep the tool and its handle dry clean and free from oil and grease Always use a clean cloth when cleaning Never use brake fluids gasoline petroleum based products or any strong solvents to clean your tool Following this rule will reduce the risk of loss of control and deterioration of the enclosure plastic GENERAL SAFETY RULES SERVICE E Tool service must be performed only by qualified repair personnel Service or maintenance performed by unqualified personnel could result in a risk of injury B When servicing a tool use only identical replace ment parts Follow instructions in the Maintenance 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 E Hold tool by insulated gripping surfaces when performing an operation where the cutting tools may contact hidden wiring or its own cord Contact with a live wire will make exposed metal parts of the cutting tool live and shock the operator ADDITIONAL SAFETY RULES Know your power tool Read operator s manual carefully Learn its applications and
9. the design of this tool making it easy to maintain and operate GENERAL SAFETY RULES A WARNING Read and understand all instructions Failure to follow all instructions listed below may result in electric shock fire and or serious personal injury SAVE THESE INSTRUCTIONS WORK AREA Keep your work area clean and well lit Cluttered benches and dark areas invite accidents Do not operate power tools in explosive atmo spheres such as in the presence of flammable liquids gases or dust Power tools create sparks which may ignite the dust or fumes Keep bystanders children and visitors away while operating a power tool Distractions can cause you to lose control ELECTRICAL SAFETY 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 E eliminates the need for the three wire grounded 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 Don t expose power tools to rain or wet conditions Water entering a power tool will increase the risk of electric shock Do not
10. DVEIN 1 Unplug the router MOTOR 2 Place the plunge base on a flat surface HOUSING 3 Loosen the locking knob 4 Align the groove in the motor housing with the rib inside the base NOTE The rib is located on the inside of the base in line with the handle Depress and hold the gold spindle lock button Slide the motor housing into the base 7 Tighten the locking knob oo A CAUTION Do not tighten the locking knob without the motor installed in the base Failure to heed this caution may result in permanent damage to the locking mechanism OPERATION TO SWITCH FROM PLUNGE BASE TO FIXED BASE OR D HANDLE BASE See Figures 6 and 7 TO REMOVE THE PLUNGE BASE 1 Unplug the router LOCKING KNOB A WARNING Failure to unplug the tool could result in accidental start ing causing serious injury GOLD 2 Place the router on a flat surface SPINDLE LOCK 3 Loosen the locking knob BUTTON 4 Depress and hold the gold spindle lock button The gold spindle lock button will not depress fully unless it is in line with the hole in the collet If the gold spindle lock button does not depress fully turn the collet nut while depressing the gold spindle lock button As they align the gold spindle lock button will depress fully Remove the motor housing from the plunge base NOTE As the motor is being removed from the base the gold spindle lock button has to be depressed until it clears the opening beneath
11. NG BY FREEHAND See Figure 21 When used freehand your router becomes a flexible and versatile tool This flexibility makes it possible to easily rout signs relief sculptures etc There are two basic techniques for freehand routing E Routing letters grooves and patterns into wood E Routing out the background leaving the letters or pattern raised above the surface When freehand routing we suggest the following B Draw or layout the pattern on workpiece E Choose the appropriate cutter NOTE A core box or V groove bit is often used for routing letters and engraving objects Straight bits and ball mills are often used to make relief carvings Veining bits are used to carve small intricate details E Rout the pattern in two or more passes Make the first pass at 25 of the desired depth of cut This will provide better control as well as being a guide for the next pass NOTE Do not rout deeper than 1 8 in per pass A WARNING Do not use large router bits for freehand routing Use of large router bits when freehand routing could cause loss of control or create other hazardous conditions that could cause possible serious personal injury When using a router table large router bits should be used for edging only Do not use router bits that are larger in diameter than the opening in router subbase for any purpose OPERATION EDGING WITH PILOTS See Figure 22 ROUTER You can cut rabbets and molded edges using
12. ON PLUNGE BASE SWITCH ADJUSTMENT RING CHIP SHIELD D HANDLE BASE UNPACKING PACKING LIST Router INSTRUCTIONS When unpacking the tool E Carefully remove the tool and accessories from the box E Make sure that all items listed in the packing list are in cluded Bi Inspect the tool carefully to make sure no breakage or damage occurred during shipping E Do not discard the packing material until you have care fully inspected and satisfactorily operated the tool E If any parts are damaged or missing please call 1 800 525 2579 for assistance A WARNING If any parts are missing do not operate the tool until the missing parts are replaced Failure to do so could result in possible serious personal injury Fixed Base Plunge Base and D Base Collet Adaptor Collet Wrench Tool Bag Template Guide Bushing Kit Straight Guide Operator s Manual Warranty Registration Card A WARNING The tool should never be connected to a power supply when you are assembling parts making adjustments cleaning performing maintenance or when the tool is not in use Disconnecting the tool will prevent accidental starting that could cause injury OPERATION A WARNING Always wear safety goggles or safety glasses with side shields when using your router Failure to do so could result in dust shavings chips loose particles or foreign objects being thrown in your eyes resulting in possible serious inj
13. RYOBI OPERATOR S MANUAL RE1802M1 ROUTER With R181FB1 Fixed Base R181PB1 Plunge Base and R181DB1 D Handle Base Double Insulated Your new router has been engineered and manufactured to our Ryobi s high standard for dependability ease of operation and operator safety When properly cared for the router will give you years of rugged trouble free performance A WARNING To reduce the risk of injury the user must read and understand the operator s manual before using this product Thank you for buying a Ryobi product SAVE THIS MANUAL FOR FUTURE REFERENCE TABLE OF CONTENTS HIMTFOCUCTIONS eM 2 General Safety R les setts actin ie Ie Ue i Ee De E Le et eee ere HD E TEE Rec a 3 4 Specific Safety RUES asrine stent eni e Hcet t e PERTH E aae Ce eo seeded rd ne a b Date e eg e bea 4 SVmbols ieitun nete muduicie p autista tertii estu ioter otisers 5 6 g HC 7 x tucp e M 8 9 ADAC as EU E aces ne ead eg 9 Operation 3 notet ui eR eee um etatem 10 22 Ele ES 23 ACCeSSOL OS cotes stacey dig tet ctl tied oet Sel etel Clicr ees Mo Or fett et sto sem citi te cA De Lone ot oa 23 Parts Ordering and Services sm rr rte ce ahmed id EX e ee E rera Ree er cede nag ie PUR Rae d rada 24 INTRODUCTION This router has many features for making its use more pleasant and enjoyable Safety performance and dependability have been given top priority in
14. Turn the depth adjusting ring counterclockwise until the tip of the cutter touches the flat surface 5 Turn the depth indicator ring until the zero lines up with the indicator point on the base Fig 10 6 Position the router so that the cutter can extend below the subbase for desired depth of cut 7 Turn the depth adjusting ring to obtain the desired depth of cut 8 Tighten the locking arm securely NOTE To adjust the depth of cut when the router is mounted to a router table turn the depth adjustment ring until the cutter reaches the desired depth of cut OPERATION TO ADJUST DEPTH OF CUT FOR PLUNGE BASE ROUTERS See Figures 11 12 and 13 Follow these steps to adjust depth of cut for plunge base routers 1 Unplug the router A WARNING Failure to unplug the tool could result in serious injury due to accidental starting Place the router on a flat surface Loosen the stop bar knob Unlock the plunge lock lever Plunge the router until the tip of the cutter touches the flat surface STOP BAR KNOB CUTTER o9 RON Lock the plunge lock lever Move the stop bar down so it touches the depth stop Tighten the stop bar knob securely Set the depth indicator to zero 0 Loosen the stop bar knob 1 Set the depth indicator to the desired depth of cut Note Each mark on the scale indicates 1 16 in 1 6 mm 12 Tighten the stop bar knob securely 13 Unlock the plunge lock lever 14 Positio
15. a clean dry rag Clean the taper in the shaft in the same manner Never immerse the collet or end of the shaft in a solvent or in water Before replacing the collet assembly put a drop of SAE30 motor oil on the inside of the nut on the threads of the shaft and on the taper in the shaft Replace the collet assembly onto the shaft by hand only Never tighten the collet nut without a bit in the collet This action could permanently damage the collet ADJUSTING LOCKING ARM TENSION Over time and with repeated use the locking arm may become loose When this occurs tighten the elastic stop nut slightly The elastic stop nut should be loose enough so there is some play in the locking arm when it is in the open position Make sure the motor housing does not move up or down when clamped NOTE Do not over tighten the elastic stop nut The locking arm should clamp tightly to secure the motor housing If the locking arm becomes worn beyond adjustment a repair kit is available Please contact your service center to order the appropriate router locking arm repair kit ACCESSORIES The following recommended accessories are included with the tool ACCESSORIES Template Guide Bushing Kit 4070177 Straight Guide sess 6090080 A WARNING The use of attachments or accessories not listed could be hazardous OPERATOR S MANUAL RE1802M1 ROUTER With R181FB1 Fixed Base R181PB1 Plunge B
16. al starting causing serious injury BI Place router upside down on workbench E Place template guide bushing in recessed portion of router subbase E Align the cutouts in guide bushing with threaded holes in subbase B6 Secure guide bushing to router subbase with screws provided B6 Tighten screws securely M Loosen the four subbase screws that secure the sub base to the router base B6 Set the cutter to desired depth and lock the depth lock B6 Adjust the subbase so that the end of the cutter is centered in the collar of the bushing B6 Tighten the four subbase screws securely A WARNING Failure to tighten screws could cause the bit to come in contact with the bushing resulting in serious injury Secure the template to the workpiece Set the router to the desired depth of cut and turn it on Place the router subbase on the template with the collar of the guide bushing against the edge of the template Lower the cutter into the workpiece and proceed around the template keeping the guide bushing pressed against the template edge When routing with the template guide bushings it is necessary to allow for size differences between the cutting edge of the cutter and the face of the guide bushing collar When making templates always allow for this size differ ence 21 ROUTER BIT TEMPLATE GUIDE BUSHING SCREW RECESS IN BASE SUBBASE TEMPLATE GUIDE
17. ase and R181DB1 D Handle Base Double Insulated e SERVICE Now that you have purchased your tool should a need ever exist for repair parts or service simply contact your nearest Ryobi Authorized Service Center Be sure to provide all pertinent facts when you call or visit Please call 1 800 525 2579 for your nearest Ryobi Authorized Service Center You can also check our Web site at www ryobitools com for a complete list of Authorized Service Centers e MODEL NO AND SERIAL NO The model number of this tool will be found on a plate attached to the motor housing Please record the model number and serial number in the space provided below e HOW TO ORDER REPAIR PARTS WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE FOLLOWING INFORMATION MODEL NUMBER RE1802M1 SERIAL NUMBER RYOBI TECHNOLOGIES INC 1428 Pearman Dairy Road Anderson SC 29625 Post Office Box 1207 Anderson SC 29622 www ryobitools com 983000 447 Phone 1 800 525 2579
18. eaken or destroy plastic Electric tools used on fiberglass material wallboard spackling compounds or plaster are subject to accelerated wear and possible premature failure as the fiberglass chips and grindings are highly abrasive to bearings brushes commutators etc Consequently we do not recommended that this tool be used for extended work on these types of materials If however you do work with any of these materials it is extremely important that you clean the tool frequently by blowing it with an air jet A 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 CUTTERS Get faster and 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 outside diameter Be sure when sharpening the end of a cutter to grind the clearance angle the same as originally ground COLLET Dust and chips may collect on the collet from time to time making it necessary to clean the collet To do so remove the collet assembly and wipe it with
19. epth setting before lowering the bit for the next pass This will also assure a uniform depth when the final pass is completed ROUTING Your router is a versatile tool and can be used for many different applications You may rout grooves carve designs using a template carve designs by freehand taper table and chair legs mortise door jambs or create joints ROUTING GROOVES See Figure 20 When routing across the face of boards set router at desired depth of cut place the edge of router base against workpiece and turn on the router Slowly feed the cutter into the workpiece along desired line of cut A WARNING If desired depth of cut is greater than can be safely cut in one pass make cuts in two or more passes When routing straight cuts across stock clamp a straight edge to the workpiece to use as a guide Position the straightedge parallel to the line of cut and offset the distance between the cutting edge of the cutter and the edge of the router base Hold the router base against the straightedge and rout the groove OPERATION When routing a groove wider than the diameter of the cutter clamp a straightedge on both sides of the cutlines Position both guides parallel to the desired line of cut and spaced equal distances from the desired edges of the groove Rout along one guide then reverse direction and rout along the other guide Clean out any remaining waste in the center of the groove freehand ROUTI
20. era A WARNING tion and instructing others who may use this product Observe all normal safety precautgions related to avoid ing electrical shock A WARNING The operation of any tool can result in foreign objects being thrown into your eyes which can result in severe eye damage Before beginning operation always wear safety goggles or safety glasses with side shields and a D full face shield when needed We recommend Wide Vision Safety Mask for use over eyeglasses or standard safety glasses with side shields Always wear eye protection which is marked to comply with ANSI Z87 1 SAVE THESE INSTRUCTIONS ELECTRICAL DOUBLE INSULATION Double insulation is a concept in safety in electric power tools which eliminates the need for the usual three wire grounded power cord All exposed metal parts are isolated from the internal metal motor components with protecting insulation Double insulated tools do not need to be grounded Important Servicing of a tool with double insulation requires extreme care and knowledge of the system and should be performed only by a qualified service technician For service we suggest you return the tool to your nearest authorized service center for repair When servicing use only identical Ryobi replacement parts A WARNING The double insulated system is intended to protect the user from shock resulting from a break in the tool s internal wiring Observe all normal safety precautions re
21. from 15 000 to 25 000 min EE EE nde ee Le aet AD Lk de ORT e 0 2in 0 51 mm 0 1 1 2 in 0 38 mm nuemtuhifuei eM E TEN aces ID Em 1 2 in 12 7 mm isti ieu iei e ha Rf Pe afr et 1 4 in 6 mm FS Da ukei c ueteri atus eae al nds ote J taut aa 10 ft 3 m rate See is ee ets IM I SS 19 Ibs 8 6 kg LOCKING ARM The locking arm secures the motor housing in the base CHIP SHIELD A plastic chip shield on the base of the router provides protection against flying dust and chips ERGONOMIC DESIGN The design of this tool provides for easy handling It is designed for comfort and ease of grasp when operating in different positions and at different angles ELECTRICAL CONNECTION Your router has a precision built electric motor It should be connected to a power supply that is 120 volts 60 Hz AC only normal household current Do not operate this tool on direct current DC A substantial voltage drop will cause a loss of power and overheating If your tool does not operate when plugged into an outlet double check the power supply DOUBLE INSULATION Double insulation is a concept in safety in electric power tools which eliminates the need for the usual three wire grounded power cord All exposed metal parts are isolated from the internal metal motor components with protecting insulation Double insulated tools do not need to be grounded FEATURES GOLD SPINDLE LOCK BUTT
22. ging a cutter im y SPINDLE LOCK BUTTON careful not to touch the cutter or collet with your hands or fingers They will get burned because of the heat buildup from cutting Always use the wrench provided 5 Choose one of these options A WARNING E Toremove the cutter If the collet nut is not securely tightened the cutter may Remove the cutter from the collet f ue detach during use causing serious personal injury W To insert the cutter a Insert the shank of the cutter until the shank bottoms out then pull it out 1 16 in 1 6 mm to A WARNING allow for expansion when the bit gets hot b Tighten the collet nut securely by turning it clockwise with the wrench provided C Release the gold spindle lock button Do not use cutters with undersized shanks Undersized shanks will not tighten properly and could be thrown from the tool causing injury A WARNING Do not use cutters that are larger in diameter than the opening in router subbase Use of such cutters will come in contact with the router subbase and damage both the cutter and router The use of larger cutters could also cause possible loss of control or create other hazardous conditions that could result in serious personal injury or death OPERATION ADJUSTING DEPTH OF CUT Proper depth of cut depends on several factors the peak horsepower of the router motor the type of cutter and the type of wood A lightweight low horsepower router
23. lated to avoiding electrical shock ELECTRICAL CONNECTION The router has a precision built electric motor It should be connected to a power supply that is 120 volts 60 Hz AC only normal household current Do not operate this tool on direct current DC A substantial voltage drop will cause a loss of power and the motor will overheat If your tool does not operate when plugged into an outlet double check the power supply EXTENSION CORDS When using a power tool at a considerable distance from a power source be sure to use an extension cord that has the capacity to handle the current the tool will draw An undersized cord will cause a drop in line voltage resulting in overheating and loss of power Use the chart to determine the minimum wire size required in an extension cord Only round jacketed cords listed by Underwriter s Laboratories UL should be used When working outdoors with a tool use an extension cord that is designed for outside use This type of cord is designated with WA on the cord s jacket Before using any extension cord inspect it for loose or exposed wires and cut or worn insulation Ampere rating on tool faceplaate 0 2 0 2 1 3 4 3 5 5 0 5 1 7 0 7 1 12 0 12 1 16 0 Cord Length Wire Size A W G 325 16 16 16 16 a 14 50 16 16 16 14 14 12 100 16 16 14 12 10 Used on 12 gauge 20 amp circuit A WARNING Keep the extension cord clear of the working area Posi
24. lve your safety Failure to keep your hands away from the blade will result in serious personal injury Failure to keep your hands away from the blade will result in serious personal injury Failure to keep your hands away from the blade will result in serious personal injury Failure to keep your hands away from the blade will result in serious personal injury SYMBOLS The following signal words and meanings are intended to explain the levels of risk associated with this product SYMBOL MEANING DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Without Safety Alert Symbol Indicates a situation that may result in property damage SERVICE Servicing requires extreme care and knowledge and should be performed only by a qualified service technician For service A WARNING we suggest you return the product to your nearest To avoid serious personal injury do not attempt to use AUTHORIZED SERVICE CENTER for repair When servicing this product until you read thoroughly and understand use only identical replacement parts completely the operator s manual Save this operator s manual and review frequently for continuing safe op
25. n smooth cuts if allowed to run freely without the overload of a forced too fast feed Three things that cause force feeding are bit size depth of cut and workpiece characteristics The larger the bit or the deeper the cut the more slowly the router should be advanced If the wood is very hard knotty gummy or damp the operation must be slowed still more You can always detect force feeding by the sound of the motor Its high pitched whine will sound lower and stronger as it loses speed Also the strain of holding the tool will be noticeably increased TOO FAST N TOO SLOW Feeding Too Slow See Figure 18 It is also possible to spoil a cut by moving the router forward too slowly When it is advanced into the work too slowly a revolving bit does not dig into new wood fast enough to take a bite instead it simply scrapes away sawdust like particles Scraping produces heat which can glaze burn or mar the cut and in extreme cases can even overheat the bit so as to destroy its hardness In addition it is more difficult to control a router when the bit is scraping instead of cutting With practically no load on the motor the bit will be revolving at close to top RPM and will have a much greater than normal tendency to bounce off the sides of the cut especially if the wood has a pronounced grain with hard and soft areas As a result the cut produced may have rippled instead of straight sides Too slow feedi
26. n the router so that the cutter can extend below the subbase for desired depth of cut 15 Plunge the router until the stop bar touches the depth stop 16 Lock the plunge lock lever to position the cutter at the desired depth of cut 2a D o WOO PLUNGE CUTTER Fig 13 OPERATION FEEDING THE ROUTER The secret of professional routing and edge shaping lies in making a careful set up for the cut and in selecting the proper rate of feed DIRECTION EXTERNAL See Figures 14 and 15 When routing the cutter rotates clockwise Therefore you should feed the router into the workpiece from left to right When you feed the router from left to right the rotation of the cutter pulls the router against the workpiece If you feed the router in the opposite direction the rotational forces of the spinning bit tend to throw the router away from the workpiece This action could cause you to lose control of the router The router motor and bit revolve in a clockwise direction This gives the tool a slight tendency to twist in a counterclockwise direction especially when the motor revs up Because of the extremely high speed of bit rotation during a proper feeding operation there is very little kickback to contend with under normal conditions However if the bit strikes a knot hard grain foreign object etc that affects the normal progress of the cutting action there will be a slight kickback This kickback is sufficie
27. nd cement and other masonry products and 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 approved safety equipment such as those dust masks that are specially designed to filter out micro scopic particles SYMBOLS Some of the following symbols may be used on this tool Please study them and learn their meaning Proper interpretation of these symbols will allow you to operate the tool better and safer SYMBOL NAME Volts Amperes Hertz Watt Minutes Alternating Current Direct Current No Load Speed Class II Construction Per Minute Wet Conditions Alert Read The Operators Manual Eye Protection Safety Alert No Hands Symbol No Hands Symbol No Hands Symbol No Hands Symbol DESIGNATION EXPLANATION Voltage Current Frequency cycles per second Power Time Type of current Type or a characteristic of current Rotational speed at no load Double insulated construction Revolutions strokes surface speed orbits etc per minute Do not expose to rain or use in damp locations To reduce the risk of injury the user must read and understand the operator s manual before using this product Always wear safety goggles or safety glasses with side shields and a full face shield when operating this product Precautions that invo
28. ness and moisture content of the wood the depth of cut and the cutting diameter of the bit When cutting shallow grooves in soft woods such as pine a faster rate of feed can be used When making deep cuts in hardwoods such as oak a slower rate of feed should be used The best rate of feed is one that does not slow down the router motor more than one third of its no load speed If the router is fed too fast it will take large chips out of the wood and leave gouge marks If the router is fed too slow it will scorch or burn the wood Feeding Too Fast See Figure 17 Clean smooth routing and edge shaping can be done only when the bit is revolving at a relatively high speed and is taking very small bites to produce tiny cleanly severed chips If your router is forced to move forward too fast the RPM of the bit becomes slower than normal in relation to its forward movement As a result the bit must take bigger bites as it revolves Bigger bites mean bigger chips and a rougher finish Bigger chips also require more power which could result in the router motor becoming overloaded Under extreme force feeding conditions the relative RPM of the bit can become so slow and the bites it has to take so large that chips will be partially knocked off rather than fully cut off resulting in splintering and gouging of the workpiece Your router is an extremely high speed tool 15 000 25 000 RPM no load speed and will make clea
29. ng can also cause your router to take off in a wrong direction from the intended line of cut Always grasp and hold your router firmly with both hands when routing You can detect too slow feeding by the runaway high pitched sound of the motor or by feeling the wiggle of the bit in the cut OPERATION DETERMINING DEPTH OF CUT See Figure 19 As previously mentioned the depth of cut is important because it affects the rate of feed that in turn affects the quality of the cut and also the possibility of damage to your router motor and bit A deep cut requires a slower feed than a shallow one and a too deep cut will cause Y mH you to slow the feed so much that the bit is no longer cutting it is scraping instead fy A Making a deep cut is never advisable The smaller bits especially those only 1 16 inch 1 6 mm in diameter are easily broken off when subjected to too much side thrust A large enough bit may not be broken but if the cut is too deep a rough cut will result and it may be very difficult to guide and control the bit as desired For these reasons we recommend that you do not exceed 1 8 in depth of cut in a single pass regardless of the bit size or the softness or condition of the workpiece To make deeper cuts it is therefore necessary to make as many successive passes as required lowering the bit 1 8 in for each new pass In order to save time do all the cutting necessary at one d
30. nt 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 bit rotation To guard against such a 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 bit is moving In short the thrust should be ina direction that keeps the sharp edges of the bit continuously biting straight into new uncut wood DIRECTION INTERNAL See Figure 16 Whenever you are routing a groove your travel should be in a direction that places whatever guide you are using at the right hand side That is when the guide is positioned as shown in the first part of the figure tool travel should be from left to right and counterclockwise around curves When the guide is positioned as shown in the second part of the figure tool travel should be right to left and clockwise around curves If there is a choice the first setup is generally the easiest to use In either case the sideways thrust you use is against the guide e lt cc e a lu a o cc 1 in to 1 in 6 35 mm to 25 4 mm ROUTER FEED DIRECTION i DIRECTION V ROUTER FEED DIRECTION GUIDE OUTSIDE BIT ROTATION GUIDE GUIDE INSIDE OPERATION RATE OF FEED The proper rate of feed depends on several factors the hard
31. t it from the receptacle Keep cord away from heat oil and sharp edges Following this rule will reduce the risk of electric shock or fire E 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 A wire gage size A W G of at least 14 is recommended for an extension cord 50 feet or less in length A cord exceeding 50 feet is not recom mended If in doubt use the next heavier gage The smaller the gage number the heavier the cord An undersized cord will cause a drop in line voltage result ing in loss of power and overheating E Inspect for and remove all nails from lumber before routing Following this rule will reduce the risk of serious personal injury E Drugs alcohol medication Do not operate tool while under the influence of drugs alcohol or any medication Following this rule will reduce the risk of electric shock fire or serious personal injury E Save these instructions Refer to them frequently and use them to instruct others who may use this tool If you loan someone this tool loan them these instructions also A WARNING Some dust created by power sanding sawing grinding drilling and other construction activities contains chemi cals known to cause cancer birth defects or other repro ductive harm Some examples of these chemicals are e lead from lead based paints crystalline silica from bricks a
32. ter to power supply when you are assembling parts making adjustments installing or re moving cutters or when not in use Disconnecting the router prevents accidental starting that could cause seri ous injury REMOVING AND INSTALLING THE ROUTER BASE gt TOSWITCHFROM THE FIXED BASE ORD HANDLE BASE n E TO THE PLUNGE BASE BUTTON See Figure 4 TO REMOVE THE FIXED OR D HANDLE BASE 1 Unplug the router LOCKING ARM A WARNING INDICATOR DEPTH ADJUSTMENT Failure to unplug the tool could result in accidental starting causing serious injury RING 2 Place the router upside down with the Ryobi label away from you L the locki th f 3 Loosen the locking arm on the base INDICATOR 4 Depress and hold the gold spindle lock button The gold POINT spindle lock button will not depress fully unless it is in line with the hole in the collet 5 Ifthe gold spindle lock button does not depress fully turn the collet nut while depressing the gold spindle lock button As they align the gold spindle lock button will depress fully 6 Turn the depth adjusting ring counterclockwise until the motor is to its highest position NOTE As the motor is rising the gold spindle lock button has to be depressed until it clears the rear window 7 Align the indicator arrow on the depth adjustment ring with the indicator point on the base 8 Pull the base until it dislodges from the motor housing TO INSTALL THE PLUNGE BASE CRO
33. than a full cut which will alter the shape of the finished edge NOTE When edge shaping with guides you can use any of the piloted bits without a pilot The size diameter of the pilot determines the maximum cut width that you can make with the pilot against the workpiece edge The small pilot exposes all of the bit the large one reduces this amount by 1 16 inch 1 6 mm When routing all edges of a panel or board rout the end grain first Any splintering that occurs at the corners will then be removed when routing the sides Start each side 1 4 in 6 35 mm away from the end Feed the cutter into the wood until the pilot contacts the uncut edge Then slowly back the router to shape the corner Next move the router forward to shape the rest of the edge Be careful to keep the pilot pressed against the uncut edge Repeat this procedure on each side of the panel TOP EDGE SHAPING 20 OPERATION ROUTER TEMPLATE GUIDE BUSHING KIT Sizes 5 16 in 7 16 in Short 7 16 in Long 1 2 in and 5 8 in ROUTING WITH THE GUIDE BUSHING You can accurately duplicate curves and complex shapes by fitting your router with a template guide bushing that extends below the subbase The router bit passes through the guide bushing The guide bushing then rides against a template TO INSTALL THE TEMPLATE GUIDE BUSHING See Figures 23 and 24 B Unplug your router A WARNING Failure to unplug your router could result in accident
34. the base TO INSTALL THE FIXED OR D HANDLE BASE 1 2 3 4 Unplug the router Place the fixed or D handle base on a flat surface Loosen the locking arm Align the indicator arrow on the depth adjustment ring with the indicator point on the base Align the groove in the motor housing with the tab inside of the base NOTE The tab is located on the inside of the base in line with the handle GROOVE IN MOTOR HOUSING 6 Depress and hold the gold spindle lock button on the motor BERT 7 Slide the motor housing into the base ADJUSTMENT 8 Turn the depth adjusting ring counterclockwise until RING the gold spindle lock snaps out as it clears the rear window just below the locking arm Tighten the locking arm INDICATOR INDICATOR POINT OPERATION REMOVING INSERTING CUTTERS See Figure 8 Follow these steps to remove or insert cutters 1 Unplug the router A WARNING Failure to unplug the tool could result in accidental start ing causing serious injury Nie TIGHTEN OO A CAUTION To prevent damage to the spindle or spindle lock always allow motor to come to a complete stop before engaging the spindle lock 2 Place the router upside down on a workbench in order to gain easy access to collet nut 3 Depress the gold spindle lock button 4 Loosenthe collet nut by turning it counterclockwise with the wrench provided A WARNING If h i tter immediately after use be you are chan
35. ury If the operation is dusty also wear a face or dust mask TURNING THE ROUTER ON OFF See Figure 2 Wi 7o turn on the router Move the switch to the I position B To turn off the router Move the switch to the O position OPERATING THE ROUTER See Figure 3 Follow these steps to operate the router 1 Unplug the router A WARNING Failure to unplug the tool could result in accidental start ing causing serious injury 2 Securely tighten the cutter in the collet nut Refer to Removing Inserting Cutters later in this manual 3 Setthe desired depth of cut Refer to Adjusting Depth of Cut later in this manual Secure the workpiece Plug the router into a power source Hold the router firmly with both hands Turn on the router and let the motor build to its full speed 8 Feed the cutter slowly into the workpiece NOTE Do not let the cutter contact the workpiece before starting the router and allowing it to develop full speed 9 Turn off the router upon completion of cut and let the motor come to a complete stop before removing the router from the workpiece nos A WARNING Never place the router down on a work surface before the cutter stops A WARNING Never attempt to use the router motor without first install ing it in one of the approved bases Failure to heed this warning could result in personal injury or damage to the motor OPERATION A WARNING Never connect the rou
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