MasterForce 241-0834 Operator's Manual

241-0834

ROUTER

For questions / comments, technical assistance or repair parts –
Please Call Toll Free: 1-866-917-4374. (M-F 8:30am-5:00pm Est.)

OPERATOR’S MANUAL

CAUTION:

To Reduce The Risk Of Injury, User Must Read And

Understand Operator’s Manual. Save These Instructions For Future
Reference.

TABLE OF CONTENTS

Safety Symbols ......................................................... Page 2

Safety Instructions ...................................................... Page 3

Overview/Specifications .................................................Page 7

Assembly .............................................................Page 8

Operation ............................................................ Page 11

Maintenance .......................................................... Page 20

Troubleshooting .......................................................Page 21

Warranty .............................................................Page 22

Page 2

SAFETY SYMBOLS

Some of these 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
more safely.

WARNING:

To ensure safety and reliability, all repairs should be performed by a

qualied service technician.

Symbol

Name

Designation / Explanation

V Volts Voltage

A Amperes Current

Hz Hertz Frequency (cycles per second)

W Watts Power

∿

Alternating current Type of current

�

Direct current Type or characteristic of current

n

o

No-load speed Rotational speed at no load

lbs Pounds Weight

Class II construction Double insulated construction

.../min

Per minute

Revolutions, strokes, surface speed
orbits, etc., per minute

Wear safety goggles

WARNING:

The operation of any
power tool can result in foreign objects
being thrown into your eyes, which can
result in severe eye damage. Before
beginning power tool operation, always
wear safety goggles or safety glasses
with side shields and a full-face shield
when needed. We recommend a Wide
Vision Safety Mask for use over eye­glasses or standard safety glasses with
side shields. Always use eye protection
which is marked to comply with
ANSI Z87.1.

Page 3

The purpose of safety symbols is to attract your attention to possible dangers. The
safety symbols, and the explanations with them, deserve your careful attention and
understanding. The symbol warnings do not, by themselves, eliminate any danger. The
instructions and warnings they give are no substitutes for proper accident prevention
measures.

WARNING:

Be sure to read and understand all safety instructions in this manual,
including all safety alert symbols such as “DANGER,” “WARNING,” and “CAUTION”
before using this tool. Failure to following all instructions listed below may result in
electric shock, re, and/or serious personal injury.

SYMBOL MEANING

SAFETY ALERT SYMBOL: Indicates DANGER, WARNING, OR CAUTION.

May be used in conjunction with other symbols or pictographs.

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,

could result in minor or moderate injury.

NOTICE:

(Without Safety Alert Symbol) Indicates a situation that may result in property

damage.

SAVE THESE INSTRUCTIONS!

SAFETY INSTRUCTIONS

Page 4

GENERAL POWER TOOL SAFETY WARN­INGS

WARNING:

Read all safety

warnings and all instructions. Failure to

follow the warnings and instructions may
result in electric shock, fire and/or serious
injury.

Save all warnings and instructions for
future reference.

The term “power tool” in the warnings refers
to your mains-operated (corded) power tool
or battery-operated (cordless) power tool.

WORK AREA SAFETY

1. Keep work area clean and well lit.
Cluttered and dark areas invite accidents.

2. Do not operate power tools in explosive

atmospheres, such as in the presence of
ammable liquids, gases or dust. Power

tools create sparks which may ignite the
dust or fumes.

3. Keep children and bystanders away
while operating a power tool. Distractions
can cause you to lose control

ELECTRICAL SAFETY

1. Power tool plugs must match the
outlet. Never modify the plug in any way.
Do not use any adapter plugs with earthed
(grounded) power tools. Unmodified plugs

and matching outlets will reduce risk of
electric shock.

2. Avoid body contact with earthed

or grounded surfaces, such as pipes,
radiators, ranges and refrigerators. There

is an increased risk of electric shock if your
body is earthed or grounded.

3. Do not expose power tools to rain or
wet conditions. Water entering a power tool
will increase the risk of electric shock.

4. Do not abuse the cord. Never use the

cord for carrying, pulling or unplugging the
power tool. Keep cord away from heat, oil,
sharp edges or moving parts. Damaged or

entangled cords increase the risk of electric
shock.

5. When operating a power tool outdoors,

use an extension cord suitable for outdoor
use. Use of a cord suitable for outdoor use

reduces the risk of electric shock.

6. If operating a power tool in a damp

location is unavoidable, use a ground-fault
circuit interrupter (GFCI) protected supply.

Use of a GFCI reduces the risk of electric
shock.

PERSONAL SAFETY

1. Stay alert, watch what you are doing
and use common sense when operating a
power tool. Do not use a power tool while
you are tired or under the inuence of
drugs, alcohol or medication. A moment of

inattention while operating power tools may
result in serious personal injury.

2. Use personal protective equipment.
Always wear eye protection. Protective
equipment such as dust mask, non-skid
safety shoes, hard hat, or hearing protection
used for appropriate conditions will reduce
personal injuries.

3. Prevent unintentional starting. Ensure

the switch is in the off-position before
connecting to power source and/or battery
pack, picking up or carrying the tool.

Carrying power tools with your finger on the
switch or energising power tools that have
the switch on invites accidents.

4. Remove any adjusting key or wrench
before turning the power tool on. A wrench
or a key left attached to a rotating part of the
power tool may result in personal injury.

5. Do not overreach. Keep proper footing
and balance at all times. This enables better
control of the power tool in unexpected
situations.

6. Dress properly. Do not wear loose

clothing or jewellery. Keep your hair,
clothing and gloves away from moving
parts. Loose clothes, jewellery or long hair

can be caught in moving parts.

7. If devices are provided for the

connection of dust extraction and
collection facilities, ensure that these are
connected and properly used. Use of these

devices can reduce dust-related hazards.

SAFETY INSTRUCTIONS

Page 5

SAFETY INSTRUCTIONS

POWER TOOL USE AND CARE

1. Do not force the power tool. Use the
correct power tool for your application.

The correct power tool will do the job better
and more safely at the rate for which it was
designed.

2. Do not use the power tool if the switch
does not turn it on and off. Any power tool
that cannot be controlled with the switch is
dangerous and must be repaired.

3. Disconnect the plug from the power

source and/or the battery pack from the
power tool before making any adjustments,
changing accessories, or storing power
tools. Such preventive safety measures

reduce the risk of starting the power tool
accidentally.

4. Store idle power tools out of the reach

of children and do not allow persons
unfamiliar with the power tool or these
instructions to operate the power tool.

Power tools are dangerous in the hands of
untrained users.

5. Maintain power tools. Check for

misalignment or binding of moving parts,
breakage of parts and any other condition
that may affect the power tool’s operation.
If damaged, have the power tool repaired
before use. Many accidents are caused by

poorly maintained power tools.

6. Keep cutting tools sharp and clean.
Properly maintained cutting tools with sharp
cutting edges are less likely to bind and are
easier to control.

7. Use the power tool, accessories,

tool bits, etc. in accordance with these
instructions, taking into account the
working conditions and the work to be
performed. Use of the power tool for

operations different from those intended
could result in a hazardous situation.

SERVICE

1. Have your power tool serviced by a
qualied repair person using only identical
replacement parts. This will ensure that the

safety of the power tool is maintained.

SAFETY GUIDELINES FOR

ROUTERS

1. Hold the power tool by insulated
gripping surfaces only, because the cutter
may contact its own cord. Cutting a “live”

wire may make exposed metal parts of the
power tool “live” and could give the operator
an electric shock.

2. Use clamps or another practical way

to secure and support the workpiece to a
stable platform. Holding the work by your

hand or against the body leaves it unstable
and may lead to loss of control.

ADDITIONAL SAFETY GUIDE-

LINES FOR ROUTERS

1. Always make sure the work surface is
free from nails and other foreign objects.

Cutting into a nail can cause the bit and the
tool to jump and damage the bit.

2. Never hold the workpiece in one hand

and the tool in the other hand when in use.
Never place hands near or below cutting
surface. Clamping the material and guiding

the tool with both hands is safer.

3. Never lay workpiece on top of hard

surfaces, like concrete, stone, etc...

Protruding cutting bit may cause tool to
jump.

4. Always wear safety goggles and dust
mask. Use only in well ventilated area.
Using personal safety devices and working
in safe environment reduces risk of injury.

5. Keep handles dry, clean and free from
oil and grease. Slippery hands cannot safely
control the power tool.

6. After changing the bits or making any

adjustments, make sure the collet and
any other adjustment devices are securely
tightened. Loose adjustment device can

unexpectedly shift, causing loss of control,
loose rotating components will be violently
thrown.

7. Never start the tool when the bit is
engaged in the material. The bit cutting
edge may grab the material causing loss of
control of the cutter.

8. Always hold the tool with two hands
during start-up. The reaction torque of the
motor can cause the tool to twist.

Page 6

SAFETY INSTRUCTIONS

9. The direction of feeding the bit into
the material is very important and it
relates to the direction of bit rotation.
When viewing the tool from the top, the
bit rotates clockwise. Feed direction of
cutting must be counter-clockwise. NOTE:

inside and outside cuts will require different
feed direction, refer to section on feeding
the router. Feeding the tool in the wrong
direction, causes the cutting edge of the bit
to climb out of the work and pull the tool in
the direction of this feed.

10. Never use dull or damaged bits. Sharp
bits must be handled with care. Damaged
bits can snap during use. Dull bits require
more force to push the tool, possibly
causing the bit to break.

11. Never touch the bit during or
immediately after the use. After use the bit
is too hot to be touched by bare hands.

12. Never lay the tool down until the motor
has come to a complete standstill. The
spinning bit can grab the surface and pull
the tool out of your control.

13. Never use bits that have a cutting

diameter greater than the opening in the
base.

WARNING:

Some dust created
by power sanding, sawing, grinding,
drilling and other construction
activities contains chemicals known to
the state of California to cause cancer,
birth defects or other reproductive
harm. Some examples of these
chemicals are:

• Lead from lead-based paints

• Crystalline silica from bricks

and cement 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 chemical: work in a well ventilated
area, and work with approved safety
equipment, such as those dust masks
that are specially designed to filter out
microscopic particles.

Page 7

OVERVIEW

0

3/64

1/64

Handle

ON/OFF switch

Fine-adjustment dial

Depth-indicator ring

Coarse-adjustment button

Dust-extraction
adaptor

Collet wrench

1/4” collet sleeve

Lock nut

Electronic keyboard

LED display screen

Power indicator

Motor clamp

Dust-extraction adaptor

Spindle lock

Chip shield

Base plate

LED worklight

1/2” collet

Page 8

SPECIFICATIONS

Rated voltage 120 V~ 60 Hz

Rated power Input 14 A

Max HP 2.5 HP

Speed 10,000–25,000 RPM

Collet capacity 1/4” & 1/2”

Fixed-base range 1-3/4”

Fixed base dimension 6”

Inside base diameter 1-3/16”

Micro-fine depth 1/64”

Weight 9 lb. (4.1 kg)

ASSEMBLY

WARNING:

If any part is broken
or missing, DO NOT attempt to plug in the
power cord or operate the tool until the
broken or missing part is replaced. Failure to
do so could result in possible serious injury.

WARNING:

Do not attempt to
modify this tool or create accessories not
recommended for use with this tool. Any
such alteration or modication is misuse
and could result in a hazardous condition
leading to possible serious injury.

WARNING:

Your tool should
never be connected to the power source
when you are assembling parts, making
adjustments, installing or removing
blades, cleaning, or when it is not in
use. Disconnecting the tool will prevent
accidental starting, which could cause
serious personal injury.

CONTENTS

Fixed base router, 1/2” collet, 1/4” collet
sleeve, collet wrench, dust-extraction adaptor
and instruction manual.

UNPACKING

1. Carefully remove the tool and any
accessories from the carton. Make sure
that all items listed in the packing list are
included.

2. Inspect the tool carefully to make sure
that no breakage or damage occurred
during shipping.

3. Do not discard the packing material
until you have carefully inspected and
satisfactorily operated the tool.

Page 9

ASSEMBLY

SELECTING THE CUTTER BIT

This router comes with 1/2”collet and 1/4”
collet sleeve that accept cutter bits with
1/2” and 1/4” shanks, respectively. The 1/2”
collet is equipped on the tool, the 1/4” collet
sleeve can be installed inside the 1/2” collet.

INSTALLING THE 1/4” COLLET

SLEEVE (FIG. 1-2)

1. Disconnect the plug from the power
supply.

2. Remove the router motor from the
base; refer to the section “REMOVING
MOTOR FROM BASE”.

3. Set the router motor upside down on its
top cap with the collet pointing up.

4. Press the spindle-lock button to engage
and lock the spindle shaft and 1/2”
collet (FIG. 1).

FIG. 1

1/2” collet

Spindle-lock
button

5. Place the wrench (included) on the 1/2”
collet and turn it counterclockwise to
loosen the collet slightly to accept the
cutter bit shank.

6. Insert the 1/4” collet sleeve into the 1/2”
collet assembly as far as it will go (FIG. 2).

FIG. 2

1/4” Collet
sleeve

7. With the 1/4” collet sleeve inserted and
the spindle-lock button pressed in to
engage the shaft, place the wrench on
the 1/2” collet and turn it clockwise until
the 1/4” collet sleeve is tightened in it.

REPLACING THE CUTTER BIT

CAUTION:

Always ensure that
the tool is switched OFF and unplugged
from the power supply before installing or
removing bits or accessories.

INSTALLING THE CUTTER BIT

(FIG. 3)

1. Disconnect the plug from the power

supply.

2. Remove the router motor from the

base; refer to the section “REMOVING
MOTOR FROM BASE”.

3. Set the router motor upside down on its

top cap, with the collet pointing up.

4. Press the spindle-lock button to engage

and lock the spindle shaft and collet.

5. Place the wrench on the collet and turn

it counterclockwise to loosen the collet
slightly to accept the cutter bit shank.

6. Insert the cutter bit shank into the

collet assembly as far as it will go, then
back the shank out until the cutters are
approximately 1/8” to 1/4” away from
the face of the collet (FIG. 3).

Page 10

ASSEMBLY

FIG. 3

Cutter

Bit shank

Spindle-lock
button

7. With the cutter bit inserted and the
spindle-lock button pressed in to
engage the shaft, place the wrench on
the collet and turn it clockwise until the
cutter bit is firmly tightened in the collet.

NOTICE: To ensure proper gripping of the
cutter bit shank and minimize run-out, the
shank of the cutter bit must be inserted
into the collet at least 5/8”.

WARNING:

Tighten the collet
securely to prevent the cutter bit from
slipping. If the collet is not securely
tightened, the cutter bit may detach
during use, causing serious personal
injury.

REMOVING THE CUTTER BIT

1. Disconnect the plug from the power

supply.

2. Remove the router motor from the

base; refer to the section “REMOVING
MOTOR FROM BASE”.

3. Set the motor upside down on its top

cap, with the collet pointing up.

4. Press the spindle-lock button to engage

and lock the spindle shaft and collet.

5. Place the wrench on the collet and turn

it counterclockwise to loosen the collet
slightly.

6. Remove the cutter bit shank.

INSTALLING MOTOR IN FIXED

BASE (FIG. 4)

FIG. 4

Coarse­adjustment
button

Arrow

Motor
clamp

WARNING:

Never use the router
motor without rst properly installing it
into an approved base. Failure to do so
could result in serious personal injury and
damage to motor.

NOTICE: Before installing the motor
housing in the xed base, have the collet
and router cutter bit installed on the motor
housing; refer to the section “REPLACING
THE CUTTER BIT”.

CAUTION:

Always ensure that
the tool is switched OFF and unplugged
from the power supply before installing or
removing bits or accessories.

1. Disconnect the plug from the power

supply.

2. Place the fixed base on a flat surface.

3. With the back of the fixed base facing

you, open the motor clamp.

4. Press in the coarse-adjustment button

while you align the motor to the fixed
base so that the arrows align.

5. Slide the motor down into the fixed base.

6. The router motor will now slide up or

down to when the coarse-adjustment
button is pressed in.

7. After all adjustments are made (see

“DEPTH ADJUSTMENT WITH FIXED
BASE”), close the router clamp securely.

Page 11

REMOVING MOTOR FROM THE

FIXED BASE (FIG. 4)

1. Disconnect the plug from the power
supply.

2. Place the router on a flat surface.

3. With the back of the router facing you,
open the router motor clamp.

4. Push in the coarse-adjustment button
while you lift the router motor out of the
fixed base.

5. Set the motor upside down on its top
cap with the collet pointing up and
remove the cutter bit.

INSTALLING THE DUST-EXTRAC-

TION ADAPTOR (FIG. 5)

0

3/64

1/64

FIG. 5

Dust-extraction
adaptor

Fixed
base

To attach the dust-extraction adaptor onto
the fixed base, insert the dust-extraction
adaptor into the adaptor slot on the back of
the fixed base. Rotate the adaptor until it is
secured on the base; as shown in fig. 5.

OPERATION

ADJUSTING THE DEPTH OF CUT

WARNING:

Your router should
never be turned on or be connected to the
power source when you are assembling
parts, making adjustments, installing or
removing collets and cutter bits, cleaning
or when it is not in use. Disconnecting
the router will prevent accidental starting,
which could cause serious personal injury.

ASSEMBLY

DEPTH ADJUSTMENT WITH

FIXED BASE (FIG. 6)

0

3/

FIG. 6

Fine-adjustment
dial

Depth-indicator
ring

NOTICE: All depth adjustments on the
xed base must be made with the motor
clamp open.

NOTICE: For xed base routers, the cutter bit
depth equals the amount of the cutter that is
exposed below the surface of the sub-base.

Page 12

OPERATION

The fixed base is designed with a fine
adjustment system. When the bit is lowered
to the approximate position desired (coarse
setting), the system can then be micro­adjusted to the precise depth.

COARSE ADJUSTMENT:

Depressing the coarse-adjustment button
allows you to quickly lower or raise the
cutter bit to an approximate depth setting.

FINE ADJUSTMENTS:

The depth-indicator ring located on the
fine-adjustment dial is marked in 1/64”
increments. Turning the fine-adjustment dial
clockwise 180º (1/2 turn), lowers the cutter
bit 1/32”. One full turn clockwise 360° (zero
“0” to zero “0”) lowers the bit 1/16”.

The depth-indicator ring may be reset to zero
“0” without moving the fine-adjustment dial.
This allows the user to begin adjustments
from any chosen reference point.

ADJUSTING DEPTH (FIG. 7)

0

3/64

1/64

FIG. 7

1. Disconnect the plug from the power

supply.

2. Place the router on a flat surface with

the back of the fixed base facing you.
Open the motor clamp.

3. With the cutter bit already installed, press

in the coarse-adjustment button and lower
the motor into the base until the cutter bit
is close to the flat surface on which the
base is sitting. Turn the fine-adjustment
dial until the cutter bit “just” touches the
flat surface on which the base is sitting.
Then lock the motor clamp.

4. Place the router on two level pieces of
wood, positioned so that the cutter bit
can be lowered below the sub-base
(FIG. 7).

5. Turn the fine-adjustment dial clockwise
to lower the bit to the desired depth of
cut. Turn the dial counterclockwise to
raise the cutter bit.

6. Once the depth of cut is set, close the
motor clamp securely.

DEEP CUTS

The proper cutting depth for each pass,
is always determined by the material, the
cutter bit size and type, and the power of
the motor.

Always make several progressively deeper
cuts by starting at one depth and then
making several passes, each time increasing
the cutting depth until your desired depth is
reached.

Making a cut that is too deep will stress the
motor and the cutter bit, and it may burn the
workpiece and dull the cutter bit. It could
also “grab” too much of the workpiece
and cause you to lose control of the router,
causing a serious accident.

To be certain that your depth settings are
correct, always make test cuts in scrap
material similar to your workpiece before
beginning your final cutting.

Remember, knowing the right depth for each
cut comes with routing experience.

Page 13

LED WORKLIGHTS (FIG. 9)

FIG. 9

Your router motor has 3 built-in worklights
located around the collet to provide high
visibility of the workpiece when cutting.
These lights are always “On” when the
toggle switch is in the “ON” position.

“LIVE TOOL INDICATOR” LIGHT

(FIG. 10)

FIG. 10

Live tool
indicator

Your router also has a “live tool indicator”
green light, located on the motor housing
top cap where the power cord enters the
motor housing. This green light is always
on when the router motor is plugged into a
power source.

TOGGLE “ON/OFF”

SWITCH (FIG. 8)

0

3/64

1/64

FIG. 8

Your router motor is turned “ON” and “OFF”
with the toggle switch located on the top
cap of the motor housing.

The left side of the toggle switch hood (as
you face it) is marked “I” and “ON” and the
right side (as you face it) is marked “O” and
“OFF.”

• To turn the motor “ON”, push the toggle
switch to the left side marked “I” and
“ON.”

• To turn the motor “OFF” push the
toggle switch to the right side marked
“O” and “OFF.”

Always hold the router and the cutter bit
away from the workpiece when turning
the toggle switch “On.” Only contact the
workpiece with the router and cutter bit
after the router has reached the full selected
speed. Only remove the router and cutter bit
from the workpiece after turning the router
motor “OFF” and after the cutter bit comes
to a complete stop.

SOFT START FEATURE

The soft start control minimizes torque
twist, customary in larger router motors, by
limiting the speed at which the motor starts.
This increases the motor’s life.

OPERATION

Page 14

ELECTRONIC VARIABLE-SPEED

CONTROL (FIG. 11)

FIG. 11

The electronic-speed control feature allows
the motor speed to be matched to the
cutter size and the material hardness for an
improved finish and extended bit life.

Press “+” or “-” to choose the cutting speed
according various materials of workpieces.

Choose the applicable cutting speed
according the bit diameter and the material
being cut. The chart below and all of the
specifications that appear on the display of
the router are for your reference.

Bit Size

and Speed

Setting

Material
Hardness

0-1”

1.25-2”2.25-

2.5”

3-3.5”

Plastic 6 4 3 2

Softwood 6 4 2 1

Hardwood 5 3 2 1

The speed chart in the next column indicates
the relationship between the speed setting
and the cutting application. Exact settings
are determined through operator experience
and preference and by recommendations
from manufacturers of cutter bits.

DIAL
SETTING

RPM APPLICATION

1 10,000/11500

Hardwoods,
larger
diameter
cutter bits

2 13,000/14500

3 16,000/17500

4 19,000/20500

Softwoods,
plastics,
countertops,
smaller
diameter
cutter bits

5 22,000/23500

6 25,000

NOTICE: Reduce the speed when using
very large bits (1-inch or greater in cutting
diameter) or heavy cutting bits. Changing
the router rate of feed can also improve
the quality of the cut.

NOTICE: The speed may be changed while
the router is “ON”, but do not change the
speed if the cutter bit is in the workpiece.

WARNING:

Before operating your
router, follow all safety instructions in this
manual. Failure to do so could result in
serious personal injury.

EDGE ROUTING OR

INTERNAL ROUTING (FIG. 12)

For ease of operation and to maintain
proper control, your router has two handles,
one on each side of the router base. When
operating the router, always hold it firmly
with both hands (FIG. 12).

0

3/64

1/64

FIG. 12

OPERATION

Page 15

EDGE ROUTING

1. With the depth-of-cut set, place the
router on the edge of workpiece, making
sure that the cutter does not contact the
workpiece.

2. Have an edge guide (or a board or a
metal straightedge) clamped in place to
help guide the router base when making
the edge cut.

3. Turn the router “ON”, and allow the
router motor to reach the selected
speed.

4. To begin the cut, gradually feed the
cutter bit into the edge of the workpiece.

5. When the cut is complete, turn the
router motor “OFF” and allow the cutter
bit come to a complete stop before
removing it from the workpiece.

6. Unplug the router from the power
source, and inspect the finished cut.

WARNING:

Always securely clamp
your workpiece and keep a rm grip on
the router base with both hands at all
times. Failure to do so could result in
loss of control causing possible serious
personal injury.

WARNING:

Removing the cutter
bit from the workpiece while it is still
rotating could damage the workpiece and
result in loss of control, causing serious
personal injury.

INTERNAL ROUTING WITH FIXED

BASE (FIG. 13)

1. With the depth-of-cut set, tilt the router

and place it on the workpiece with the
leading edge of the sub-base contacting
the workpiece first (FIG. 13).

2. Turn the router motor “ON” and allow

the router motor to reach the selected
speed, being careful not to allow the
cutter bit to contact the workpiece.

3. To begin your cut, gradually lower the

cutter bit into the workpiece until the
sub-base is flush with the workpiece
(FIG. 13).

FIG. 13

4. When the cut is complete, turn the
router motor “OFF” and allow the cutter
bit come to a complete stop before
removing it from the workpiece.

5. Unplug the router from power source,
place the router upside down on the
worktable, and inspect the finished cut
in the workpiece.

WARNING:

Always securely clamp
your workpiece and keep a rm grip on the
router base with both hands at all times.
Failure to do so could result in loss of
control causing possible serious personal
injury. If using a router table, large cutter
bits should be used for edging only.

WARNING:

Removing the cutter bit
from workpiece while it is still rotating could
damage the workpiece and result in loss of
control, causing serious personal injury.

OPERATION

Page 16

FREEHAND ROUTING WITH THE

FIXED BASE (FIG. 14)

0

3/64

1/64

FIG. 14

WARNING:

Do not use large cutter
bits for freehand routing. Using large
cutter bits when freehand routing could
cause loss of control or create other
hazardous conditions that could result
in personal injury. If using a router table,
large bits should be used for edging only.

When used freehand, the router becomes
a flexible and versatile tool. This flexibility
makes it possible to easily rout signs, relief
sculptures, etc.

When freehand routing:

1. Draw or lay out the pattern on the

workpiece.

2. Choose the appropriate bit.

3. Follow the instructions for INTERNAL

ROUTING, and rout the pattern in two or
more passes. Do not exceed 1/8” depth
of cut in a single pass. This will help
provide better control, as well as serve
as a guide on the next passes.

NOTICE: A core-box bit 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.

NOTICE: Making a single deep cut is
never advisable. Smaller-diameter bits are
easily broken by too much side thrust and
torque. Larger bits will cause a rough cut
and be difcult to guide and control.

OPERATION

For these reasons, do not exceed 1/8”
depth of cut in a single pass.

WARNING:

Always securely clamp
your workpiece in place, and keep a rm
grip on the router base with both hands at
all times. Failure to do so could result in
loss of control causing possible serious

personal injury.

EDGING WITH A PILOT

BIT (FIG. 15-16)

Arbor-type bits with pilots are excellent for
edge shaping of any workpiece edge that is
either straight or curved at a curvature that
is as great as or greater than the radius of
the bit to be used. The pilot prevents the bit
from making an excessively deep cut; and
holding the pilot firmly in contact with the
workpiece edge throughout prevents the cut
from becoming too shallow.

TOP EDGE SHAPING (FIG. 15)

FIG. 15

Motor
housing

Fixed base
sub-base

Work piece

TOP EDGE SHAPING

Spindle lock

Cutter bit

Pilot

Whenever the workpiece thickness, together
with the desired depth of cut (as adjusted by
the cutting-depth setting) are such that only the
top part of the edge is to be shaped (leaving at
least a 1/16”. thick uncut portion at the bottom),
the pilot can ride against the uncut portion,
which serves to guide it (FIG. 15).

Page 17

WHOLE EDGE SHAPING

(FIG. 16)

FIG. 16

Work piece

Guide board

WHOLE EDGE SHAPING

Whole edge of
workpiece

If the workpiece is too thin or the bit is set so
low that there will be no uncut edge against
which to ride the pilot, an extra board must
be placed under the workpiece to act as
a guide (FIG. 16). This “guide” board must
have exactly the same contour - straight
or curved - as the workpiece edge. If it is
positioned so that its edge is flush with the
workpiece edge, the bit will make a full cut
(in as far as the bit radius). On the other
hand, if the guide is positioned so that it
extends beyond the edge of the workpiece),
the bit will make less than a full cut - which
will alter the shape of the finished edge.

NOTICE: The size (diameter) of the pilot
that is used determines the maximum
cut width that can be made with the pilot
against the workpiece edge. (The small
pilot exposes the entire bit; the large one
reduces this amount by 1/16”.) Any of the
piloted cutter bits can be used without a
pilot for edge shaping with guides.

WARNING:

Always securely clamp
your workpiece and keep a rm grip on
the router base with both hands at all
times. Failure to do so could result in
loss of control causing possible serious
personal injury.

OPERATION

FEEDING THE ROUTER (FIG. 17)

FIG. 17

Router feed direction

Router feed
direction

The secrets to professional routing are a
careful set-up for the cut, selecting the
proper depth of cut, knowing how the cutter
bit reacts in your workpiece, and the rate
and direction of feed of the router.

DIRECTION OF

FEED - EXTERNAL CUTS (FIG. 17)

The cutter bit rotates clockwise. (When
installed on a router table, the rotation is
counterclockwise.) Feeding the bit from left
to right will cause the bit to pull the router
towards the workpiece (FIG. 17). If the router
is fed in the opposite direction (right to left),
the rotating force of the cutter bit will tend to
throw the bit away from the workpiece.

This is called “Climb-Cutting”. “Climb­Cutting” may cause loss of control, possibly
resulting in personal injury. When “Climb­Cutting” is required (e.g. backing around
a corner), exercise extreme caution to
maintain control of the router. The high
speed of the cutter bit during a proper
feeding operation (left to right), results in
very little kickback under normal conditions.
However, if the cutter bit strikes a knot,
an area of hard grain, or a foreign object,
“Kickback” may result. Kickback may
damage your workpiece and could cause
you to lose control of the router, possibly
causing personal injury. Kickback is always
in the opposite direction of the clockwise
cutter bit rotation, or counterclockwise. To
guard against and help prevent Kickback,

Page 18

plan your set-up and direction of feed so
that you’re always keeping the sharp edges
of the cutter bit biting straight into uncut
wood. Always inspect your workpiece for
knots, hard grain, and foreign objects.

WARNING:

Kickback causes the
power tool to jerk back toward the user,
causing possible loss of control and
serious injury. Always take precautions
against kickback as described in the
operator’s manual.

KICKBACK

Because of the high speed of the cutting
bit during a proper feeding operation (left
to right), there is very little kickback under
normal conditions. However, if the cutting
bit strikes a knot, an area of hard grain in
the workpiece, or a foreign object, the
normal cutting action could be affected
and cause “Kickback.” This Kickback may
cause damage to your workpiece, and could
cause you to lose control of the router,
possibly causing serious personal injury.
Kickback is always counterclockwise: the
opposite direction of the clockwise cutting
bit rotation.

To guard against and help prevent kickback,
always inspect the workpiece for knots,
hard grain, and foreign objects that could
cause a kickback problem and plan the set­up and direction of feed so that the router is
always moving, and keep the sharp edges
of the cutting bit continuously biting straight
into new (uncut) wood (workpiece).

DIRECTION OF FEED – INTERNAL

CUTS (FIG. 18-19)

When making an internal cut, such as a
groove, dado, or slot, always try to have the
guide you are using with the router (edge
guide, straight edge, board guide), on the
right-hand side of the router as you make
the cut (FIG. 18).

FIG. 18

GUIDE OUTSIDE

BIT
ROTATION

THRUST

BIT
ROTATION

ROUTER FEED
DIRECTION

GUIDE

When the guide is positioned on the
right-hand side of the router, the router
travel should be from left to right and
counterclockwise around curves (FIG. 18).
This counterclockwise action around the
curve could cause “Climb cutting”. Always
be alert and exercise extreme caution to
maintain control of the router when making
this type of cut around curves.

When the guide is positioned as shown in
FIG. 19, the router travel should be from left
to right and clockwise around curves.

FIG. 19

GUIDE INSIDE

BIT
ROTATION

BIT
ROTATION

ROUTER FEED DIRECTION

GUIDE

THRUST

If there is a choice, the set-up in FIG. 19
is easier to use, but there is the possibility
of “Climb Cutting” around curves. In either
case, Fig. 18 or Fig. 19, the sideways thrust
of the router cutting is always against the
guide, as is proper.

OPERATION

Page 19

OPERATION

WARNING:

Always securely clamp
the workpiece in place, and keep a rm
grip on the router base with both hands at
all times. Failure to do so could result in
loss of control causing possible serious
personal injury.

RATE OF FEED (FIG. 20-21)

The proper rate of feed depends on several
factors: the hardness and moisture content
of the workpiece, the depth of cut, and the
cutting diameter of the bit.

When cutting shallow grooves in soft woods,
such as pine, you may use a faster rate of
feed. When making deep cuts in hardwoods,
such as oak, you should use a slower rate
of feed.

FEEDING TOO RAPIDLY (FIG. 20)

FIG. 20

Bit shank

TOO FAST

Cut

Cutter

Clean and smooth finished cuts can only
be achieved when the cutting bit is rotating
at a relatively high speed, taking very small
bites, and producing tiny, clean-cut chips.

Forcing the feed of the cutting bit forward
too rapidly slows the revolution of the
cutting bit, and the bit takes larger bites as it
rotates. Larger bites mean larger chips and
a rough finish. This forcing action can also
cause the router motor to overheat.

Under extreme force-feeding conditions,
the revolutions can become so slow and
the bites become so large that chips are
only partially cut off, causing splintering and
gouging of the workpiece.

The router will make clean, smooth cuts if it
is allowed to run freely without the overload
of forced feeding. You can detect forced
feeding by the sound of the motor. Its usual
high-pitched whine will sound lower and
stronger as it loses speed. Holding the
router against the workpiece will also be
more difficult to do.

FEEDING TOO SLOWLY (FIG. 21)

FIG. 21

Bit shank

TOO SLOW

Cut

Cutter

When you feed the cutting bit too slowly, the
rotating cutting bit does not cut into new
wood rapidly enough to take a bite. Instead,
it scrapes away sawdust-like particles. This
scraping produces heat, which can glaze,
burn, and mar the cut in the workpiece and,
in extreme cases, overheat the cutting bit.

When the cutting bit is scraping instead of
cutting, the router is more difficult to control
as you feed it.

With almost no load on the motor, the
cutting bit has a tendency to bounce off the
sides of the cut in the workpiece, producing
a cut with a rippled finish instead of clean,
straight sides.

Page 20

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.

If the supply cord is damaged, it must
be replaced by a specially prepared cord
available through the service organization.

WARNING:

Do not let brake uids,
gasoline, petroleum-based products,
penetrating oil, etc. come into contact with
plastic parts. They contain chemicals that
can damage, weaken, or destroy plastic.

WARNING:

To ensure safety and
reliability, all repairs should be performed
by a qualied service technician.

REPLACEMENT OF CARBON

BRUSHES (FIG. 22)

FIG. 22

Brushes

Ears

Cap

1. Disconnect the plug from the power

supply.

2. Replace both carbon brushes when

either has less than 1/4-in. length of
carbon remaining, or if the spring or wire
is damaged or burned.

3. Using a slotted screwdriver, remove

the black plastic cap on each side of
the router motor (FIG. 22) and carefully
withdraw the spring-loaded brush
assemblies. Keep brushes clean and
sliding freely in their guide channels.

NOTICE: To reinstall the same brushes,
make sure that the brushes go back in the
same way they came out. This will avoid
the need for a break-in period.

4. Insert new brush assemblies into the
guide channels with the carbon part
going in first, being certain to fit the
two metal “ears” into their slots in the
channel (FIG. 22).

5. Remember to replace both end caps
after inspecting or servicing brushes.
Tighten the caps snugly, but do not over­tighten. The router should be allowed to
“run in” (run at no load without a cutter
bit) for 5 minutes before use, to seat the
new brushes properly.

WARNING:

For your safety, always
turn off the switch and unplug the router
motor from the power source before
performing any maintenance or cleaning.

Page 21

PROBLEM CAUSE SOLUTION

The router does
not work.

Plug is not plugged into the
power source.

Plug the cord into the power source.

Switch is in “OFF” position. Move the switch to “ON” position.

The carbon brushes have
worn out completely.

Remove the brush caps and replace the
old brushes with new ones.

The surface of
the workpiece is
not smooth after
cutting.

The bit is dull. Change to a sharp bit.

Routing at an inappropriate
bit speed.

Select an appropriate bit speed.

Bit cannot be
installed.

Bit size is inappropriate for
the collet.

Use only 1/4” diameter bits with the 1/4”
collet; use only 1/2” diameter bits with
the 1/2” collet.

TROUBLESHOOTING

Page 22

SAVE YOUR RECEIPTS

THIS WARRANTY IS VOID WITHOUT THEM

ROUTER

WARRANTY

90-DAY MONEY BACK GUARANTEE:

This MASTERFORCE® brand power tool carries our 90-DAY Money Back
Guarantee. If you are not completely satisfied with your MASTERFORCE® brand
power tool for any reason within ninety (90) days from the date of purchase, return
the tool with your original receipt to any MENARDS® retail store, and we will provide
you a refund – no questions asked.

3-YEAR LIMITED WARRANTY:

This MASTERFORCE® brand power tool carries our famous No Hassle 3-Year
Limited Warranty to the original purchaser. If, during normal use, this
MASTERFORCE® power tool breaks or fails due to a defect in material or
workmanship within three (3) years from the date of original purchase, simply bring
this tool with the original sales receipt back to your nearest MENARDS® retail store.
At its discretion, MASTERFORCE

®

agrees to have the tool or any defective part(s)

repaired or replaced with the same or similar MASTERFORCE

®

product or part
free of charge, within the stated warranty period, when returned by the original
purchaser with original sales receipt. Not withstanding the foregoing, this limited
warranty does not cover any damage that has resulted from abuse or misuse of the
Merchandise. This warranty: (1) excludes expendable parts including but not limited
to blades, brushes, belts, bits, light bulbs, and/or batteries; (2) shall be void if this
tool is used for commercial and/or rental purposes; and (3) does not cover any
losses, injuries to persons/property or costs. This warranty does give you specific
legal rights and you may have other rights, which vary from state to state. Be
careful, tools are dangerous if improperly used or maintained. Seller’s employees
are not qualified to advise you on the use of this Merchandise. Any oral
representation(s) made will not be binding on seller or its employees. The rights
under this limited warranty are to the original purchaser of the Merchandise and may
not be transferred to any subsequent owner. This limited warranty is in lieu of all
warranties, expressed or implied including warranties or merchantability and fitness
for a particular purpose. Seller shall not be liable for any special, incidental, or
consequential damages. The sole exclusive remedy against the seller will be for the
replacement of any defects as provided herein, as long as the seller is willing or
able to replace this product or is willing to refund the purchase price as provided
above. For insurance purposes, seller is not allowed to demonstrate any of these
power tools for you.
For questions / comments, technical assistance or repair parts – Please Call Toll
Free at: 1-866-917-4374. (M-F 8:30am-5:00pm Est.)

08/2016

© 2016 Menard, Inc., Eau Claire, WI 54703