Porter-Cable A22440 User Manual

Instruction Manual

Manuel d’Utilisation

Manual de Instrucciones

MODELS 690LR, 691, & 690LRVS AND 6931 PLUNGE BASE

ROUTER

TOUPIES

CONTORNEADORES

ADVERTENCIA: Lease este instructivo antes de usarel producto.

www.porter-cable.com

Instructivo de operacion,

centros de servicio y poliza de garantia.

A22440-02-06-07-Rev.A

General Safety Rules

shock, ﬁ re and/or serious injury. The term “power tool” in all of the warnings listed below refers to your

Read all instructions. Failure to follow all instructions listed below may result in electric

mains-operated (corded) power tool or battery-operated (cordless) power tool.

SAVE THESE INSTRUCTIONS

chips often accumulate on interior surfaces and could create a risk of serious injury, electrical shock or death.

• Never run the motor unit when it is not inserted in one of the router bases. The motor is not designed to be handheld.

• Keep handles dry, clean, and free from oil and grease. This will enable better control of the tool.

• Keep hands away from cutting area. Never reach under the workpiece for any reason. Keep the router base firmly in contact with the workpiece when cutting. Hold the router only by the handles. These precautions will reduce the risk of personal injury.

• Use sharp cutters. Dull cutters 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 stopped completely before you lay the router down. If the cutter head is still spinning when the tool is laid down, it could cause injury or damage.

• 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 it could make the router jump, causing damage or injury.

• Do not press spindle lock button while the motor is running. Doing so can damage the spindle lock.

Wear appropriate hearing protection during use [ANSI S12.6 (S3.19)]. Under some con-

ditions and duration of use, noise from this product may contribute to hearing loss.

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.

• arsenic and chromium from chemically-treated lumber (CCA).

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 filter out microscopic particles.

other construction activities. Wear protective clothing and wash exposed areas with soap and water. Allowing dust to get into your mouth, eyes, or lay on the skin may promote absorption of harmful chemicals.

permanent respiratory or other injury. Always use NIOSH/OSHA approved respiratory protection appropriate for the dust exposure. Direct particles away from face and body.

Also use face or dust mask if cutting operation is dusty. ALWAYS WEAR CERTIFIED SAFETY EQUIPMENT:

• ANSI Z87.1 eye protection (CAN/CSA Z94.3)

• ANSI S12.6 (S3.19) hearing protection

• NIOSH/OSHA/MSHA respiratory protection

SYMBOLS

The label on your tool may include the following symbols. The symbols and their definitions are as follows:

V....................... volts A........................... amperes

Hz .................... hertz W ......................... watts

min .................. minutes

(grounded) ........................ safety alert symbol

(double insulated) per minute

BPM ..............beats per minute

Some dust created by power sanding, sawing, grinding, drilling, and other construction

Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling, and

Use of this tool can generate and/or disburse dust, which may cause serious and

ALWAYS USE SAFETY GLASSES. Everyday eyeglasses are NOT safety glasses.

....................... alternating current

............... direct current

.................... Class I Construction ......................... earthing terminal

..................... Class II Construction …/min ................. revolutions or reciprocations

o ......................... no load speed

SAVE THESE INSTRUCTIONS

MOTOR

Do not operate tools rated A.C. only on D.C. current. To do so may seriously damage the tool.

Do not operate your tool on a current on which the voltage is not within correct limits.

1) Work area safety

a) Keep work area clean and well lit. Cluttered or dark areas invite accidents. b) Do not operate power tools in explosive atmospheres, such as in the presence of

ﬂ ammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.

c) Keep children and bystanders away while operating a power tool. Distractions can

2) Electrical safety

cause you to lose control.

a) Power tool plugs must match the outlet. Never modify the plug in any way. Do not use

anyadapter plugs with earthed (grounded) power tools. Unmodiﬁ ed plugs and matching outlets will reduce risk of electric shock.

b) Avoid body contact with earthed or grounded surfaces such as pipes, radiators, rang-

es and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.

c) Do not expose power tools to rain or wet conditions. Water entering a power tool will

increase the risk of electric shock.

d) 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. Use only 3-wire extension cords that have 3-prong grounding-type plugs and 3-pole receptacles that accept the tool’s plug.

e) When operating a power tool outdoors, use an extension cord suitable for outdoor

use. If an extension cord is to be used outdoors, it must be marked with the sufﬁ x W-A or W following the cord type designation. Use of a cord suitable for outdoor use reduces the risk of electric shock. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. The following table shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

Minimum Gauge for Cord Sets

Volts Total Length of Cord in Feet

120V 0-25 26-50 51-100 101-150 240V 0-50 51-100 101-200 201-300

Ampere Rating Gauge of wire in AWG units

From 10 to 12 amps 16 16 14 12

3) Personal safety a) 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 inﬂ uence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in

serious personal injury.

b) Use safety equipment. Always wear eye protection. Safety equipment such as dust

mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.

c) Avoid accidental starting. Be sure the switch is in the off-position before plugging in.

Carrying power tools with your ﬁ nger on the switch or plugging in power tools that have the switch on invites accidents.

d) 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.

e) Do not overreach. Keep proper footing and balance at all times. This enables better

control of the power tool in unexpected situations.

f) Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and

gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts. Air vents often cover moving parts and should also be avoided.

g) If devices are provided for the connection of dust extraction and collection facilities,

ensure these are connected and properly used. Use of these devices can reduce dustrelated hazards.

4) Power tool use and care

a) Do not force the power tool. Use the correct power tool for your application. The cor-

rect power tool will do the job better and safer at the rate for which it was designed.

b) 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.

c) Disconnect the plug from the power source before making any adjustments, chang-

ing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.

d) 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.

e) Maintain power tools. Check for misalignment or binding of moving parts, breakage

of parts and any other condition that may affect the power tools operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly

maintained power tools.

f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting

edges are less likely to bind and are easier to control.

g) Use the power tool, accessories and tool bits etc., in accordance with these instruc-

tions and in the manner intended for the particular type of power tool, 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

a) Have your power tool serviced by a qualiﬁ ed repair person using only identical re-

placement parts. This will ensure that the safety of the power tool is maintained.

ADDITIONAL SPECIFIC SAFETY RULES

• Hold tool by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord. Contact with a “live” wire will make exposed metal parts of the tool “live” and shock the operator.

• Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body leaves it unstable and may lead to loss of control.

• Metal cutting with router: If using router for metal cutting, clean out tool often. Metal dust and

To reduce the risk of injury, turn unit off and disconnect it from power source before

OPERATION

installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

between 10,000 and 13,000 RP

INSTALLING THE BIT (1001 BASE)

installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

To remove the motor unit from the base unit:

2. Clean and insert the shank of the bit into the collet until the shank bottoms, then back it out

3. Lay the power unit on its side on a bench with the collet pointing AWAY from you.

4. Place one wrench on the flats of the chuck with the opposite end of the wrench resting on the

5. Place the other wrench on the collet and tighten COUNTER-CLOCKWISE. Tighten firmly.

6. To remove the bit, reverse the procedure.

INSTALLING THE MOTOR

installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

1. Open the clamp (A) Fig. 1 and set the power unit in the base unit.

2. Align the lower pin of the power unit (B) Fig. 1 with the groove in the base.

3. Rotate the power unit CLOCKWISE into the base until the upper guide pins are set in the groove of

4. Close the clamp.

ADJUSTING THE DEPTH OF CUT

installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

1. Open the clamp (A) Fig. 3.

2. Hold the base (E) and turn the power unit (F) Fig. 3 counter-clockwise until the tip of the bit is above

3. Set the tool on a flat surface.

4. Turn the power unit (F) Fig. 3 clockwise until the bit touches the work.

5. Close the clamp (A) Fig. 3.

6. Rotate the depth adjusting ring (B) Fig. 3 until the zero-line (C) is opposite the index line (D) on

7. Open the clamp (A) Fig. 3.

8. Tip the router so that the bit is clear of the work surface. Turn the power unit (F) Fig. 3 clockwise

9. Close the clamp (A) Fig. 3. NOTE: Setting the index line to 1/4" on the ring means the cutting edge of the bit is exposed 1/4" below the base.

ADJUSTING THE SUB-BASE ALIGNMENT (Plunge Base)

installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

Applications using a template guide require the bit to be centered in the guide. This, in turn, requires the center hole in the sub-base to be in line with the collet of the motor unit. Your model has an adjustable sub-base that has been aligned at the factory. The fixed-base router comes with the large hole.

1. Loosen the sub-base mounting screws (C) Fig. 4 just enough to allow the sub-base (D) to move.

2. Open the clamp (A) and adjust the power unit so that the collet nut (B) engages the center hole

3. Tighten the sub-base mounting screws (C) Fig. 4 securely.

INSTALLING THE MOTOR (6931 Plunge Base)

installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

1. Support the motor clamp (D) Fig. 5 and loosen the motor clamp screw (A) Fig. 5 approximately

2. Insert the motor unit into the base with the switch positioned at the front of the left handle. Align the

3. Seat the motor in the base and tighten the motor clamp screw.

REMOVING THE MOTOR

installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

1. Remove the clamp screw (A) Fig. 5, flat washer (B), lock washer (C), and clamp-locking nut (A)

2. Insert the hex wrench (A) Fig. 8 to contact the locking plate (B) Fig. 6. Tap lightly to release and

3. Slide the motor out of the base.

4. Reattach the clamp screw, lock washer, flat washer, locking plate and clamp locking nut to the

Use

router bits with a diameter larger than

To reduce the risk of injury, turn unit off and disconnect it from power source before

(a) Open the clamp (A) Fig. 1. (b) While holding the base, turn the power unit COUNTER-CLOCKWISE until the lower pin (B)

in the motor housing is disengaged from groove in base.

approximately 1/16".

bench to your left (Fig. 2).

Avoid possible damage to the collet. Never tighten the collet without a bit.

To reduce the risk of injury, turn unit off and disconnect it from power source before

the base.

To reduce the risk of injury, turn unit off and disconnect it from power source before

the bottom of the base.

the housing.

until the index line (D) on the motor housing reaches the desired depth indicated on the ring.

To reduce the risk of injury, turn unit off and disconnect it from power source before

in the sub-base (D). Allow the sub-base to center itself on the collet nut. Close the clamp.

To reduce the risk of injury, turn unit off and disconnect it from power source before

1/2" with the hex wrench (furnished).

four pins (A) Fig. 7 (two of which are shown) in the motor case with the slots (B) Fig. 6 in the base.

To reduce the risk of injury, turn unit off and disconnect it from power source before

Fig. 6.

remove the locking plate.

base and tighten lightly.

The maximum diameter bit is 3

2-1/2" ONLY

-1/2".

when the speed control is set

]

/2"

Fig. 1

Fig. 6

Fig. 3

Fig. 2

Fig. 7

Fig.8

Fig. 4

Fig. 5

Fig. 9

Fig. 10

Fig. 11A

Fig. 11B

1-1/4"

Fig. 12

Fig. 13

Fig. 14

F B

B A

Fig. 15

ADJUSTING THE PLUNGE BASE

installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

1. Loosen the depth rod locking knob (A) Fig. 9, and the depth indicator knob (D), allowing the depth rod (E) to contact one of the turret stops (B). Normally the deepest desired cut is set with the depth rod resting on the shortest turret stop (A) Fig. 10. The other two fixed stops (B) Fig. 10 provide reduced cutting depths of 1/4" and 1/2" respectively. You can adjust the three stops (C) Fig. 10 to any desired height. You can utilize any combination of fixed and/or adjustable stops to achieve the desired depths required for a particular job.

2. Release the plunge mechanism by pulling the locking lever (B) Fig. 11A to the left. Lower the plunge mechanism until the router bit touches the work surface. Release the lever and push it to the right to lock the mechanism in this position.

3. Tighten the depth-rod locking knob.

4. Position the depth indicator (A) Fig. 11B at the "0" position and tighten the knob.

5. Loosen depth-rod locking knob (A) Fig 9. Raise the indicator until it aligns with the graduation representing the desired depth of plunge. (The example in Fig. 12 shows setting for 1" plunge.)

6. Turn the lower travel-limiting nut (A) Fig. 12 until it is approximately 1/4" above the top of the the plunge housing. While holding the lower nut, turn the upper nut (B) until it "jams" against the lower nut (A) Fig. 12.

which could prevent full bit retraction.

clear of the workpiece.

Increasing the travel beyond 2-1/2" can cause the mechanism to jam.

ADJUSTING THE PLUNGE LOCKING LEVER

installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

You can adjust the plunge-locking mechanism to reposition the lever (in the locked position), or to compensate for wear.

1. While holding the lever in the upright position (Fig. 13), remove the retaining screw. Continue

to hold the lever through the remaining steps.

2. Use an 1/8" hex wrench (A) Fig. 14 (not furnished) to turn the adjustment screw counter-clock-

wise approximately 1/2 turn.

3. Move the lever to the desired locked position and tighten the adjustment screw.

4. Remove the hex wrench and replace the retaining screw.

ATTACHING THE POWER UNIT TO THE "D" HANDLE BASE

installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

1. Loosen the clamp screw (A) Fig. 15 to set the power unit in the base unit.

2. With the motor switch (C) Fig. 15 in the "ON" position, insert the motor unit into the base aligning the lower pin (B) with the groove in the base.

3. Rotate the motor unit into the base CLOCKWISE until the motor switch (A) Fig. 16 is directly above the knob handle (B).

4. Connect the motor unit cord to the outlet in handle (C) Fig. 16.

5. Continue rotating the motor unit into the base until upper guide pins set rigidly into base.

6. Tighten the clamp screw firmly.

ADJUSTING THE DEPTH OF CUT

installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

1. Loosen the clamp screw (A) Fig. 17.

2. Hold the base (E) and turn the motor unit (F) Fig. 17 counter-clockwise until the tip of the bit is above the bottom of the base.

3. Set the router on a flat surface.

4. Turn the motor unit (F) Fig. 17 clockwise until bit touches the wood surface.

5. Tighten the clamp screw (A) Fig. 17.

6. Rotate the depth adjusting ring (B) Fig. 17 until the zero-line (C) is opposite the index line (D) on the housing.

7. Loosen the clamp screw (A) Fig. 17.

8. Tip the router so that the bit is clear of the wood surface. Turn the motor unit (F) Fig. 17 clockwise until the index line (D) on the motor housing reaches the desired depth indicated on the ring.

9. Tighten the clamp screw (A) Fig. 17 firmly.

NOTE: Setting the index line to 1/4" on the ring means the cutting edge of the bit is exposed 1/4" below the base.

CONNECTING TO POWER SOURCE

"OFF" position. Also, check the power circuit to see that it is the same as that shown on specification plate of the tool.

STARTING AND STOPPING THE MOTOR

grip on tool to resist starting torque.

To start the tool, move the rocker switch (A) Fig. 18 to the "ON" or "1" position. To stop the tool, move the rocker switch to the "OFF" or "O" position.

unit to come to a COMPLETE STOP before putting the tool down.

STARTING AND STOPPING THE MOTOR - “D” HANDLE

firm grip on the tool to resist starting torque.

COMPLETE STOP before putting the tool down. Check to see that the motor unit power cord (D) Fig. 16 is plugged into the handle, and that the

switch (A) on the motor is set to the “ON” position. The starting and stopping of the motor is then

To reduce the risk of injury, turn unit off and disconnect it from power source before

Jam the travel-limiting nuts together to prevent movement (caused by vibration)

Set the travel limiting nuts so that bit can be retracted into the base of the router,

DO NOT attempt to increase the plunge travel by readjusting the stop nut.

To reduce the risk of injury, turn unit off and disconnect it from power source before

Before connecting tool to power source, check to see that the switch is in the

Before starting the tool, clear the work area of all foreign objects. Also keep firm

To avoid personal injury and/or damage to finished work, always allow the power

Before starting the tool, clear the work area of all foreign objects. Also keep a

To avoid injury and/or damage to finished work, always allow motor to come to a

Fig. 16

Fig. 18

Fig. 17

controlled by pressing and releasing the trigger switch (E) Fig. 16 in the handle of the base. To allow the tool to run without continually pressing the trigger, press the trigger (E) into the handle and engage the switch locking button (F) on the side of the handle. While holding the button in, slowly release the trigger. To stop the tool, squeeze the trigger into the handle and release.

To avoid injury and/or damage to finished work, always allow motor to come to a

COMPLETE STOP before putting the tool down.

VARIABLE SPEED CONTROL (690LRVS)

This router is equipped with a variable speed control (A) Fig. 19 with an infinite number of speeds between 10,000 and 27,000 RPM. Adjust the speed by turning the speed control knob (A), labeled 1 through 4, with 1 being the slowest speed and 4 being the highest.

USING THE TOOL

Always be sure the work is rigidly clamped or otherwise secured before making a cut. When routing the edges, hold the router firmly down and against the work with both guiding knobs. Since the cutter rotates clockwise (when viewing router from top), the router should be moved from left to right as you stand facing the work.

When working on the inside of a template, move the router in a clockwise direction. When working on the outside of a template, move the router in a counter- clockwise direction.

Avoid “Climb-Cutting” (cutting in direction opposite that shown in Fig. 20).

“Climb-Cutting” increases the chance for loss of control resulting in possible injury. When “Climb-Cutting” is required (backing around a corner), exercise extreme caution to maintain control of router. The speed and depth of cut will depend largely on the workpiece. Keep the cutting pressure constant but do not crowd the router so the motor speed slows excessively. On exceptionally hard woods or problem materials, more than one pass at various settings may be necessary to get the desired depth of cut.

When making cuts on all four edges of the workpiece, make the first cut on the end of the piece across the grain. If chipping of wood occurs at the end of a cut, it will be removed when making the next cut parallel with the grain. Periodically wipe columns clean with a dry cloth. DO NOT lubricate the columns.

Fig. 19

TROUBLESHOOTING

For assistance with your tool, visit our website at www.porter-cable.com for a list of service centers, or call the Porter-Cable Customer Care Center at (888) 848-5175.

MAINTENANCE

To reduce the risk of injury, turn unit off and disconnect it from power source before installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

REPAIRS

For assistance with your tool, visit our website at www.porter-cable.com for a list of service centers, or call the Porter-Cable Customer Care Center at (888) 848-5175.

CLEANING

Periodically blow out all air passages with dry compressed air.

Use only mild soap and a damp cloth to clean the tool.

FAILURE TO START

Should your tool fail to start, check to make sure the prongs on the cord plug are making good contact in the outlet. Also, check for blown fuses or open circuit breakers in the line.

LUBRICATION

This tool has been lubricated with a sufﬁ cient amount of high grade lubricant for the life of the unit under normal operating conditions. No further lubrication is necessary.

BRUSH INSPECTION (If applicable)

For your continued safety and electrical protection, brush inspection and replacement on this tool should ONLY be performed by a PORTER-CABLE FACTORY SERVICE CENTER OR PORTER-CABLE AUTHORIZED WARRANTY SERVICE CENTER.

At approximately 100 hours of use, take or send your tool to your nearest Porter-Cable Factory Service center or Porter-Cable Authorized Warranty Service Center to be thoroughly cleaned and inspected. Have worn parts replaced and lubricated with fresh lubricant. Have new brushes installed, and test the tool for performance.

Any loss of power before the above maintenance check may indicate the need for immediate servicing of your tool. DO NOT CONTINUE TO OPERATE TOOL UNDER THIS CONDITION. If proper operating voltage is present, return your tool to the service station for immediate service.

Wear ANSI Z87.1 safety glasses while using compressed air.

Never let any liquid get inside the tool; never immerse any part of the tool into a liquid. Never use solvents or other harsh chemicals for cleaning the non-metallic parts of the tool.

SERVICE

REPLACEMENT PARTS

Use only identical replacement parts. For a parts list or to order parts, visit our website at servicenet. porter-cable.com. You can also order parts from your nearest Porter-Cable Factory Service Center or Porter-Cable Authorized Warranty Service Center. Or, you can call our Customer Care Center at (888) 848-5175.

SERVICE AND REPAIRS

All quality tools will eventually require servicing and/or replacement of parts. For information about Porter-Cable, its factory service centers or authorized warranty service centers, visit our website at www. porter-cable.com or call our Customer Care Center at (888) 848-5175. All repairs made by our service centers are fully guaranteed against defective material and workmanship. We cannot guarantee repairs made or attempted by others.

You can also write to us for information at PORTER-CABLE, 4825 Highway 45 North, Jackson, Tennessee 38305 - Attention: Product Service. Be sure to include all of the information shown on the nameplate of your tool (model number, type, serial number, etc.).

ACCESSORIES

A complete line of accessories is available from your Porter-Cable Factory Service Center or a PorterCable Authorized Warranty Service Center. Please visit our Web Site www.porter-cable.com for a catalog or for the name of your nearest supplier.

Since accessories other than those offered by Porter-Cable have not been tested with this product, use of such accessories could be hazardous. For safest operation, only Porter-Cable recommended accessories should be used with this product.

WARRANTY

To register your tool for warranty service visit our website at PORTER-CABLE LIMITED ONE YEAR WARRANTY: Porter-Cable warrants its Professional Power Tools for a

www.porter-cable.com

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Porter-Cable A22440 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual