MasterForce 241-0836 Operating instructions
- Category
- Power tools
- Type
- Operating instructions
1
OPERATING MANUAL
11 A 2.0 HP Plunge/Fixed Router
241-0836
Parts missing or damaged? Questions?
Toll-Free Help Line – 1-866-917-4374
IMPORTANT :
Read this operating manual carefully before using your new tool. Pay
close attention to all Safety Instructions, Warnings, and Caution sections.
Use your tool properly and only for its intended use
Safety symbols in this manual are used to indicate possible dangers. The
safety symbols and their explanations require your full understanding. The
safety warnings do not eliminate any danger by themselves, and they are not
a substitute for proper accident prevention measures.
This Safety Alert Symbol indicates caution, warning, or danger. Failure
to obey a safety warning may result in serious injury to yourself or to others.
To reduce the risk of injury, fire, or electric shock, always follow the safety
precautions.
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TABLE OF CONTENTS
Specification……………..…………………………..………..…..……Page 2
Rules for Safe Operation…………………………………………….…Page 3
Operation..………..………..………..………..………..………..………Page 8
Accessories..………..………..………..………..………..………...… Page 15
Maintenance..………..………..………..………..………..………..…Page 15
Exploded view and part list.............................................................................Page16
Warranty..………..………..………..………..………..………..…...…Page 23
SPECIFICATIONS
Motor: 120 V 60 Hz 11 A
Horsepower: 2.0 HP
Speed: 11000–25000 RPM, soft start (no load)
Collet capacity: 1/4 & 1/2”
Plunge stroke: 2 ”
Base imension:
Fixed base 6”
Plunge base 6 1/2”
Inside base diameter: 2”
Micro-fine depth: Adjusts to 1/64”
Spindle lock: Yes
Depth stop: 4-stage turret stop
Weight: 12 lb (5.4 kg)
RULES FOR SAFE OPERATION
KNOW YOUR TOOL
Before operating this tool, carefully read this operating manual and all of the
labels affixed to the router. Keep this manual available for future reference.
IMPORTANT
This tool should only be serviced by a qualified service technician.
READ ALL INSTRUCTIONS THOROUGHLY
GENERAL SAFETY RULES FOR ALL POWER TOOLS
WARNING!Read and understand all instructions. Failure to follow all in-
structions listed below may result in electric shock, fire and/or serious per-
sonal injury.
WORK AREA
Keep the work area clean and well lit. Cluttered benches and dark areas
invite accidents.
Do not operate power tools in an explosive environment, such as in the
presence of flammable liquids, gases, or dust. Power tools create sparks
which may ignite 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
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.
120V ~ 60Hz
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Water entering a power tool will increase the risk of electric shock.
Do not 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. The following table shows the correct size to
use, depending on cord length and nameplate amperage rating of the tool.
When in doubt, use the next heavier gauge. Always use UL and CSA listed
extension cords.
Recommended sizes of extension cords
Tool’s Ampere rating Volts
Total length of cord in feet
Cord size in A. W. G.(minimum)
25’ 50’ 100’ 150’
0-6
120
V~
18 16 16 14
6-10 18 16 14 12
10-12 16 16 14 12
PERSONAL SAFETY
Stay alert, watch what you are doing and use common 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 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 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.
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.
Do not overreach. Keep proper footing and balance at all times.Proper footing
and balance enables better control of the 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.
Before connecting the tool to a power source (receptacle, outlet, etc.), be
sure voltage supplied is the same as that specified on the nameplate of
the tool. A power source with voltage greater than that specified for the
tool can result in serious injury to the user – as well as damage to the tool.
TOOL USE AND CARE
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.
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 is designed.
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.
Disconnect the 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.
Store idle tools out of reach of children and other untrained persons.
Tools are dangerous in the hands of untrained users.
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.
Check for misalignment or binding of moving parts, breakage of parts,
and any other condition that may affect the tools operation. If damaged,
have the tool serviced before using. Many accidents are caused by poorly
maintained tools.
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.
Do not alter or misuse tool. These tools are precision built. Any alteration or
modification not specified is misuse and may result in a dangerous condition.
Service
Tool service must be performed only by qualified repair personnel.
Service or maintenance performed by unqualified personnel could result
in a risk of injury.
When servicing a tool, use only identical replacement 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.
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SPECIFIC SAFETY INSTRUCTIONS FOR THE PLUNGE ROUTER
WARNING: Read all instructions. Failure to comply with all of the follow-
ing instructions may result in electric shock, fire and/or serious injury.
• Hold the power tool by its insulated grips when performing any operation
in which the cutting tool may come into contact with concealed wiring
or its own cord. Contact with a “live” wire will also make exposed metal
parts of the tool “live” and subject the operator to electric shock.
• Use clamps or another practical means of securing and supporting the
workpiece to a stable platform. Holding the work by hand or against your
body leaves it unstable and may result in loss of control.
• Keep the handles dry, clean, and free of oil or grease. This will permit
better control of the tool.
• Keep hands away from cutting area. Never place your hands beneath the
workpiece for any reason. Keep the base of the router in firm contact with
the workpiece when cutting. Grip the router only by its handles. These
precautions will reduce the risk of personal injury.
• Use sharp bits. Dull bits may cause the router to swerve or stall under
pressure.
• Never touch the bit immediately after use. It may be extremely hot.
• Be sure that the motor has completely stopped before you put the router
down. Injury or damage could result from a head that is still spinning when
the tool is laid down.
• Be sure that the router bit is clear of the workpiece before starting the
motor. If the bit is in contact with the workpiece when the motor starts, the
router could jump, resulting in damage or injury.
• Only use router bits with a shank diameter equal to the size of the tool’s
collet.
• Only use router bits suitable for the tool’s no-load speed.
• Make sure the collet nut is securely tightened to prevent the router bit
from slipping during use.
• Avoid prolonged contact with dust from power sanding, sawing, grinding,
drilling, and other construction activities. Wear protective clothing and
wash exposed areas with soap and water. Allowing dust to get into your
mouth, eyes or remain on your skin may promote absorption of harmful
chemicals.
WARNING: Use of this tool can generate and/or disperse dust, which may
cause serious and permanent respiratory or other injuries. Always use the ap-
propriate certified respiratory device to protect against dust exposure. Direct
particles away from face and body.
CAUTION: Wear an appropriate personal hearing protective device dur-
ing use. Noise caused by this product could contribute to hearing loss under
certain conditions and periods of use.
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OPERATION
KNOW YOUR ROUTER (see Fig. 1)
Before attempting to use this router, familiarize yourself with all of its
operating features and safety requirements.
This electric router is designed to be used only for straight and grooved
milling and edge forming in wood or similar materials. Any other use of
the router that is not indicated in this manual could damage the router or
seriously injure the operator, and therefore, is expressly excluded from the
application range.
1. ON/OFF switch. Push
the ON/OFF switch to
the ”I” position to turn
the router on. Return
the switch to the “O”
position when the
routing operation is
completed.
2. Locking arm. Use the
locking arm to set the
desired cutting depth.
3. Cable. Provides power
to the router when
connected to a power
source.
4. Lock nut. Locks the
parallel guide.
5. Base plate. Supports
the router.
6. Depth stop. Adjust to
four different cutting
depths by turning it
clockwise or counter-
clockwise.
7. Handle. Hold both
handles when starting
the routing operation.
8. Adjustment bar. Adjust
the cutting depth by
moving it up or down.
9. Variable speed dial. Six variable speeds allow the operator to control and
adjust to speed and power specifications. The speed and power of the
router can be increased or decreased by rotating the dial.
10. Collet. Clamps the bits in place.
11. Dust extraction adaptor. Collects the dust that is produced by the routing
operation.
12. Lock lever. Locks the motor pack into the fixed base or the plunge base.
13. Adjustment button. Press the button in order to allow the motor pack to
move freely.
14. Depth adjustment knob. When using the fixed base, adjust the cutting
depth by turning it clockwise or counter-clockwise.
15. Spindle lock. Locks the spindle when changing the milling cutter.
16. Ready indicator. When the router is plugged in, the ready indicator
displays a green light to indicate that the router is ready to use. The light
goes off when the router is unplugged.
17. LED worklight. When the router is plugged in and the ON/OFF switch is in
the ON position, the LED worklight illuminates the milling area (see Fig. 6).
SWITCHING FROM THE FIXED BASE TO THE PLUNGE BASE (see Fig. 2 to Fig. 5)
To remove the fixed base
• Unplug the router.
• Loosen the lock lever on the xed
base.
• Hold the motor pack with one
hand, and depress and hold the
adjustment button with the other
hand.
• Remove the motor pack from the
fixed base.
To Install the plunge base
• Loosen the lock lever
• Tighten the locking arm for
stability.
• Align the tab on the motor pack
with the slot in the plunge base.
• Tighten the lock lever.
• Loosen the locking arm.
Fig. 1
Plunge Base
Fix Base
9
3
7
8
15
17
6
5
1
7
10
4
16
2
14
7
12
4
11
7
5
7
13
12
11
Fig. 2
Fig. 3
Fix Base Motor
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SWITCHING FROM THE PLUNGE
BASE TO THE FIXED BASE (see
Fig. 2. to Fig. 5)
To remove the plunge base
• Unplug the router.
• Loosen the lock lever.
• Tighten the locking arm for
stability.
• Remove the motor pack from the
plunge base.
To install the fixed base
• Loosen the lock lever on the xed
base.
• Depress and hold the adjustment
button.
• Align the tab on the motor pack
with the slot in the fixed base.
• Tighten the lock lever.
INSTALLING/REMOVING THE MILLING CUTTER
To install the cutter (see Fig.6)
• Unplug the router.
• Hold the collet nut using the
wrench that is provided, and
depress the spindle lock until it
locks into place.
• Loosen the collet nut, insert the
cutter.
• Tighten the collet nut using the
wrench that is provided.
• Release the spindle lock.
To remove the cutter
• Hold the collet nut using the wrench that is provided, and depress the
spindle lock until it locks into place.
• Loosen the collet nut, and remove the cutter.
• Release the spindle lock.
SETTING THE CUTTING DEPTH FOR
FIXED BASE ROUTING (see Fig. 7)
The bit depth can be adjusted by
turning the depth adjustment knob
clockwise or counter-clockwise.
The cutting depth can be read on
the depth adjustment knob. Each
mark on the scale indicates a
change in the depth setting of 1/64”.
• Unplug the router.
• Loosen the lock lever.
• Turn the depth adjustment knob clockwise or counter-clockwise to move
the collet down or up.
• When the desired cutting depth is set, tighten the lock lever.
SETTING THE CUTTING DEPTH FOR PLUNGE BASE ROUTING(see Fig. 8)
The cutting depth can be adjusted
in two ways: by depressing the
handles, or by turning the depth
stop on the plunge base.
• Unplug the router.
• Loosen the adjustment bar knob.
• Pull the locking arm up.
• Lower the router until the router
bit touches the workingpiece.
• Push the locking arm down.
• Move the pointer of adjustment bar to the zero position on the scale.
• Add the desired depth of cut to the position on the scale.
• Move the adjustment bar to the calculated position on the scale.
• Tighten the adjustment bar knob.
• Fine adjust using the ne adjustment knob.
• Pull the locking arm up and let the router return to its original positon.
• Swith the router on, then lower the unit to make the desired cut.
Fig. 5
Fig. 7
Depth adjustment knob
Fig. 4
Plunge Base
Fig. 6
LED
worklight
Fig. 8
Adjustment bar
Adjustment
bar knob
Depth stop
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OPERATING THE ROUTER
• Place the router on the workpiece and turn it on.
• Slowly push the router downward until the milling cutter contacts the
workpiece.
• Mill out the groove using a continuous, even motion.
• When the milling process is complete, raise the router and turn it off.
ELECTRONIC SPEED ADJUSTER
The speed of your router is variable (6 variable speeds). Use the variable
speed dial (9) to produce uniform results in wood, plastics and similar
material. Use lower settings for large diameter bits and higher settings for
small diameter bits.
USING THE ROUTER
• Make sure that the material to be cut is securely clamped and provides
sufficient stability to support the router while it is operating.
• To control the router, keep both hands on the grips.
• Rotate the router counter-clockwise when cutting outside edges. Rotate it
clockwise when cutting inside edges.
• Always hold the router from the front, ensuring that the chip shield is
between yourself and the bit.
• After setting the cutting depth as described, position the router so that
the bit is directly above the point you plan to cut. With the router running,
lower the unit smoothly into the workpiece. (DO NOT FORCE THE ROUTER
DOWN.) When the tool reaches its pre-set depth, tighten the plunge
release lever. Once you have finished routing, loosen the plunge release
lever and allow the spring to lift the router directly out of the workpiece.
NOTE: Always feed the workpiece to the router against the direction of the
bit’s rotation.
FEED SPEED AND RATE OF CUT
Feed rate depends on the material and bit configuration. Experience is the
best guide. Become familiar with the sound and feel of the router by making
practice cuts on scrap materials. Perform a preliminary adjustment of the
speed control, selecting a higher speed for smaller diameter bits and a lower
speed for larger diameter bits.
The router bit rotates at a very high speed and may heat up, causing burn
marks if the router is moved too slowly through the wood. Feeding the
router too quickly or trying to remove too much material in a single pass will
overload the motor. Use two or more passes for extra-large cuts, especially
in the case of hardwood.
ROUTING WITH AN EDGE GUIDE
The edge guide is an accessory that allows you to rout a straight groove or
other shape parallel to the edge of your workpiece.
Mount the edge guide as following:
• Loosen the two lock bolts on the router
• Feed the metal rods on the edge guide through the holes in the router’s
base.
• Adjust the distance between the router bit and the edge guide by moving
the guide until it is at the correct distance.
• Tighten the lock bolts to secure the edge guide in position.
• Place the router on the edge of the workpiece with the bit not contacting
the workpiece.
• Turn the router on and allow the motor to reach full speed.
• Gradually move the bit toward the workpiece
• When cutting is complete, turn the router off and let the bit come to a
complete stop before removing the router from the workpiece.
CHIP SHIELD DEFLECTOR (Fig.9)
WARNING: ALWAYS wear eye protection. The chip shield deflector
is intended as a safety guard.
The chip shield deflector help keep dust and chips away from the operator;
they will not stop objects larger than woodchips thrown from the bit. The chip
shield deflector on the plunge base is held in position by a screw. To remove
the shield from the plunge base, simply remove the screw and take the shield
off of the base.
WARNING: The chip shield
deflector helps keep dust and chips
away from the operator; it will not
stop objects larger than woodchips
thrown from the bit.
CAUTION: ALWAYS have the
chip shield deflector in place on the
base when operating the router.
DUST COLLECTION WITH DUST
Fig. 9
screw
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EXTRACTION HOOD
There are two dust extraction
hoods included with this router.
The hood is sized to accept a
1-1/2-in. vac hose adapter(sold
separately).
To attach the hood onto the plunge
/fixed base, position and secure it
to the base with the two screws
(included) as shown in Fig.10a &
Fig.10b.
WARNING: ALWAYS turn mo-
tor off and unplug router from power
source before making any adjustments
or installing accessories. Failure to turn
motor off and unplug router could result
in accidental starting which can cause
serious personal injury.
TIPS FOR OPTIMAL USE
• The feed motion of the router
must always be carried out
against the rotation direction of the router bit (up-grinding).
When milling in the direction with the rotation of the router bit (down-
cutting),the router can break loose, eliminating control by the user.
• Use HSS (high speed steel) router bits for softwood.
• Use TCT (tungsten carbide tipped) router bits for hardwood.
• No guide is required for use of the tool. This is useful for writing signs and
performing creative work. Only make shallow cuts.
• Refer to the following table for common types of router bits.
ACCESSORIES
(see Fig. 11)
1. Collet wrench
2. Straight edge guide
3. Pattern guid
4. Dust-extraction adaptors
MAINTENANCE
Before cleaning or performing any maintenance, verify that the router has
been disconnected from the power supply. Keep all ventilation openings
clean. Avoid using solvents when cleaning plastic parts. Most plastics are
susceptible to damage from various types of commercial solvents. Use a
clean cloth to remove dirt, oil, and grease.
WARNING: Do not let brake fluids, gasoline, petroleum-based products,
penetrating oil, etc., come into contact with plastic parts. They contain chemi-
cals that can damage, weaken, or destroy plastic.
WARNING: To ensure safety and reliability, all repairs should be performed
by a qualified service technician.
Fig. 10a
2 screws included
2 screws included
Fixed base
Plunged base
Fig. 10b
Fig. 11
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Exploded View
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Parts List
No. Part Name Qty
Motor Unit:
1 Screw 2
2 Rear Cover 1
3 Screw 2
4 Transparent Cap 1
5 PCB Plate 1
6 Seal Ring 1
7 Switch 1
8 Screw 2
9 Taping Screw 2
10 Cord Anchorage 1
11 Power Indicator Light 1
12 Screw 2
13 Power Cord 1
14 Cord Guard 1
15 Bush Cover 2
16 Carbon Brush 2
17 Brush Holder 2
18 Middle Housing 1
19 Stator 1
20 Screw 2
21 Bearing Holder 1
22 Washer 1
23 Gasket 1
24 Bearing 1
25 Fan Baffle 1
26 Rotor 1
27 Depth Indicator 7
28 Depth Adjusting Bolt 1
29 Depth Stop Bar 1
30 Screw 2
31 Plunge Lock Lever 1
32 Slotted Set Screw 1
33 Wave Washer 1
34 Nut 2
35 Left Handle Cover 1
36 Hexagon Socket Screw 1
37 Spring Washer 2
38 Plain Washer 1
39 Left Handle 2
40 Plunge Frame 2
Fixed Unit:
41 Screw 2
42 Right Handle 1
43 Left Handle 1
No. Part Name Qty
44 Lock Bolt 5
45 Mounting 1
46 Chip Shield 1
47 Base Plate 1
48 E Ring 1
49 Spring 1
50 Lock Gear 1
51 Gear 1
52 Gear Shaft 1
53 Button 1
54 Shaft 1
55 Worm 1
56 Screw 1
57 Indicator Ring 1
58 Adjusting Knob 1
59 Screw 1
60 Screw 1
61 Lock Pin 1
62 Clamping Lever 1
63 Plate 1
64 Lock Nut 2
65 Screw 6
66 Washer 1
67 Located Pin 2
Plunge Unit:
68 Screw 1
69 Depth Adjusting Cap/ 1
70 ‘’O’’ Ring 1
71 Depth Stop Bar 1
72 Adjusting Pole 1
73 Depth Indicator 1
74 Screw 4
75 Left Handle Cover 1
76 Screw 2
77 Left Handle 1
78 Right Handle 1
79 Right Handle Cover 1
80 Cover 1
81 Circlips of Shaft 1
82 Spring Washer 1
83 Plunge Lock Lever 1
84 Torsion Spring 1
85 Bolt 1
86 Pin 1
87 Clamping Lever 1
88 Mitre Lock Bolt 1
89 Plunge Frame 1
22
23
No. Part Name Qty
90 Oil Impreging Bearing 1
91 Bush 1
92 Spring 2
93 Bellows Seal 2
94 ‘’O’’Ring 1
95 Long Plunge Rod 1
96 Plunge Rod 1
97 Screw 1
98 Wave Washer 1
99 Turn Table 1
100 Steel Ball 1
101 Spring 1
102 Chip Shield 1
103 Spring Pin 2
104 Mouting 1
105 Base Plate 1
Accessory:
106 Screw 2
107 Spring Washer 2
108 Plain Washer 2
109 Parallel Guide 1
110 Guiding Rod 2
111 Vaccum Adapter 1
112 Collet 1
113 Screw 3
114 Vaccum Adapter 1
115 Wrench 1
116 Screw 2
117 Guide Bush 1
118 Nut 2
WARRANTY
If, during normal use, this MASTERFORCE
TM
power tool breaks or fails due
to a defect in material or workmanship within three years from the date of
original purchase, simply bring this tool and its sales receipt back to your
nearest Menards
®
retail store for a free equivalent replacement within those
three years.
The warranty:
(1) excludes expendable parts including but not limited to blades, bits, light
bulbs, and/or batteries;
(2) shall be void if this tool is used for commercial or/and rental purposes;
and
(3) does not cover any losses, injuries to persons/properties, or costs. This
warranty does give you specific legal rights and you may have other
rights, which vary from state to state.
*SAVE YOUR RECEIPTS. Your warranty is void without them. For help, please
call to our customer center, toll free number: 1-866-917-4374.
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MasterForce 241-0836 Operating instructions
- Category
- Power tools
- Type
- Operating instructions
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