Page 1
MODEL D4945
ROUTER LIFT
W/TABLE INSERT
OWNER'S MANUAL
(FOR MODELS MANUFACTURED SINCE 11/20)
Phone: (360) 734-3482 • Online Technical Support: [email protected]
COPYRIGHT © NOVEMBER, 2020 BY WOODSTOCK INTERNATIONAL, INC.
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT
THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC.
#21497MN Printed in Taiwan
Page 2
This manual provides critical safety instructions on the proper setup,
operation, maintenance, and service of this machine/tool. Save this
document, refer to it often, and use it to instruct other operators.
Failure to read, understand and follow the instructions in this manual
may result in fire or serious personal injury—including amputation,
electrocution, or death.
The owner of this machine/tool is solely responsible for its safe use.
This responsibility includes but is not limited to proper installation in
a safe environment, personnel training and usage authorization,
proper inspection and maintenance, manual availability and comprehension, application of safety devices, cutting/sanding/grinding tool
integrity, and the usage of personal protective equipment.
The manufacturer will not be held liable for injury or property
damage from negligence, improper training, machine modifications or
misuse.
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, cement and other masonry products.
• Arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, depending on how often you
do this type of work. To reduce your exposure to these chemicals:
Work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter
out microscopic particles.
Page 3
Contents
INTRODUCTION .................................................................................................. 2
Woodstock Technical Support
Machine Specifications
Identification
Controls & Components
SAFETY ............................................................................................................6
Standard Machinery Safety Instructions
Additional Safety for Router Tables
SETUP .............................................................................................................9
Unpacking
Items Needed for Setup
Inventory
Installing Router
Installing Router Lift Assembly
Installing Crank Handle Bracket
............................................................................................... 4
................................................................................................... 9
.................................................................................................... 9
.......................................................................................... 10
.................................................................................... 3
............................................................................ 2
................................................................................... 5
................................................................ 6
..................................................................... 8
................................................................................... 9
......................................................................... 11
....................................................................... 12
SAFETYINTRODUCTION
OPERATIONS ................................................................................................... 13
Operation Overview
Stock Inspection & Requirements
Table T-Slots
Squaring Fence & Table T-Slot
Adjusting Router Height
Using Table Insert
Edge Jointing
Profile Routing
Routing Small Stock
Free-Hand Routing
ACCESSORIES .................................................................................................. 21
Router Accessories
MAINTENANCE ................................................................................................. 22
General
Cleaning & Protecting
SERVICE ......................................................................................................... 23
General
Aligning Mounting Plate
Troubleshooting........................................................................................... 24
.............................................................................................. 15
............................................................................................. 17
.................................................................................................... 22
.................................................................................................... 23
..................................................................................... 13
..................................................................... 14
......................................................................... 15
................................................................................. 16
........................................................................................ 16
............................................................................................ 18
...................................................................................... 18
....................................................................................... 19
....................................................................................... 21
................................................................................... 22
................................................................................. 23
SETUPELECTRICAL MAINTENANCE
OPERATIONS
SERVICE PARTS
PARTS ........................................................................................................... 25
........................................................................................................ 25
Main
Main Parts List
WARRANTY ..................................................................................................... 27
............................................................................................ 26
USE THE QUICK GUIDE PAGE LABELS TO SEARCH OUT INFORMATION FAST!
Page 4
Model D4945 (For Machines Mfd. Since 11/20)
INTRODUCTION
INTRODUCTION
Woodstock Technical Support
This machine has been specially designed to provide many years of trouble-free service. Close attention
to detail, ruggedly built parts and a rigid quality control program assure safe and reliable operation.
Woodstock International, Inc. is committed to customer satisfaction. Our intent with this manual is to
include the basic information for safety, setup, operation, maintenance, and service of this product.
We stand behind our machines! In the event that questions arise about your machine, please
contact Woodstock International Technical Support at (360) 734-3482 Ext. 2 or send e-mail to:
[email protected]. Our knowledgeable staff will help you troubleshoot problems and process warranty claims.
If you need the latest edition, you can download it from http://www.woodstockint.com/manuals.
If you have comments about this manual, please contact us at:
Woodstock International, Inc.
Attn: Technical Documentation Manager
P.O. Box 2309
Bellingham, WA 98227
Email: [email protected]
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Page 5
INTRODUCTION
MACHINE
Model D4945 (For Machines Mfd. Since 11/20)
Machine Specifications
SPECIFICATIONS
© Woodstock International, Inc. • Phone #: (800) 840-8420 • Web: www.shopfox.biz
MODEL D4945
ROUTER LIFT WITH 11-3/4" X 9-1/4" TABLE INSERT
Product Dimensions
Weight ....................................................................................................................13 lbs.
Width (side-to-side) x Depth (front-to-back) x Height ....................................11-3/4 x 9-1/4 x 7-1/2 in.
Shipping Dimensions
Type .............................................................................................................. Cardboard Box
Content ..................................................................................................................Machine
Weight .....................................................................................................................14 lbs.
Length/Width/Height ........................................................................................15 x 13 x 11 in.
Must Ship Upright ............................................................................................................ Yes
Main Specifications
Suitable Routers for Mounting ..................................................................... 3.200", 3.500", 4.200"
Plate Size ........................................................................................... 11-3/4 x 9-1/4 x 3/8 in.
Plate Opening Size.................................................................................................... 3-3/4 in.
Table Insert Size ..................................................................................................... 3-3/4 in.
Table Insert Opening Size ........................................................................................... 1-1/4 in.
Router Lift Travel ..................................................................................................... 2-3/4 in.
Router Lift Index Ring Increment ................................................................... 0.05 in. per full turn
Construction
Router Lift ................................................................................................... Aluminum, Steel
Plate .......................................................................................................Anodized Aluminum
Table Insert ..................................................................................................... Polycarbonate
Other
Country of Origin ...................................................................................................... Taiwan
Warranty ................................................................................................................. 2 Years
ISO 9001 Factory ............................................................................................................. Ye s
Features
Precision-Machined Router Lift
Inch/Millimeter Settings
Index Ring for Fine Lift Adjustment of Router
Accessories
Table Insert w/1-1/4" Diamter Bit Hole
Table Insert Wrench
Starting Pin
Hex Wrench 3mm
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Page 6
INTRODUCTION
Become familiar with the names and locations of the controls and features shown below to better
Model D4945 (For Machines Mfd. Since 11/20)
Identification
Crank
Handle
Table
Insert
Mounting
Plate
Carriage
Index
Ring
For Your Own Safety Read Instruction Manual Before Operating Router Table
a) Wear eye protection.
b) Always keep router bit guard in place and in proper operating condition.
c) Feed workpiece AGAINST rotation of router bit.
d) Keep fingers away from revolving bit–use fixtures when necessary.
e) Do not use awkward hand positions.
Clamp
Plates
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Page 7
Model D4945 (For Machines Mfd. Since 11/20)
Controls & Components
Refer to the Figures 1–2 and the following descriptions to
become familiar with the basic controls and components
of this machine. Understanding these items and how they
work will help you understand the rest of the manual and
stay safe when operating this machine.
A. Mounting Plate. Attaches router to table.
B. Table Insert. Provides additional workpiece control
and safety near bit during operations.
C. Carriage Lock. Secures carriage position to prevent
movement during operations.
D. Index Ring. Insert crank handle and rotate to move
carriage up and down.
INTRODUCTION
To reduce your risk of serious injury
or damage to the machine, read this
entire manual BEFORE using machine.
A
D
B
C
E. Crank Handle. Inserts into index ring to raise and
lower carriage.
F. Router Clamp Plates. Secure router to carriage.
G. Carriage. Moves up and down the guides as
leadscrew is turned with crank handle.
Figure
1. Mounting plate components.
E
G
Figure 2. Lift components.
F
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Page 8
Model D4945 (For Machines Mfd. Since 11/20)
SAFETY
OWNER’S MANUAL.
TRAINED OPERATORS ONLY.
DANGEROUS ENVIRONMENTS.
MENTAL ALERTNESS REQUIRED.
electrical components or improperly grounded
manual uses a series of symbols and signal words intended to convey the level of importance of the
safety messages. The progression of symbols is described below. Remember that safety messages by
SAFETY
For Your Own Safety,
Read Manual Before Operating Machine
The purpose of safety symbols is to attract your attention to possible hazardous conditions. This
SAFETY
themselves do not eliminate danger and are not a substitute for proper accident prevention measures—this responsibility is ultimately up to the operator!
NOTICE
Standard Machinery Safety Instructions
Standard Machinery Safety Instructions
Indicates an imminently hazardous situation which, if not avoided,
WILL result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
COULD result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
MAY result in minor or moderate injury.
This symbol is used to alert the user to useful information about
proper operation of the equipment or a situation that may cause
damage to the machinery.
Read and understand this
owner’s manual BEFORE using machine.
have a higher risk of being hurt or killed. Only
allow trained/supervised people to use this
machine. When machine is not being used,
disconnect power, remove switch keys, or
lock-out machine to prevent unauthorized
use—especially around children. Make
workshop kid proof!
machinery in areas that are wet, cluttered,
or have poor lighting. Operating machinery
in these areas greatly increases the risk of
accidents and injury.
alertness is required for safe operation of
machinery. Never operate under the influence
of drugs or alcohol, when tired, or when
distracted.
Untrained operators
Do not use
Full mental
ELECTRICAL EQUIPMENT INJURY RISKS. You can
be shocked, burned, or killed by touching live
machinery. To reduce this risk, only allow an
electrician or qualified service personnel to
do electrical installation or repair work, and
always disconnect power before accessing or
exposing electrical equipment.
DISCONNECT POWER FIRST. Always disconnect
machine from power supply BEFORE making
adjustments, changing tooling, or servicing
machine. This eliminates the risk of injury
from unintended startup or contact with live
electrical components.
EYE PROTECTION. Always wear ANSI-approved
safety glasses or a face shield when operating
or observing machinery to reduce the risk of
eye injury or blindness from flying particles.
Everyday eyeglasses are not approved safety
glasses.
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Page 9
Model D4945 (For Machines Mfd. Since 11/20)
WEARING PROPER APPAREL. Do not wear
HAZARDOUS
HEARING PROTECTION.
REMOVE ADJUSTING TOOLS.
INTENDED USAGE.
AWKWARD POSITIONS.
CHILDREN & BYSTANDERS.
GUARDS & COVERS.
FORCING MACHINERY. Do not force machine. It
will do the job safer and better at the rate for
loss of control. Before starting, verify machine
malfunction, leading to serious personal injury
from heated surfaces, high traffic areas, harsh
clothing, apparel, or jewelry that can become
entangled in moving parts. Always tie back
or cover long hair. Wear non-slip footwear to
avoid accidental slips, which could cause loss
of workpiece control.
DUST. Dust created while using
machinery may cause cancer, birth defects,
or long-term respiratory damage. Be aware of
dust hazards associated with each workpiece
material, and always wear a NIOSH-approved
respirator to reduce your risk.
Always wear hearing
protection when operating or observing
loud machinery. Extended exposure to this
noise without hearing protection can cause
permanent hearing loss.
machinery can become dangerous projectiles
upon startup. Never leave chuck keys,
wrenches, or any other tools on machine.
Always verify removal before starting!
intended purpose—never make modifications
without prior approval from Woodstock
International. Modifying machine or using
it differently than intended will void the
warranty and may result in malfunction or
mechanical failure that leads to serious
personal injury or death!
balance at all times when operating machine.
Do not overreach! Avoid awkward hand
positions that make workpiece control difficult
or increase the risk of accidental injury.
bystanders at a safe distance from the work
area. Stop using machine if they become a
distraction.
Only use machine for its
Tools left on
Keep proper footing and
Keep children and
which it was designed.
NEVER STAND ON MACHINE. Serious injury may
occur if machine is tipped or if the cutting
tool is unintentionally contacted.
STABLE MACHINE. Unexpected movement during
operation greatly increases risk of injury or
is stable and mobile base (if used) is locked.
USE RECOMMENDED ACCESSORIES. Consult
this owner’s manual or the manufacturer for
recommended accessories. Using improper
accessories will increase risk of serious injury.
UNATTENDED OPERATION. To reduce the risk
of accidental injury, turn machine OFF and
ensure all moving parts completely stop
before walking away. Never leave machine
running while unattended.
MAINTAIN WITH CARE. Follow all maintenance
instructions and lubrication schedules to
keep machine in good working condition. A
machine that is improperly maintained could
or death.
CHECK DAMAGED PARTS. Regularly inspect
machine for any condition that may affect
safe operation. Immediately repair or replace
damaged or mis-adjusted parts before
operating machine.
MAINTAIN POWER CORDS. When disconnecting
cord-connected machines from power, grab
and pull the plug—NOT the cord. Pulling the
cord may damage the wires inside, resulting
in a short. Do not handle cord/plug with wet
hands. Avoid cord damage by keeping it away
chemicals, and wet/damp locations.
SAFETY
accidental contact with moving parts or flying
debris—make sure they are properly installed,
undamaged, and working correctly.
Guards and covers reduce
EXPERIENCING DIFFICULTIES. If at any time
you experience difficulties performing the
intended operation, stop using the machine!
-7-
Contact Technical Support at (360) 734-3482.
Page 10
Model D4945 (For Machines Mfd. Since 11/20)
AVOIDING AMPUTATION.
SECURING LEVERS AND KNOBS.
DO NOT FORCE WORKPIECE.
BLIND CUTTING.
ROUTER BIT ROTATION.
ROUTER BIT HEIGHT
ROUTER BIT SPEED
without using a fence, jig, or miter gauge as a
without special fixtures or jigs.
circumstances. Use an overhead guard if fence
stock should be flattened with a jointer before
from power, rotate router spindle to test any
of bit
between shank and bottom of collet to ensure
Serious cuts, amputation, entanglement, or death can occur from contact with spinning bit.
or blindness. To minimize risk of getting hurt or killed, anyone operating router MUST completely
Additional Safety for Router Tables
Improperly secured bits or spindle parts/fasteners can fly off and strike nearby operators or
bystanders with great force. Flying dust or debris from cutting operation can cause eye injuries
heed hazards and warnings below.
SAFETY
with spinning router bit, never place hands
directly over or in front of bit. As one hand
approaches bit, move it away and over to other
side. Always keep hands at least 6" away from
spinning bit.
router table without first making sure all
lock levers and knobs are tight, and all
fence hardware and guide rails are secure.
Otherwise, workpiece can slip out of alignment
while cutting and cause injury from kickback.
materials past router. Let router bit do the
work. Excessive force is likely to result in
poor cutting results and will cause kickback
conditions that could cause serious personal
injury.
Keep router bit on underside
of workpiece when making blind cuts. This
will decrease risk of accidental contact with
spinning bit.
against rotation direction of bit. Otherwise,
workpiece could be aggressively pulled from
your hands, drawing them into spinning bit.
bit below the table surface to minimize risk of
your hand contacting spinning bit.
speed of any router bit. Doing so can cause bit
to fracture or explode and cause injury.
To avoid making contact
Never operate
Never force
Always feed workpiece
. Keep any unused portion of
. Do not exceed recommended
CUTTING SUPPORT. NEVER cut workpiece
support guide. Otherwise, workpiece could be
aggressively pulled from your hands, drawing
them into spinning bit.
WORKPIECE SIZING. NEVER use workpiece
shorter than 6"
Otherwise, workpiece can become trapped
between fence and router bit, which could
draw your hands into spinning bit.
USING SAFETY GUARDS. To prevent amputation
or other injuries, always use a guard.
Fabricate additional guards or jigs for special
is removed.
TRIPPING HAZARD. To prevent tripping over
power cord of router when not in use, always
disconnect it and safely store it out of way.
APPROPRIATE WORKPIECES. Danger of kickback
and injury is increased when workpiece has
knots, holes, or foreign objects in it. Warped
you shape it with router.
TESTING ROTATION. With router disconnected
new setup to ensure proper bit clearance
before starting router.
INSTALLING ROUTER BIT. Insert at least
shank into collet, and allow 1⁄8" of clearance
bit is securely installed.
3
⁄4
-8-
Page 11
Model D4945 (For Machines Mfd. Since 11/20)
This machine has been carefully packaged for safe
transportation. If you notice the machine has been
damaged during shipping, please contact your authorized
Shop Fox dealer immediately.
The following items are needed, but not included, to set
up your machine.
This machine presents
serious injury hazards
to untrained users. Read
to become familiar with
tions before starting the
The following is a list of items shipped with your machine.
Before beginning setup, lay these items out and inventory
them.
Note:
check around/inside the machine and packaging materials.
Often, these items get lost in packaging materials while
unpacking or they are pre-installed at the factory.
SETUP
Unpacking
through this entire manual
the controls and opera-
Items Needed for Setup
Description Qty
• Straightedge 48" ...........................................1
• Hex Wrenches 3, 5mm ................................1 Ea
• 12" 2x4s .....................................................2
Inventory
If you cannot find an item on this list, carefully
Box Inventory (Figure 3) Qty
A. Router Lift Assembly ......................................1
Crank Handle ...............................................1
B.
Table Insert Wrench .......................................1
C.
Flange Bolts 5⁄16"-18 x 1⁄2" ................................2
D.
Crank Handle Storage Bracket ..........................1
E.
Cap Screws M4-.7 x 16 ....................................2
F.
Starting Pin .................................................1
G.
Hex Wrench 3mm ..........................................1
H.
Table Insert .................................................1
I.
machine!
Wear safety glasses during
entire setup process!
SETUP
A
B
C
DE
FGHI
Figure 3. Inventory.
-9-
Page 12
Installing Router
The Model D4945 router lift is designed with clamping
plates (see Figure 4) that accept router body diameters of
3.200", 3.500", or 4.200."
Each one of the four clamping plates has two curved
edges—one deep and one shallow. Through a process of
trial and error, determine which curvature best holds
your router in position. Do not mix and match shallow and
deep curves or the router will not be centered over the
hole in the mounting plate, and you run the risk of hitting
the plate with a bit during operations.
Model D4945 (For Machines Mfd. Since 11/20)
Clamping Plates
For larger router bodies, remove the clamping plates
completely (see Figure 5) and use the clamp block and
slide block to secure the router in position.
Tools Needed: Qty
Hex Wrench 5mm ...............................................1
To install router, do these steps:
SETUP
1. Insert crank handle in index ring on mounting plate
(see Figure
just touches the bottom of the plate.
2. Place lift assembly upside down on two blocks of
wood (see Figure 6) so router collet will be able
to extend through the center hole in the mounting
plate.
2 on Page 5) and turn clockwise until lift
Clamping Plates
Figure 4. Location of router clamping
plates.
Slide Block
Clamp Block
Figure 5. Clamping plates removed.
Slide
Block
x 4
3. Loosen (4) cap screws that secure clamp block to
slide block (see Figure 6).
IMPORTANT: When positioning the router in the clamping
plates, take into account access to router controls, such
as variable-speed dial, depth adjustments, and other locks
or levers.
-10-
Clamp
Block
Figure 6. Lift assembly resting on wood
blocks.
Page 13
Model D4945 (For Machines Mfd. Since 11/20)
4. Secure router with best configuration of clamping
plates that hold it securely, then retighten cap
screws (see Figure 7).
Note: Router body should just touch the back of the
mounting plate.
5. Install lift assembly in router table (see below).
If router unexpectedly moves or router bit contacts
table insert or fence during operation, serious
personal injury could result from the router bit or
flying debris. ALWAYS make sure router is firmly
secured in clamping plates before beginning
operations.
Figure 7. Example of router installed in
clamping plates.
Installing Router
Lift Assembly
To ensure a workpiece does not catch on the mounting
plate and cause kickback, the mounting plate must be
aligned evenly with the top of your router table (not
included).
Tools Needed: Qty
Hex Wrench 3mm ...............................................1
Straightedge 48"
To install lift assembly, do these steps:
1. Position router lift assembly inside table opening
(see Figure 8) so mounting plate is flush with table
top. Then snap table insert into position.
Lay straightedge across mounting plate, table insert,
2.
and table surfaces in pattern shown in Figure 9.
Adjust set screws (see Figure 8) in mounting plate
3.
so ends of straightedge lay flat on table surface at
all positions of pattern.
................................................1
SETUP
Set Screws
(1 of 8)
Cap
Screws
Table Insert
Figure 8. Example of router lift assembly
positioned inside table opening.
Table Surface
Mounting
Plate
Once mounting plate is even with table surface,
4.
secure position with (2) M4-.7 x 16 cap screws
included with machine (see Figure 8.)
Note: If position of holes in your table does not
match this size and location, it will be necessary to
modify your table by drilling and/or tapping new
holes to fit.
-11-
Straightedge
Figure 9. Pattern for aligning mounting
plate.
Page 14
Installing Crank Handle
Bracket
The Model D4945 comes with a bracket for storing the
crank handle when not in use.
To install crank handle bracket, do these steps:
1. Locate position on router table where bracket is to
be installed.
Model D4945 (For Machines Mfd. Since 11/20)
Hold bracket in position and scribe locations where
2.
(2) holes are to be drilled.
3. Drill and tap (2) holes to receive 5⁄16"-18 x 1⁄2" flange
bolts that come with machine.
Note: Alternatively, you may also drill (2) "through
holes" and bolt the bracket in place using your own
fasteners.
4. Tighten bolts to secure bracket in place (see Figure
SETUP
10).
x 2
Crank
Handle
Bracket
Figure 10. Example of crank handle
bracket installed on router table leg.
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Page 15
Model D4945 (For Machines Mfd. Since 11/20)
The purpose of this overview is to provide the novice
machine operator with a basic understanding of how
the machine is used during operation, so the
controls
easier to understand.
Due to the generic nature of this overview, it is
intended to be an instructional guide. To learn more
about specific operations,
seek
operators
manual by reading "how-to" books, trade magazines, or
websites.
OPERATIONS
Operation Overview
machine
/components discussed later in this manual are
not
read this entire manual and
additional training from experienced machine
, and do additional research outside of this
To complete a typical operation, the operator does the
following:
Examines workpiece to make sure it is suitable for
1.
cutting.
Adjusts fences close to the bit for maximum
2.
workpiece support, then secures fences in place.
Adjusts bit height for desired cutting profile.
3.
4. Adjusts fence position to establish depth of cut and
makes sure that it is parallel with the table T-slot.
Wears safety glasses, respirator, and hearing
5.
protection. Locates push sticks or blocks if needed.
Starts router.
6.
IMPORTANT: For small or odd-shaped workpieces, a
zero-clearance fence or jig is used.
To reduce your risk of serious injury
or damage to the machine, read this
entire manual BEFORE using machine.
Eye injuries, respiratory problems, or
hearing loss can occur while operating
this tool. Wear personal protective
equipment to reduce your risk from
these hazards.
If you are an inexperienced operator,
we strongly recommend that you read
books or trade articles, or seek training
from an experienced operator of this
type of machinery before performing
unfamiliar operations. Above all, safety
must come first!
OPERATIONS
Holds workpiece firmly and flatly against table
7.
and fence, then pushes workpiece into bit at a
steady and controlled rate until workpiece moves
completely beyond router bit.
WARNING: Keep workpiece firmly against table and
fence, and keep hands away from spinning router bit
during entire cut.
Stops router once operation is complete.
8.
No list of safety guidelines can be
complete. Every shop environment is
different. Always consider safety first,
as it applies to your individual working
conditions. Use this and other machinery with caution and respect. Failure
to do so could result in serious personal injury, damage to equipment, or
poor work results.
-13-
Page 16
Stock Inspection &
Requirements
Always follow these rules when choosing and
routing stock:
• DO NOT cut stock that contains large
or loose knots. Injury to the operator or
damage to the workpiece can occur if a
knot becomes dislodged during the cutting
operation.
• DO NOT cut against the grain direction.
Cutting against the grain increases the
likelihood of kickback, as well as tearout
on the workpiece.
• Routing with the grain produces a better
finish and is safer for the operator.
Cutting with the grain is described as
feeding the stock on the router table so
the grain points down and toward you
as viewed on the edge of the stock (see
Figure below).
Model D4945 (For Machines Mfd. Since 11/20)
• Only process natural and man-made wood
products. Your router is designed to cut
only natural wood fiber products. It is NOT
designed to cut metal, glass, stone, tile,
products with lead-based paint, or products
that contain asbestos. Cutting these
materials with a router may lead to injury.
• Scrape all glue off the workpiece before
jointing. Glue deposits on the workpiece,
hard or soft, will gum up the router bit,
produce poor results, and increase the risk
of kickback.
• Remove foreign objects from the
workpiece. Make sure that any stock you
process with the router is clean and free of
dirt, nails, staples, tiny rocks, or any other
foreign objects that could damage the
router bit and be thrown from the machine
with significant speed/force.
Note: Wood stacked on a concrete or dirt
surface can have small pieces of concrete
or stone pressed into the surface.
Note: If the grain changes direction along
the edge of the board, decrease the
cutting depth and make additional passes.
End View
OPERATIONS
Outfeed
Fence
Direction of Feed
Figure 11. Proper grain alignment with the
router bit.
Infeed
Fence
• Make sure all stock is sufficiently dried
before routing. Wood with a moisture
content over 20% will cause unnecessary
wear on the router bits, produce poor
cutting results, and increase the risk of
kickback. Excess moisture can also hasten
rust and corrosion.
Like all machinery there is potential danger
when operating this machine. Accidents are
frequently caused by lack of familiarity or
failure to pay attention. Use this machine
with respect and caution to decrease the
risk of operator injury. If normal safety
precautions are overlooked or ignored,
serious personal injury may occur.
-14-
Page 17
Model D4945 (For Machines Mfd. Since 11/20)
Table T-Slots
Many router tables include one or more T-slots
(see Figure 12) for attaching accessories like a miter
gauge, jig, or featherboard.
T-slots
Figure 12. Example of T-slots featured on
a router table.
Squaring Fence
& Table T-Slot
When using a miter gauge, it is important to make sure
the fence is parallel with the table T-slot. This will help
ensure that the workpiece does not bind or kick back
during operation. If your router table has a T-slot, use a
fine ruler to make the distance equal between the fence
and the T-slot along the full length of the table (see
Figure 13).
To avoid workpiece kickback or binding when
using a miter gauge, ALWAYS make sure fence is
parallel with table T-slot before beginning routing
operations.
Fence
Ruler
Figure 13. Example of adjusting fence
parallel with table T-slot.
OPERATIONS
-15-
Page 18
Adjusting Router Height
The Model D4945 is equipped with a manually operated
router lift that can be adjusted by rotating the index ring
in the face of the mounting plate.
Tools Needed: Qty
Hex Wrench 5mm ...............................................1
Open-End Wrench 11mm.......................................1
To adjust router height, do these steps:
1. DISCONNECT MACHINE FROM POWER!
2. Insert crank handle into index ring (see Figure 14) in
mounting plate.
Turn handle clockwise to raise router; turn handle
3.
counterclockwise to lower router.
Note: One full rotation moves lift 0.05".
Model D4945 (For Machines Mfd. Since 11/20)
Crank
Handle
Index
Ring
Figure 14. Example of lift crank handle
installed in table.
Jam Nut
Lock
Screw
Secure height setting by turning lock screw (see
4.
Figure 14) clockwise until it engages rocker arm
beneath mounting plate. Ensure lock screw is snug,
but do not overtighten.
Underneath mounting plate, tighten lock screw jam
5.
nut (see Figure 15) against mounting plate to secure
position.
OPERATIONS
Using Table Insert
The Model D4945 comes with a 11⁄4" table insert (see
Figure 16) that snaps into the center of the mounting
plate and provides additional safety and control near the
router bit during router operations.
Lock
Screw
Rocker Arm
Figure 15. Location of lock screw
components.
Table Insert
-16-
Figure
16. Location of table insert.
Page 19
Model D4945 (For Machines Mfd. Since 11/20)
Edge Jointing
Jointing the edge of a board requires a straight- cutting
router bit to remove wood from the face of the board.
The result is a perfectly flat and square edge.
To joint edge of a workpiece, do these steps:
1. DISCONNECT MACHINE FROM POWER!
2. Secure straight-cutting bit in router according to
manufacturer's instructions.
Install table insert.
3.
4. Insert spacer (not included) between outfeed
fence and fence base. The width of the spacer will
determine the amount of material removed with
each pass.
IMPORTANT: To reduce the risk of kickback, DO NOT
take more than
1
⁄16" off during any single pass.
Always feed workpiece against router
bit rotation direction, as illustrated
below. Otherwise, workpiece could be
aggressively pulled from your hands,
drawing them into spinning router bit.
Bit
Rotation
Workpiece
Feed Direction
Raise bit just above top of workpiece, then rotate it
5.
by hand until cutting flute is perpendicular to fence.
Place straightedge against outfeed fence, then
6.
adjust fence base so straightedge is also against bit
flute (see
Lock fence base in place, and tighten all knobs.
7.
Figure 17).
8. Connect router to power, then perform cut (see
Figure 18).
To reduce risk of hand injury from accidental
contact with spinning router bit, ALWAYS make sure
fence and router bit guard are properly positioned
and secured before connecting router to power
(does not apply to free-hand routing).
Top View
Spacer
Outfeed
Fence
Straight
Router Bit
(Enlarged)
Straightedge
Bit
Flute
Infeed
Fence
Figure 17. Example of fence set up for
edge jointing.
Top View
Spacer
Workpiece
Cutting Direction
OPERATIONS
-17-
Figure 18. Example of edge jointing
operation.
Page 20
Profile Routing
Model D4945 (For Machines Mfd. Since 11/20)
Profile router bits are used to shape the edges of a
workpiece and give them a more decorative appearance.
Some examples include beading, cove, chamfer, ogee,
and moulding bits. By changing the depth of cut and the
cutting height, many different shapes can be cut with
each bit.
To cut a profile into a workpiece, do these steps:
1. DISCONNECT MACHINE FROM POWER!
2. Secure bit in router according to router
manufacturer's instructions.
Raise router bit to desired height, then adjust fence
3.
so it sits behind the bit the same distance as desired
depth-of-cut (see
Make sure both infeed/outfeed fences are parallel
4.
with table if using T-slot.
Lock fence in place, tighten all knobs, connect
5.
router to power, then perform cut.
Figure 19).
Top View
Outfeed Fence
Bit
Side View
Depth-of-Cut
Bit
Table
Figure 19. Groove cutting setup.
Infeed Fence
Depth-of-Cut
Infeed
Fence
Routing Small Stock
Feeding small stock past the router bit increases the
risk of kickback from the workpiece slipping into the
space between the fence and bit. If you must rout small
OPERATIONS
stock, use a zero-clearance fence board. This will provide
greater protection for the operator, better workpiece
support, and reduced tearout on narrow or fragile stock.
To make a zero-clearance fence, do these steps:
1. DISCONNECT MACHINE FROM POWER!
2. Remove infeed/outfeed fences from fence base.
3. Select piece of straight, smooth stock that is same
height and thickness as infeed/outfeed fences
and approximately the same length of the infeed/
outfeed fences combined.
ALWAYS use hold-downs or
featherboards and push sticks when
shaping small or narrow stock. These
devices keep your hands away from
spinning router bit and sufficiently
support stock to allow a safe and
effective cut, reducing risk of
personal injury.
-18-
Page 21
Model D4945 (For Machines Mfd. Since 11/20)
4. Cut outline of spindle and router bit from center of
the stock selected in Step 3, as shown in Figure 20.
Note: Make outline as close as possible to router bit
and spindle without interfering with rotation.
Create countersunk mounting holes in zero-clearance
5.
fence board (see Figure 20) to secure new fence
and router bit guard to base.
Secure zero-clearance fence board and
6.
router bit guard to fence base.
Check for proper clearance, connect router to
7.
power, then make test cut to verify results.
Free-Hand Routing
Irregular or free-hand routing takes a high degree of skill
and dexterity and is done without the protection and aid
of the fence and router bit guard. The most dangerous
part of free-hand routing is beginning the cut, when the
router bit first contacts the workpiece. It tends to jerk or
kick back, presenting an injury hazard to the operator.
Countersunk
holes
Wood stock
Cut out profile
of cutter & spindle
Figure 20. Example of a zero-clearance
fence board.
Mount with
flat head screws
To reduce the likelihood of kickback when free-hand
routing, use the starting pin or a block (see
for examples). This will allow you to anchor and slowly
pivot the workpiece into the bit as the cut is started,
making the operation more stable and safe.
ALWAYS use an auxiliary jig and extreme care when
free-hand routing. Routing without fence and router
bit guard greatly increases risk of accidental contact
with spinning router bit, causing serious
personal injury.
Figures 21–22
Free-hand or irregular routing greatly
increases the chance that the operator
may lose control of the workpiece,
which could result in serious personal
injury. Therefore, a starting pin
or block and a custom guard or
workpiece holding jig MUST be used.
Swing
Starting Pin
t
a
i
o
t
n
Rub
Collar
Figure 21. Illustration of free-hand routing
o
R
Feed Direction
using a starting pin.
Workpiece
OPERATIONS
-19-
Page 22
To free-hand rout, do these steps:
1. DISCONNECT MACHINE FROM POWER!
2. Fabricate a jig to use with workpiece that matches
desired finished shape, then attach it to workpiece
Figure 22).
(see
Note: Make sure any fasteners used will not
make contact with the router bit during routing
operation. Hot glue can be used as an alternative.
Remove fence from table.
3.
4. If possible, fabricate and mount a custom guard over
the bit that safely protects your hands from spinning
router bit.
5. Insert starting pin in hole on mounting plate (see
Figure 23) or clamp a starting block to table (see
Figure 22).
Model D4945 (For Machines Mfd. Since 11/20)
Figure 22. Example of using a jig with a
starting block.
Starting Pin
OPERATIONS
Install a router bit with bearing guide as directed by
6.
router manufacturer's instructions, then raise it to
desired height (see
Rest workpiece against starting pin, turn router ON,
7.
Figure 24).
then slowly pivot and feed workpiece into router bit.
After cut is started, move workpiece against guide
bearing and away from starting pin.
Figure 23. Example of router table set up
with starting pin for free-hand routing.
Bearing
Guide
Template
Workpiece
Figure 24. Using a template and bearing
guide for free-hand routing.
-20-
Page 23
Model D4945 (For Machines Mfd. Since 11/20)
ACCESSORIES
Router Accessories
The following router accessories may be available through your local Woodstock International Inc.
Dealer. If you do not have a dealer in your area, these products are also available through online
dealers. Please call or e-mail Woodstock International Inc. Customer Service to get a current listing of
dealers at: 1-800-840-8420 or at [email protected].
D3728 26 Pc. Carbide Tipped Router Bit Set 1⁄4" Shank. These are
super sharp, micro-grain carbide tipped bits that are ground up to
800 grit to glide through your cuts. Includes protective wooden case
with see-thru top.
1
⁄4" shank.
DC1826 Deluxe 3⁄4" Rabbeting Set with 5 Bearings with a 1⁄2"
Shank. Interchangeable bearings allow five different rabbet widths:
1
⁄4", 1⁄8", 3⁄16", 3⁄8", and 5⁄16". Includes bearings, bushings, washers and
screws.
Shop Fox D3118 Inlay Kit with Brass Adapter and Solid Carbide Bit.
Cut perfect inlays with this Inlay Kit and your shop-made template.
Simply slide on the bushing to rout the cutout and then remove the
bushing to cut the perfectly matched inlay. Includes a
bide spiral cutter and alignment pin. Fits Porter-Cable® routers and
other routers with template guide adapters.
Model D4130 8" Decimal/Fractional Digital Caliper. These 8" Digital
Calipers let you switch between decimal and fractional inches and
millimeters. Large digital readout makes precision measurements
easy with a resolution of 0.0005". Features include hardened stainless
steel jaws and beam, thumb roll, lock knob, zero reset button, and
an absolute and relative measurement function.
1
⁄8" solid car-
OPERATIONS
-21-
Page 24
Model D4945 (For Machines Mfd. Since 11/20)
D2675 Safety Glasses w/Metal Frame. A metal band across the top
of these glasses is not only stylish, but it adds strength. This band is
linked to the metal ear pieces through a tough hinge. These glasses
have a wide field of view and side shields for added protection.
Exceeds ANSI Z87.1 - 1989 standards for impact resistance.
Model W1844 Wall-Mount Dust Collector with Canister Filter.
Nothing beats the convenience of this wall-mounted dust collector
and the efficiency of the large surface area, pleated filter with
internal paddle brushes. Whenever efficiency is being diminished due
to dust cake, just a couple of turns of the handle rotates the paddle
brushes against the inside of the filter to drop the fine dust cake into
the plastic collection bag. It's as easy as that!
OPERATIONS
-22-
Page 25
Model D4945 (For Machines Mfd. Since 11/20)
MAINTENANCE
General
For optimum performance from this machine, this
maintenance schedule must be strictly followed.
Ongoing
To minimize your risk of injury and maintain proper
machine operation, shut down the machine immediately
if you ever observe any of the items below, and fix the
problem before continuing operations:
• Loose router clamping plates.
• Loose mounting plate fasteners.
• Loose stand and table fasteners.
• Worn or damaged cords/plugs.
• Any other unsafe condition.
MAKE SURE that your machine is
unplugged during all maintenance
procedures! If this warning is ignored,
serious personal injury may occur.
Weekly Maintenance
• Clean/vacuum dust buildup off of router, mounting
plate, and table.
Cleaning & Protecting
Cleaning the Model D4945 is relatively easy. Vacuum excess
wood chips and sawdust, and wipe off the remaining dust
with a dry cloth. If any resin has built up, use a resin
dissolving cleaner to remove it.
Protect the unpainted steel by wiping it clean after every
use—this ensures moisture from wood dust does not remain
on bare metal surfaces. Keep the parts rust-free with
regular applications of quality lubricants.
MAINTENANCE
-23-
Page 26
General
This section covers the most common service adjustments
or procedures that may need to be made during the life
of your machine.
If you require additional machine service not included
in this section, please contact Woodstock International
Technical Support at (360) 734-3482 or send e-mail to:
[email protected].
Model D4945 (For Machines Mfd. Since 11/20)
SERVICE
MAKE SURE that your machine is
unplugged during all maintenance
procedures! If this warning is ignored,
serious personal injury may occur.
Aligning Mounting Plate
To ensure a workpiece does not catch on the mounting
plate and cause kickback, the mounting plate must be
aligned evenly with the top of the table.
Tools Needed: Qty
Hex Wrench 3mm ...............................................1
Straightedge 48"
To align mounting plate, do these steps:
1. DISCONNECT MACHINE FROM POWER!
2. Remove fence assembly from router table.
3. Remove screws that secure mounting plate to router
table.
Lay straightedge across mounting plate, table insert,
4.
and table surfaces in pattern shown in Figure 25.
5.
Adjust set screws (see Figure 26) in mounting plate
SERVICE
as necessary so that straightedge lies flat on table
surface at all positions of pattern.
................................................1
Table Surface
Mounting
Plate
Straightedge
Figure 25. Pattern for aligning mounting
plate to table.
Repeat Steps 4–5 as needed until mounting plate is
6.
aligned with table surface.
Secure mounting plate to table with cap screws
7.
removed in Step 3.
-24-
Mounting Plate
Figure 26. Example of using a straightedge
to align mounting plate with table surface.
Set Screws
(1 of 8)
Page 27
Model D4945 (For Machines Mfd. Since 11/20)
The following troubleshooting tables cover common problems that may occur with this machine. If you
need replacement parts or additional troubleshooting help, contact our Technical Support.
Note:
available, your original purchase receipt. This information is required to properly assist you.
Troubleshooting
Before contacting Tech Support, find the machine serial number and manufacture date, and if
Operations
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION
Workpiece catches on mounting
plate.
Workpiece catches on infeed/
outfeed fences.
Workpiece
catches on gap
between infeed/
outfeed fences.
Workpiece is
burned when
cut.
Fuzzy grain.
Chipping.
Divots in edge of
cut.
1. Mounting plate and table not evenly aligned.
1. Fence and table T-slot not parallel.
1. Workpiece too small for fence.
1. Router bit dull.
2. Feeding workpiece too slowly.
3. Depth of cut too deep.
1. Wood may have high moisture content or surface wetness.
2. Router bit dull.
1. Knots or conflicting grain direction in wood.
2. Nicked or chipped router bit.
3. Feeding workpiece too fast.
4. Depth of cut too deep.
5. Cutting against wood grain.
1. Inconsistent feeding speed.
2. Inconsistent pressure against fence.
3. Fence not adjusted correctly.
1. Align mounting plate (Page 24).
1. Make fence parallel with T-slot (Page 15). Consult
fence and table manufacturer's instructions.
1. Create zero-clearance fence for operation
(
Page 18).
1. Replace router bit.
2. Increase feed rate.
3. Take a smaller depth of cut. (Always reduce cutting
depth when working with hard woods.)
1. Inspect workpiece moisture content; allow to dry if
moisture is more than 20% (Page 14).
2. Replace router bit.
1. Inspect workpiece for knots and grain direction;
only use clean stock (Page 14).
2. Replace router bit.
3. Decrease feed rate.
4. Take a smaller depth of cut. (Always reduce cutting
depth when working with hard woods.)
5. Cut with grain of wood (Page 14).
1. Use consistent feed rate.
2. Apply constant pressure.
3. Consult fence manufacturer's instructions for
adjusting fence.
-25-
SERVICE
Page 28
Model D4945 (For Machines Mfd. Since 11/20)
PARTS
Main
13
14
14
13
18
17
3
4
20
22
24
38
36
15
32
1
33
19
25
6
15
36
8
2
11
19
7
19
5
21
37
35
39
13
16
17
10
9
12
31
34
19
29
27
30
26
28
PARTS
-26-
Page 29
Model D4945 (For Machines Mfd. Since 11/20)
Main Parts List
REF PAR T # DESCRIPTION REF PAR T # DESCRIPTION
1 XD4945001 MOUNTING PLATE 11-3/4" X 9-1/4" 20 XD4945020 INSERT 1-1/4"
2 XD4945002 CLAMP BLOCK 21 XD4945021 STARTING PIN
3 XD4945003 SLIDE BLOCK 22 XD4945022 HEX SHAFT 5 X 175
4 XD4945004 CLAMP GUIDE 24 XD4945024 FIXED HANDLE 22 X 77, M10-1.5 X 14
5 XD4945005 CLAMP GUIDE MOUNT 25 XD4945025 CRANK M10-1.5, 95L
6 XD4945006 LEADSCREW M14-1.5 X 135 26 XD4945026 ROCKER ARM MOUNT 1/4-20 X 1/2
7 XD4945007 LEADSCR EW CONNECTOR 27 XD4945027 ROCKER ARM
8 XD4945008 INDEX RING 28 XD4945028 SET SCREW M4-.7 X 5
9 XD4945009 HEX NUT M14-2 29 XD4945029 HEX NUT 1/4-20
10 XD4945010 LEADSCR EW MOUNT 30 XD4945030 CAP SCREW M3- .5 X 16
11 XD4945011 COPPER PLATE 31 XD4945031 LOCK NUT M3-.5
12 XD4945012 BUSHING 20 X 24 X 12 COP PER 32 XD4945032 CAP SCREW 1/4-20 X 1-1/4
13 XD4945013 CAP SCREW 1/4-20 X 3/4 33 XD4945033 LOCK NUT 1/4-20
14 XD4945014 ROUTER CLAMP PLATE 34 XD4945034 BRAKE DIS C
15 XD4945015 FLAT HD CAP SCR 1/4-20 X 5/8 35 XD4945035 SP ANNER WRENCH 70MM PIN-T YP E
16 XD4945016 GUIDE T UBE (ALUMINUM) 36 XD4945036 CAP SCREW M4- .7 X 16
17 XD4945017 BUSHING 16 X 20 X 20 COP PER 37 XD4945037 FLANGE BOLT 5/16-18 X 1/2
18 XD4945018 LEADSCREW PILOT NUT M14- 1.5 38 XD4945038 ROUTER LIFT CRANK HOLDER
19 XD4945019 SET SCREW M6-1 X 6 39 XD4945039 HEX W RENCH 3MM
-27-
PARTS
Page 30
Page 31
warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence or accidents,
WARRANTY
WARRANTY
Woodstock International, Inc. warrants all Shop Fox machinery to be free of defects from workmanship
and materials for a period of two years from the date of original purchase by the original owner. This
lack of maintenance, or reimbursement of third party expenses incurred.
Woodstock International, Inc. will repair, replace, or arrange for a dealer refund, at its expense and
option, the Shop Fox machine or machine part proven to be defective for its designed and intended
use, provided that the original owner returns the product prepaid to an authorized warranty or repair
facility as designated by our Bellingham, Washington office with proof of their purchase of the product
within two years, and provides Woodstock International, Inc. reasonable opportunity to verify the
alleged defect through inspection. If it is determined there is no defect, or that the defect resulted
from causes not within the scope of Woodstock International Inc.'s warranty, then the original owner
must bear the cost of storing and returning the product.
This is Woodstock International, Inc.’s sole written warranty and any and all warranties that may be
implied by law, including any merchantability or fitness, for any particular purpose, are hereby limited
to the duration of this written warranty. We do not warrant that Shop Fox machinery complies with
the provisions of any law, acts or electrical codes. We do not reimburse for third party repairs. In no
event shall Woodstock International, Inc.’s liability under this limited warranty exceed the purchase
price paid for the product, and any legal actions brought against Woodstock International, Inc. shall be
tried in the State of Washington, County of Whatcom. We shall in no event be liable for death, injuries
to persons or property or for incidental, contingent, special or consequential damages arising from the
use of our products.
Every effort has been made to ensure that all Shop Fox machinery meets high quality and durability
standards. We are commited to continuously improving the quality of our products, and reserve the
right to change specifications at any time.
To register the warranty, go to https://www.woodstockint.com/warranty, or scan the QR code below.
You will be directed to the Warranty Registration page on www.woodstockint.com. Enter all applicable
production information.
WARRANTY
WOODSTOCKINT.COM
Page 32
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