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Installing the Bit
It is not necessary to remove the motor from the
base to install a collet assembly or a bit. If removal
of the base is desired, see previous section. Always
remove wood chips, dust or other foreign materials
from the collet shaft and collet assembly before
assembling.
Insert the collet assembly into the collet shaft. Insert
the bit shank into the collet as follows:
1. Unplug the tool.
2. Insert the bit shank into the collet as far as it will
go.
3. Back the bit shank out slightly to avoid bottoming
out.
4. Be sure there is a minimum of 1/16" between the
bottom of the collet assembly and the radius to
the cutting portion of the bit (Fig. 10).
Fig. 10
Collet nut
Collet
Bit shank
Minimum
1/16"
5. Be sure that the collet is not clamped to a fl uted
section on the bit shank. The collet should be
clamped to a solid part on the bit shank to ensure
a tight grip.
Fig. 11
To tighten the bit in the
collet assembly, use two
wrenches (Fig. 11).
NOTE: Never tighten a
collet assembly without
inserting a bit shank of
the proper size. This may
damage the collet.
Removing the Bit
1. Unplug the tool.
2. Loosen the collet nut from the collet shaft using
two wrenches.
3. Once loose, unscrew the collet nut by hand until
it feels tight again.
4. Use the wrenches again until the bit shank can
be pulled out.
OPERATION
WARNING
To reduce the risk of injury,
wear safety goggles or glasses with side
shields.
Unplug the tool before changing accessories
or making adjustments.
Never make adjustments while the router is
running.
DO NOT use the router if the locking lever
does not hold the motor securely in the
base.
NEVER use the Plunge Base Router models
in a router table.
Adjusting the Depth of Cut
Bodygrip®, D-Handle and Production bases:
The tool depth can be adjusted by using the depth
adjustment knob or a 3/8" socket wrench with an
extension, or the Above-the-table Depth Wrench
(Cat. No. 49-96-0370).
When using the depth adjustment knob, fully open
the locking lever and rotate knob to the desired
depth of cut. One revolution of the depth adjust-
ment knob is equal to 0.2". For fi ne adjustments
less than 5/32", use the independent scale on the
depth adjustment knob.
For deeper cuts:
1. Align the "0" on the scale with the arrow on the
tool.
2. Rotate depth adjustment knob clockwise to
desired depth measurement.
For shallower cuts:
1. Align the desired depth measurement with the
arrow on the tool.
2. Rotate depth adjustment knob counterclockwise
to "0."
Push in locking lever to fully closed position when
fi nished adjusting.
When using a socket wrench, place the router
upside down on a fl at surface and fully open the
locking lever. Insert a 3/8" socket wrench into the
hole on the base and turn to desired depth (Fig. 12).
Push in locking lever to fully closed position.
Fig. 12
8
Plunge base:
1. Unplug the tool.
2. Install the bit.
3. Press the plunge release lever and push down
on the handles until the bit touches the work-
piece.
4. Loosen the depth stop rod locking screw.
5. Turn the turret so the full depth position is directly
below the rod
6. Press the depth stop rod release button to lower
the rod. It should rest on the full depth position
of the turret.
7. Place the adjustable pointer on "0".
8. Press in the depth stop rod release button Move
the rod up to the desired depth of cut.
9. Use the depth adjustment knob to fi nely tune the
depth of cut.
10.Tighten the depth stop rod locking screw.
11.To obtain the cut making multiple passes, rotate
the turret to a higher step. Each step is 1/8"
NOTE: A fi ne fi nish can be made using the turret
and multiple passes.
Fig. 13
Depth stop rod
1/2"
5/8"
3/8"
1/4"
1/8"
full
Turret
depth
position
Holding the Tool
These tools should be held using both hands at all
times for maximum control.
For Bodygrip® bases:
Fig. 14
Alternate
strap
positions
You can hold this tool using the body grip and ball
handle or both ball handles. The body grip fea-
tures an adjustable strap, which can be attached
in two different positions for maximum control and
comfort.
One handle on these bases may be adjusted to
three different positions for maximum control and
comfort.
For D-Handle base:
Fig. 15
Alternate
handle
positions
Grip the D-handle with one hand and place the
other on the ball handle.
One handle on these bases may be adjusted to
three different positions for maximum control and
comfort.
For Plunge and Production bases:
WARNING
To reduce the risk of
injury, NEVER use the Plunge Base Router
in a router table.
Fig. 16
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