Milwaukee 5626-68 User Manual

OPERATOR'S MANUAL MANUEL de L'UTILISATEUR MANUAL del OPERADOR

FOR USE IN JESSEM ROUTER LIFT AND ROUTER TABLE APPLICATIONS ONLY. (NOT FOR HANDHELD USE)

CONVIENT UNIQUEMENT POUR L’UTILISATION AVEC LES SYSTÈMES D’ÉLÉVATEUR DE TOUPIE JESSEM ET LES TABLES À TOUPIE JESSEM. (NE CONVIENT PAS POUR L’USAGE MANUEL)

PARA SER UTILIZADO SÓLO CON LAS APLICACIONES DE LA CONTORNEADORA CON SISTEMAS DE ELEVACIÓN Y CON LA CONTORNEADORA PARA MESA DE JESSEM. (NO PUEDE SER UTILIZADO DE MANERA PORTÁTIL)

Cat. No.

No de cat.

5626-68*

ROUTER TABLE MOTOR TABLE À TOUPIE À TÉLÉALIMENTATION MOTOR DE LA CONTORNEADORA

TO REDUCE THE RISK OF INJURY, USER MUST READ OPERATOR'S MANUAL. AFIN DE RÉDUIRE LE RISQUE DE BLESSURES, L'UTILISATEUR DOIT LIRE LE

MANUEL DE L'UTILISATEUR. PARA REDUCIR EL RIESGO DE LESIONES, EL USUARIO DEBE LEER EL MANUAL

DEL OPERADOR.

GENERAL SAFETY RULES

WARNING

READ AND UNDERSTAND ALL INSTRUCTIONS

Failure to follow all instructions listed below, may result in electric shock, ﬁ re and/or serious personal injury.

SAVE THESE INSTRUCTIONS

WORK AREA

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

2. Avoid dangerous environments. Do not use your power tool in rain, damp or wet locations or in the presence of explosive atmospheres (gaseous fumes, dust or ﬂ ammable materials). Remove materials or debris that may be ignited by sparks.

3. Keep bystanders away. Children and bystanders should be kept at a safe distance from the work area to avoid distracting the operator and contacting the tool or extension cord.

4. Protect others in the work area from debris such as chips and sparks. Provide barriers or shields as needed.

5. Make workshop child proof with pad- locks, master switches, or by removing starter keys.

ELECTRICAL SAFETY

Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances. Never remove

the grounding prong or modify the plug in any way. Do not use any adaptor plugs. Check with a qualiﬁ ed electrician if you are in doubt as to whether the outlet is properly grounded. If the tool should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user.

7. Double insulated tools are equipped

with a polarized plug (one blade is wider than the other). This plug will ﬁ t in a polarized outlet only one way. If the plug does not ﬁ t fully in the outlet, reverse the plug. If it still does not ﬁ t, contact a qualiﬁ ed 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.

8. Guard against electric shock. Prevent body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators. When making blind or plunge cuts, always check the work area for hidden wires or pipes. Hold your tool by insulated nonmetal grasping surfaces. Use a Ground Fault Circuit Interrupter (GFCI) to reduce shock hazards.

9. Do not expose to rain or use in damp

locations.

10. Do not abuse the cord. Never use the cord to carry the tools or pull the plug from an outlet. Keep cord away form heat, oil, sharp edges or moving parts. Replace damaged cords immediately. Damaged cords increase

the risk of electric shock.

PERSONAL SAFETY

11. Know your power tool. Read this manual carefully to learn your power tool’s applications and limitations as well as potential hazards associated with this type of tool.

12. Stay alert, watch what you are do-

ing, and use common sense when operating a power tool. Do not use tool while tired or under the inﬂ uence of drugs, alcohol, or medication. A

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

13. Dress properly. Do not wear loose clothing or jewelry. Wear a protective hair covering to contain long hair. These ma

y be caught in moving parts. When working outdoors, wear rubber gloves and insulated non-skid footwear. Keep hands and gloves away from moving parts.

14. Reduce the risk of unintentional starting. Be sure your tool is turned off before plugging it in. Do not use a tool if the power switch does not turn the tool on and off. Do not carry a plugged-in tool with your ﬁ nger on the switch.

15. Remove all adjusting keys and wrenches. Make a habit of checking that adjusting keys, wrenches, etc. are removed from the tool before turning it on.

16. Do not overreach. Maintain control. Keep proper footing and balance at all times.

17. Use safety equipment. Everyone in the work area should wear safety goggles or glasses with side shields complying with current safety standards. Everyday eyeglasses only have impact resistant lenses. They are not safety glasses. Wear hearing protection during extended use and a dust mask for dusty operations. Hard hats, face shields, safety shoes, etc. should be used when speciﬁ ed or necessary. Keep a ﬁ re ex- tinguisher nearby.

18. Keep guards in place and in working order.

19. Never stand on tool. Serious injury could occur if the tool is tipped or if the cutting tool is unintentionally contacted.

20. Keep hands away from all cutting edges and moving parts.

TOOL USE AND CARE

21. Secure work. Use clamps or a vise to hold work when practical. It is safer than using your hand and it frees both hands to operate the tool.

22. Do not force tool. Your tool will per- form best at the rate for which it was designed. Excessive force only causes operator fatigue, increased wear and reduced control.

23. Use the right tool. Do not use a tool or attachment to do a job for which it is not recommended. For example, do not use a circular saw to cut tree limbs or logs. Do not alter a tool.

24. Unplug tool when it is not in use, before changing accessories or performing recommended maintenance.

25. Store idle tools. When not in use, store your tool in a dry, secured place. Keep out of reach of children.

26. Never leave the tool running unat- tended. Turn power off. Do not leave the tool until it comes to a complete stop.

27. Check for damaged parts. Inspect guards and other parts before use. Check for misalignment, binding of moving parts, improper mounting, broken parts and any other conditions that may affect operation. If abnormal noise or vibration occurs, turn the tool off immediately and have the problem corrected before further use. Do not use a damaged tool. T ag damaged tools “DO NOT USE” until repaired. A guard or other damaged part should be properly repaired or replaced by a MILWAUKEE service facility. For all repairs, insist on only identical replacement parts.

28. Use proper accessories. Consult this manual for recommended accessories. Using improper accessories may be hazardous. Be sure accessories are properly installed and maintained. Do not defeat a guard or other safety device when installing an accessory or attachment.

29. Maintain tools carefully. Keep cutting edges sharp and clean. Follow instructions for lubricating and changing accessories. Periodically inspect tool cords and extension cords for damage. Have damaged parts repaired or replaced by a MILWAUKEE service facility.

30. Maintain labels & nameplates. These carry important information. If unreadable or missing, contact a MILWAUKEE service facility for a free replacement.

SERVICE

31. Tool service must be performed only by qualiﬁ ed repair personnel. Service

or maintenance performed by unqualiﬁ ed personnel may result in a risk of injury.

32. When servicing a tool, use only iden-

tical 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 shock or injury.

2 3

SPECIFIC SAFETY RULES

FUNCTIONAL DESCRIPTION

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

• lead from lead-based paint

• crystalline silica from bricks and cement and other masonry products, and

• arsenic and chromium from chemicallytreated 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 speciﬁ cally designed to ﬁ lter out microscopic particles.

2. Read, understand, and follow the

instructions packaged with the router table and router lift. Do not plug in

Remote Power until Router T able Motor is fully installed.

3. Only use the following recommended

router tables and router lifts with this motor.

JessEm Mast-R-Lift #02101 with

required Shim Kit #02116

JessEm Mast-R-Lift #02102 with

required Shim Kit #02116

JessEm Mast-R-Lift Excel #02201 with

required Shim Kit #02116.

Using tables and lifts that are not spe-

ciﬁ cally recommended may not prop- erly secure the Router Table Motor with Remote Power. An improperly secured Motor increases the risk of injury or product damage.

4. Do not place motor in a router base

or hold motor by hand during use. Motor is designed only for use properly

secured in a recommended JessEm router lift or router table. This motor is not designed for use in a MILWAUKEE router base. Do not use this motor unless it is securely installed into a recommended JessEm router lift and router table.

5. Always wear safety goggles and dust

mask. Use only in a well ventilated area. Using personal safety devices and

in a safe environment reduce the risk for injury.

6. Some woods contain preservatives that can be toxic. Take extra care to prevent inhalation and skin contact when working with these materials. Request, and follow, any safety information available from your material supplier.

7. Always make sure the workpiece is

free from nails, screws and other foreign objects. Keep the working edge away from the clamping surface.

Cutting these objects can cause loss of control of the workpiece and damage to the bit.

8. Never place hands near cutting sur-

face.

9. Never use dull or damaged bits. Sharp bits must be handled with care. Damaged bits can break during

use. Dull bits require more force, which could cause the bit to break. Damaged bits can throw carbide pieces and burn the workpiece.

10. After changing the bit or making any

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

devices can unexpectedly shift, causing loss of control. Loose rotating components will be violently thrown. Watch for vibration or wobbling that could indicate an improperly installed bit.

11. Always keep the power supply cord

away from moving parts on the tool.

12. Never start the tool when the bit is in contact with the material. The bit cut-

ting edge may grab the material causing loss of control of the workpiece.

13. Never touch the bit during or imme- diately after use. After use the bit may be hot enough to burn bare skin.

14. To reduce the risk of injury, avoid “climb cutting.” Climb cutting can cause the workpiece to be thrown violently out of your control. Even small router bits can result in climb cutting. Always feed the workpiece against the cutter rotation.

4 5

Cat. No. 5626-68 *

1. Variable speed dial

2. Lock key

3. On/Off switch

4. Cord

5. Power box nameplate (on back)

6. Motor unit nameplate (on back)

7. Motor

8. Collet assembly

Symbology

Double Insulated

Volts Alternating Current No Load Revolutions

per Minute (RPM) Amperes

Do not expose to rain or use in damp locations.

* Consists of 5626-69 motor and

23-37-0175 power box.

Speciﬁ cations

Motor

Cat. No 5626-69

For use with:

JessEm Mast-R-Lift™ #02101 with required Shim Kit #02116

JessEm Mast-R-Lift™ #02102 with required Shim Kit #02116

JessEm Mast-R-Lift™ Excel #02201 with required Shim Kit #02116

Volts

120

Amps

No Load

RPM

10,000 -22,000

GROUNDING

EXTENSION CORDS

WARNING

Improperly connecting the grounding wire can result in the risk of electric shock. Check with a qualiﬁ ed electri- cian if you are in doubt as to whether the outlet is properly grounded. Do not modify the plug provided with the tool. Never remove the grounding prong from the plug. Do not use the tool if the cord or plug is damaged. If damaged, have it repaired by a MILWAUKEE service facility before use. If the plug will not ﬁ t the outlet, have a proper outlet installed by a qualiﬁ ed electrician.

Grounded Tools: Tools with Three Prong Plugs

Tools marked “Grounding Required” have a three wire cord and three prong grounding plug. The plug must be connected to a properly grounded outlet (See Figure A). If the tool should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user, reducing the risk of electric shock.

The grounding prong in the plug is connected through the green wire inside the cord to the grounding system in the tool. The green wire in the cord must be the only wire connected to the tool's grounding system and must never be attached to an electrically “live” terminal.

Your tool must be plugged into an appropriate outlet, properly installed and grounded in accordance with all codes and ordinances. The plug and outlet should look like those in Figure A.

Double Insulated Tools: Tools with Two Prong Plugs

Tools marked “Double Insulated” do not require grounding. They have a special double insulation system which satisfies OSHA requirements and complies with the applicable standards of Underwriters Laboratories, Inc., the Canadian Standard Association and the National Electrical Code. Double Insulated tools may be used in either of the 120 volt outlets shown in Figures B and C.

Grounded tools require a three wire extension cord. Double insulated tools can use either a two or three wire extension cord. As the distance from the supply outlet increases, you must use a heavier gauge extension cord. Using extension cords with inadequately sized wire causes a serious drop in voltage, resulting in loss of power and possible tool damage. Refer to the table shown to determine the required minimum wire size.

The smaller the gauge number of the wire, the greater the capacity of the cord. For example, a 14 gauge cord can carry a higher current than a 16 gauge cord. When using more than one extension cord to make up the total length, be sure each cord contains at least the minimum wire size required. If you are using one extension cord for more than one tool, add the nameplate amperes and use the sum to determine the required minimum wire size.

Guidelines for Using Extension Cords

• If you are using an extension cord outdoors, be sure it is marked with the sufﬁ x “W-A” (“W” in Canada) to indicate that it is acceptable for outdoor use.

• Be sure your extension cord is properly wired and in good electrical condition. Always replace a damaged extension cord or have it repaired by a qualiﬁ ed person before using it.

• Protect your extension cords from sharp objects, excessive heat and damp or wet areas.

Recommended Minimum Wire Gauge

Nameplate

* Based on limiting the line voltage drop to ﬁ ve volts at 150% of the rated amperes.

for Extension Cords*

Amperes

0 - 2.0

2.1 - 3.4

3.5 - 5.0

5.1 - 7.0

7.1 - 12.0

12.1 - 16.0

16.1 - 20.0

Extension Cord Length

25' 18

18 18 18 16 14 12

50'

18 18 18 16 14 12 10

75'

18 18 16 14 12 10

100'

18 16 14 12 10

150'

16 14 12 12

Fig. A

READ AND SAVE ALL INSTRUCTIONS FOR FUTURE USE.

Fig. B

6 7

Fig. C

TOOL ASSEMBLY

WARNING

To reduce the risk of injury, always unplug tool before attaching or removing accessories or making adjustments. Use only speciﬁ cally recommended accessories. Others may be hazardous.

Collets

The collet must be attached to the collet nut before it is put into the collet shaft. Be sure that the size of the collet matches the size of the bit shank being used. If the wrong size bit shank is used, the collet may break. For attaching or detaching the collet nut to the collet, follow the illustrated instructions on this page.

Attaching Collet to Collet Nut

To assemble, place the narrow end of the collet on an even surface. Take the nut and place it over the collet (Fig. 1).

Fig. 1

Position nut squarely over collet with the smaller opening of the nut facing up (Fig. 2).

Fig. 2

Snap nut and collet together by ﬁ rmly apply- ing downward pressure into assembly with palm of hand (Fig. 3).

Fig. 3

To remove collet from nut, hold nut ﬁ rmly with one hand and press the collet to one side with the other hand (Fig. 4).

Fig. 4

WARNING

To reduce the risk of injury, wear safety goggles or glasses with side shields. To reduce the risk of injury, always unplug tool before attaching or removing accessories or making adjustments. Use only speciﬁ cally recommended accessories. Others may be hazardous.

Installing the Motor into the Lift

WARNING

To reduce the risk of injury , use only the following router tables and lifts with this motor.

JessEm Mast-R-Lift™ #02101 with required Shim Kit #02116

JessEm Mast-R-Lift™ #02102 with required Shim Kit #02116

JessEm Mast-T-Excel™ #02201 with required Shim Kit #02116.

Using other tables and lifts may not properly secure the Router Table Motor with Remote Power. An improperly secured motor increases the risk of injury or product damage.

To install the motor into a router lift, read, understand, and follow the instructions packaged with the router lift.

Installing the Bit

It is not necessary to remove the motor from the lift to install a collet assembly or a bit. (If removal of the motor is desired, see the lift instructions.) Raise the motor as high as possible. Always wipe 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. Insert the bit shank into the collet as far as it will go.

2. Back the bit shank out slightly to avoid bottoming out.

3. 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. 5).

4. 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.

5. To tighten the bit in the collet assembly, use two wrenches (Fig. 6).

Fig. 6

NOTE: Never tighten a collet assembly

without inserting a bit shank of the proper size. This may damage the collet.

Removing the Bit

1. Loosen the collet nut from the collet shaft using two wrenches.

2. Once loose, unscrew the collet nut by hand until it feels tight again.

3. Return to using the wrenches until the bit shank can be pulled out.

Fig. 5

Minimum

Collet nut

8 9

1/16"

Collet

Bit shank

OPERATION

WARNING

WRONG! CLIMB CUTTING

WARNING

To reduce the risk of injury, wear safety goggles or glasses with side shields. Always wait for the bit to stop completely and unplug the tool before changing accessories or making adjustments. Never make adjustments while the router is running. Do not defeat the guards.

Do not use this router unless it is securely installed into a recommended JessEm router lift and table.

Using the Variable Speed Dial

The variable speed dial allows the user to adjust the rotating speed (RPM) of the tool.

Variable speed dial settings range from numbers (7) seven through (1) one. Higher numbers correspond to higher speeds and lower number correspond to lower speeds.

T o change the speed, set the variable speed control dial to the desired number.

Use the following chart to determine the best speed for the bit diameter.

Speed setting

1 2 3 4 5 6 7

RPM 10,000 12,000 14,000 16,000 18,000 20,000 22,000

Max. Bit

Diameter 3" to 3-1/2" 3" to 3-1/2"

2-1/4" to 2-1/2" 2-1/4" to 2-1/2"

1-1/4" to 2"

1" 1"

Starting and Stopping Motor

1. To start the motor, lift up the On/Off switch. The switch will stay up until it is pushed down.

2. To stop the motor, push down the On/Off switch.

3. To lock the motor, pull out the lock key. With the lock key removed, the On/Off switch will not turn on the motor when lifted up. However, if the lock key is removed when the motor is on, pushing down the on/off switch will still turn off the motor.

Electronic Overload Protection

Before the motor is overloaded, the electronic overload protection circuit will turn off the tool.

If the motor shuts off during use, push down the On/Off switch. Wait at least three (3) seconds. This will reset the electronics in the tool. Lift up the On/Off switch to continue use.

Soft Start

The Soft-Start feature reduces the amount of torque reaction to the tool. This feature gradually increases the motor speed up from zero to the speed set by the variable speed dial.

Feedback Control

The electronic speed control system allows the tool to maintain constant speed between no-load and load conditions.

To reduce the risk of injury, always use feather boards, push sticks or push blocks with proper guarding. Keep hands away from moving bit. Refer to the Router Table manual for proper table setup and use.

Making the Cut

The speed and depth of cut will depend largely on the type of material being worked. Keep the cutting pressure constant but do not use excessive force so the motor speed slows excessively. It may be necessary on exceptionally hard woods or problem materials to make more than one pass to get the desired depth of cut.

Before beginning the cut on the actual workpiece, it is advisable to take a sample cut on a scrap piece of lumber. This will show you exactly how the cut will look as well as enable you to check dimensions.

Position the fence so that the workpiece feeds against the cutter rotation. Feeding the workpiece with the cutter rotation is called climb cutting, which is very dangerous. Climb cutting can result in the workpiece being thrown violently out of your control at great speed.

WARNING

To reduce the risk of injury, avoid “climb cutting.” Climb cutting can cause the workpiece to be thrown violently out of your control. Even small router bits can cause in climb cutting.

Fence

Direction of Rotation

Direction of Feed

CORRECT! FEED AGAINST

CUTTER ROTATION.

Fence

Direction of Rotation

Direction of Feed

CAUTION! CLIMB CUTTING COULD

OCCUR IF CUTTING COMPLETELY THROUGH THE STOCK.

Fence

Direction of Rotation

Direction of Feed

10 11

MAINTENANCE

WARNING

To reduce the risk of injury, always unplug your tool before performing any maintenance. Never disassemble the tool or try to do any rewiring on the tool's electrical system. Contact a MILWAUKEE service facility for ALL repairs.

Maintaining Tools

Keep your tool in good repair by adopting a regular maintenance program. Before use, examine the general condition of your tool. Inspect guards, switches, tool cord set and extension cord for damage. Check for loose screws, misalignment, binding of moving parts, improper mounting, broken parts and any other condition that may affect its safe operation. If abnormal noise or vibration occurs, turn the tool off immediately and have the problem corrected before further use. Do not use a damaged tool. Tag damaged tools “DO NOT USE” until repaired (see “Repairs”).

Under normal conditions, relubrication is not necessary until the motor brushes need to be replaced. After six months to one year, depending on use, return your tool to the nearest MILWAUKEE service facility for the following:

• Lubrication

• Brush inspection and replacement

• Mechanical inspection and cleaning (gears, spindles, bearings, housing, etc.)

• Electrical inspection (switch, cord, armature, etc.)

• T esting to assure proper mechanical and electrical operation

WARNING

To reduce the risk of injury, electric shock and damage to the tool, never immerse your tool in liquid or allow a liquid to ﬂ ow inside the tool.

Cleaning

Clean dust and debris from vents. Keep the tool handles clean, dry and free of oil or grease. Use only mild soap and a damp cloth to clean your tool since certain cleaning agents and solvents are harmful to plastics and other insulated parts. Some of these include: gasoline, turpentine, lacquer thinner, paint thinner, chlorinated cleaning solvents, ammonia and household detergents containing ammonia. Never use ﬂ ammable or combustible solvents around tools.

Repairs

If your tool is damaged, return the entire tool to the nearest service center.

ACCESSORIES

WARNING

To reduce the risk of injury, always unplug the tool before attaching or removing accessories. Use only speciﬁ cally recommended accessories. Others may be hazardous.

For a complete listing of accessories refer to your MILWAUKEE Electric Tool catalog or go on-line to www.milwaukeetool.com. To obtain a catalog, contact your local distributor or a service center.

For a complete list of JessEm router tables and lifts, visit JessEm at www.jessem.com or contact a distributor near you.

The following JessEm lifts accept the Milwaukee Motor with Control Box.

JessEm Mast-R-Lift™ #02101 with required Shim Kit #02116

JessEm Mast-R-Lift™ #02102 with required Shim Kit #02116

JessEm Mast-R-Lift™ Excel #02201 with required Shim Kit #02116

FIVE YEAR TOOL

LIMITED WARRANTY

Every MILWAUKEE tool is tested before leaving the factory and is warranted to be free from defects in material and workmanship. MILWAUKEE will repair or replace (at MILWAUKEE’s discretion), without charge, any tool (including battery chargers) which examination proves to be defective in material or workmanship from ﬁ ve (5) years after the date of purchase. Return the tool and a copy of the purchase receipt or other proof of purchase to a MILW AUKEE Factory Service/Sales Support Branch location or MILWAUKEE Authorized Service Station, freight prepaid and insured. This warranty does not cover damage from repairs made or attempted by other than MILW AUKEE authorized personnel, abuse, normal wear and tear, lack of maintenance, or accidents.

The warranty period for V28 Battery Packs is two (2) years from the date of purchase. The warranty period for Ni-Cd battery Packs, Flashlights, Radios are warranted for one (1) year from the date of purchase.

THE REPAIR AND REPLACEMENT REMEDIES DESCRIBED HEREIN ARE EXCLUSIVE. IN NO EVENT SHALL MILWAUKEE BE LIABLE FOR ANY INCIDENTAL, SPECIAL, OR CONSEQUENTIAL DAMAGES, INCLUDING LOSS OF PROFITS.

THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, OR CONDITIONS, WRITTEN OR ORAL, EXPRESSED OR IMPLIED FOR MERCHANTABLILITY OR FITNESS FOR P ARTICULAR USE OR PURPOSE.

This warranty gives you speciﬁ c legal rights. Y ou may also have other rights that vary from state to state and province to province. In those states that do not allow the exclusion of implied warranties or limitation of incidental or consequential damages, the above limitations or exclusions may not apply to you. This warranty applies to the United States, Canada, and Mexico only.

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