For technical questions or replacement parts, please call 1-800-444-3353.
Page 2
SAVE THIS MANUAL
Keep th i s manua l for the safety
warnings and precautions, assem b ly,
operating, inspection, maintenance and
cleaning procedures. Write the product’s
serial number in the back of the manual near
the assembly diagram (or month and year of
purchase if product has no number). Keep
this manual and the receipt in a safe and dry
place for future reference.
NOTICE is used to
address practices
not related to personal injury.
CAUTION, without
the safety alert
symbol, is used to address
practices not related to
personal injury.
IMPORTANT SAFETY
Safety Alert Symbol and Signal
Words
In this manual, on the labeling,
and all other information
provided with this product:
This is the safety alert
symbol. It is used to alert
you to potential personal
injury hazards. Obey all
safety messages that
follow this symbol to avoid
possible injury or death.
DANGER indicates
a hazardous
situation which, if not
avoided, will result in death or
serious injury.
INSTRUCTIONS
INSTRUCTIONS PERTAINING
TO A RISK OF FIRE,
ELECTRIC SHOCK, OR
INJURY TO PEOPLE
WARNING – When using tools, basic
precautions should always be
followed, including the following:
General
To reduce the risks of electric a.
shock, re, and injury to people,
read all the instructions before
using the tool.
Work area
WARNING
indicates a
hazardous situation which, if
not avoided, could result in
death or serious injury.
CAUTION, used
with the safety
alert symbol, indicates a
hazardous situation which, if
not avoided, could result in
minor or moderate injury.
Keep the work area clean and well a.
lighted. Cluttered benches and dark
areas increase the risks of electric
shock, re, and injury to people.
Do not operate the tool in b.
explosive atmospheres, such as in
the presence of ammable liquids,
gases, or dust. The tool is able to
create sparks resulting in the ignition
of the dust or fumes.
Keep bystanders, children, and c.
visitors away while operating the
Do not use the tool if the Trigger e.
does not turn the tool on or off.
Any tool that cannot be controlled
with the Trigger (3) is dangerous and
must be repaired. Do not use the tool
if the lock mechanism cannot lock the
Trigger in the “OFF” position.
Service
Tool service must be performed a.
only by qualied repair personnel.
When servicing a tool, use only b.
identical replacement parts. Use
only authorized parts.
Disconnect the tool from the air f.
source before making any adjustments, changing accessories, or
storing the tool. Such preventive
safety measures reduce the risk of
starting the tool unintentionally. Turn
off and detach the air supply, safely
discharge any residual air pressure,
and let the Trigger (3) return to its
“OFF” position.
Store the tool when it is idle out of g.
reach of children and other untrained people. A tool is dangerous
in the hands of untrained users.
Maintain the tool with care. h. Keep a
cutting tool sharp and clean. A properly maintained tool, with sharp cutting edges reduces the risk of binding
and is easier to control.
Use only the lubricants supplied c.
with the tool or specied by the
manufacturer.
Air source
a. Never connect to an air
source that is capable of
exceeding 200 psi. Over
pressurizing the tool may
cause bursting, abnormal operation,
breakage of the tool or serious injury
to people. Use only clean, dry,
regulated compressed air at the rated
pressure or within the rated pressure
range as marked on the tool. Always
verify prior to using the tool that the
air source has been adjusted to the
rated air pressure or within the rated
air-pressure range.
Check for misalignment or bind-i.
ing of moving parts, breakage of
parts, and any other condition that
affects the tool’s operation. If dam-
aged, have the tool serviced before
using. Many accidents are caused
by poorly maintained tools. There is a
risk of bursting if the tool is damaged.
Use only accessories that are j.
identied by the manufacturer for
the specic tool model. Use of an
accessory not intended for use with
the specic tool model, increases the
risk of injury to people.
Never use oxygen, carbon dioxide, b.
combustible gases or any bottled
gas as an air source for the tool.
factors which cannot be built into this
product, but must be supplied by the
operator.
INSTRUCTIONS
Symbol Denitions
Property or statement1.
n
o
.../min
PSI
ft-lb
BPM
CFM
SCFM
NPT
NPS
Specic Safety Instructions
The warnings and precautions 1.
discussed in this manual cannot
cover all possible conditions and
situations that may occur. It must
be understood by the operator that
common sense and caution are
No-load speed
Revolutions or reciprocation per
minute
Pounds per square inch of pressure
Foot-pounds of torque
Blows per minute
Cubic Feet per Minute ow
Cubic Feet per Minute ow at
standard conditions
National pipe thread, tapered
National pipe thread, straight
WARNING marking concerning Risk
of Eye Injury. Wear ANSI-approved
eye protection.
WARNING marking concerning Risk
of Hearing Loss. Wear hearing
protection.
WARNING marking concerning Risk
of Respiratory Injury. Wear NIOSH-
approved dust mask/respirator.
WARNING marking concerning Risk
of Explosion.
WARNING:2. 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
approved safety equipment, such as
those dust masks that are specially
designed to lter out microscopic
particles. (California Health & Safety
Code § 25249.5, et seq.)
WARNING: The brass components
of this product contain lead, a
chemical known to the State of
California to cause birth defects (or
other reproductive harm). (California
Health & Safety code § 25249.5, et seq.)
Only use with accessories rated to 3.
handle the forces exerted by this tool
during operation. Other accessories
not designed for the forces generated
may break and forcefully launch
pieces.
Attach all accessories properly to the 4.
tool before connecting the air supply.
A loose accessory may detach or
break during operation.
When unpacking, check to make sure
that the item is intact and undamaged. If
any parts are missing or broken, please
call Harbor Freight Tools at the number
shown throughout the manual as soon as
possible.
This air tool may be shipped with a •
protective plug covering the air inlet.
Remove this plug before set up.
TOOL SET UP & ASSEMBLY
Read the ENTIRE IMPORTANT
SAFETY INFORMATION
section at the beginning of this
manual including all text under
subheadings therein before set
up or use of this product.
FIGURE B
3/4”
SPANNER
WRENCH
(34)
RETAINER (26)
COLLET (28)
COLLET NUT (29)
9/16””
SPANNER
WRENCH
(35)
Assembly
A male Quick Connector (not 1.
included) must be installed prior to
operating the Air Router. To do so:
Note: For additional information regarding
the parts listed in the following pages,
refer to the Assembly Diagram near
the end of this manual.
Components and Controls
Wrap about three inches of pipe •
thread sealer tape (not included)
around the threads of the Quick
Connector. Then screw the Quick
Connector rmly into the Air Inlet
(14) of the tool. (See Figure A.)
To install a 1/4” Router Bit (not 2.
included) into the Air Router:
Firmly grasp the Housing (1) and •
the Housing Cap (30), turning them
in opposite directions. Completely
unwind and separate the two items.
Use the 3/4” Spanner Wrench (34) •
and 9/16” Spanner Wrench (35) to
loosen the Collet Nut (29).
Insert the Router Bit fully into the •
Collet (28).
Firmly tighten the Collet Nut, •
using the Spanner Wrenches.
(See Figure B.)
the Housing (1) and turn clockwise
to tighten securely. At least two full
threads of the Router Base should
engage the threads of the Housing
Cap (30).
CAUTION: For added safety, •
remove the bit after each use.
Air Supply
TO PREVENT
EXPLOSION:
Use only clean, dry, regulated,
compressed air to power this
tool. Do not use oxygen,
carbon dioxide, combustible
gases, or any other bottled
gas as a power source for this
tool.
Valve
Male
Connector
Quick
Coupler
Oiler
Filter
Male
Connector
Air Hose
on Reel
Note: If an automatic oiler system is not
used, add a few drops of Pneumatic
Tool Oil DAILY into the tool’s male
Quick Coupler before operation.
(See Figure A.)
Attach an air hose to the 2.
compressor’s air outlet. Connect
the air hose to the air inlet of the
tool. Other components, such as
a connector and quick coupler, will
make operation more efcient, but
are not mandatory.
WARNING! TO PREVENT SERIOUS
INJURY FROM ACCIDENTAL
OPERATION:
Do not install a female quick
coupler on the tool. Such a coupler
contains an air valve that will allow
the air tool to retain pressure and
operate accidentally after the air
supply is disconnected.
Note: Air ow, and therefore tool
performance, can be hindered by
undersized air supply components.
The air hose must be long enough 3.
to reach the work area with enough
extra length to allow free movement
while working.
Quick
Coupler
Regulator with
Pressure Gauge
Recommended Air Line Components
1. Incorporate an in-line oiler, shut-off
valve, regulator with pressure gauge,
and lter for best service, as shown
in the diagram above. An in-line
shutoff valve is an important safety
device because it controls the air
supply if the air hose is ruptured.
Make sure the tool’s Trigger (3) is in 4.
the off position; refer to Operation
section for description of controls.
Close the in-line safety valve between 5.
the compressor and the tool.
Turn on the air compressor according 6.
to the manufacturer’s directions and
allow it to build up pressure until it
cycles off.
Adjust the air compressor’s output 7.
regulator so that the air output is
enough to properly power the tool,
but the output will not exceed the
tool’s maximum air pressure at any
time. Adjust the pressure gradually,
while checking the air output gauge
until the required pressure valve is
indicated on the gauge.
Inspect the air connections for leaks. 8.
Repair any leaks found.
If the tool will not be used at this 9.
time, turn off and detach the air
supply, safely discharge any
residual air pressure, and release
the throttle and/or turn the switch to
its off position to prevent accidental
operation.
Note: Residual air pressure should not be
present after the tool is disconnected
from the air supply. However, it is a
good safety measure to attempt to
discharge the tool in a safe fashion
after disconnecting to ensure that the
tool is disconnected and unpowered.
OPERATING INSTRUCTIONS
Read the ENTIRE IMPORTANT
SAFETY INFORMATION
section at the beginning of this
manual including all text under
subheadings therein before set
up or use of this product.
Inspect tool before use, looking
for damaged, loose, and
missing parts. If any problems
are found, do not use tool until
repaired.
Work Piece and Work Area Set Up
Designate a work area that is clean 1.
and well-lit. The work area must not
allow access by children or pets to
prevent injury and distraction.
Route the air hose along a safe 2.
route to reach the work area without
creating a tripping hazard or exposing
the air hose to possible damage.
The air hose must be long enough
to reach the work area with enough
extra length to allow free movement
while working.
Secure loose workpieces using a vise 3.
or clamps (not included) to prevent
movement while working.
There must not be hazardous objects 4.
(such as utility lines or foreign
objects) nearby that will present a
hazard while working.
General Operating Instructions
If an automatic oiler is not used, 1. add
a few drops of Pneumatic Tool Oil into
the Quick Connector before use. Add
a few drops daily.
Once the Router Bit (not included) 2.
has been installed, depth of the cut
should be adjusted. To do so, grasp
the Housing Cap (30) and Lock Nut
(31) and turn in opposite directions.
Rotating the Router Base (32) in a
clockwise direction will decrease
the cut depth, and when turned in a
counterclockwise direction, depth of
cut would increase. (See Figure A.)
Attach an air hose to the Air Router. 3.
Then turn on the air compressor and
set its regulator at no more than 90
PSI. Never exceed 90 PSI for this
tool.
For ease of gliding, both work piece 4.
surface and face of the Router Base
Place the Router Base (32) of the Air 5.
Router on the work piece, but avoid
contacting the Router Bit with the
work piece. (See Figure A.)
cloth, and apply a thin coat of tool oil.
Then remove the bit and store the
tool indoors out of children’s reach
and other unauthorized people.
MAINTENANCE
Push the Trigger (3) lock forward and 6.
gently squeeze the Trigger to start
the Air Router. (See Figure A.)
Wait until the Router Bit rotates at 7.
full speed. Then, gradually feed the
Router Bit into the work piece while
keeping the Router Base (32) at on
the work piece. (See Figure A.)
NOTE: 8. If the tool requires more force
to accomplish the task, verify that the
tool receives sufcient, unobstructed
airow (CFM) and increase the
pressure (PSI) output of the regulator
up to the maximum air pressure
rating (90 PSI) of this tool.
CAUTION! TO PREVENT TOOL
AND ACCESSORY FAILURE,
RESULTING IN INJURY:
Do not exceed the tool’s maximum
air pressure rating (90 PSI).
If the tool still does not have sufcient
force at maximum pressure and
sufcient airow, then a larger tool
will be required.
INSTRUCTIONS
Procedures not specically
explained in this manual
must be performed only by a
qualied technician.
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
OPERATION:
Turn off the tool, detach the
air supply, safely discharge
any residual air pressure in
the tool, and release the
Trigger (3) before performing
any inspection, maintenance,
or cleaning procedures.
TO PREVENT SERIOUS
INJURY FROM TOOL
FAILURE:
Do not use damaged
equipment. If abnormal
noise, vibration, or leaking
air occurs, have the problem
corrected before further use.
When nished routing, remove Air 9.
Router away from work piece, and
release pressure on the Trigger (3)
to stop the Air Router. Wait until the
Router Bit stops rotating, then set the
tool down. (See Figure A.)
To prevent accidents, detach the air 10.
supply, safely discharge any residual
air pressure in the tool, and release
the Trigger (3). Clean external
surfaces of the tool with clean, dry
Lubricate the air inlet
using only pneumatic tool
oil. Lubricate the internal
mechanism using only
white lithium grease. Other
lubricants may damage the
mechanism and may be
highly ammable, causing an
explosion.
Maintenance, Lubrication, and
Cleaning
Note: These procedures are in addition to
the regular checks and maintenance
explained as part of the regular
operation of the air-operated tool.
Daily - Air Supply Maintenance: 1.
Everyday, perform maintenance
on the air supply according to
the component manufacturers’
instructions. The lubricator’s oil
level needs to be maintained and
the moisture lter must be regularly
drained. Performing routine
maintenance on the air supply will
allow the tool to operate more safely
and will also reduce wear on the tool.
Daily - Tool Maintenance: 2.
Apply several drops of pneumatic tool
oil into the Quick Connector of the Air
Router (if inline oiler is not used).
Daily - Tool Cleaning: 3.
Clean the Air Router with a damp
cloth and mild detergent. Do not use
solvents. Do not introduce water into
the internal mechanisms of the tool.
Severe air
leakage.
(Slight air leakage
is normal,
especially on
older tools.)
or air ow.
Obstructed trigger. 2.
Incorrect lubrication or not 3.
enough lubrication.
Blocked air inlet screen (if 4.
equipped).
Air leaking from loose 5.
housing.
Mechanism contaminated. 6.
Vane wear or damage.7.
Incorrect lubrication or not 1.
enough lubrication.
Worn parts.2.
Cross-threaded housing 1.
components.
Loose housing. 2.
Damaged valve or housing.3.
Dirty, worn or damaged valve. 4.
Check for loose connections and make sure 1.
that air supply is providing enough air ow
(CFM) at required pressure (PSI) to the
tool’s air inlet. Do not exceed maximum air
pressure.
Clean around trigger to ensure free 2.
movement.
Lubricate using air tool oil according to 3.
directions.
Clean air inlet screen of buildup. 4.
Make sure housing is properly assembled 5.
and tight.
Have qualied technician clean and lubricate 6.
mechanism. Install in-line lter in air supply
as stated in Initial Set Up: Air Supply.
Replace all vanes.7.
Lubricate using air tool oil and grease 1.
according to directions.
Have qualied technician inspect internal 2.
mechanism and replace parts as needed.
Check for incorrect alignment and uneven 1.
gaps. If cross-threaded, disassemble and
replace damaged parts before use.
Tighten housing assembly. If housing cannot 2.
be tightened properly, internal parts may be
misaligned.
Replace damaged components.3.
Clean or replace valve assembly.4.
Follow all safety precautions whenever diagnosing or servicing the tool.
Disconnect air supply before service.
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL
AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR 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 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.
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 this product is
free from defects in materials and workmanship for the period of one year from the date
of purchase (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. THIS
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 veries 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 specic 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
Record Product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Note: Some parts are listed and shown for illustration purposes only, and are not