Router/Table Combo DO NOT RETURN TO STORE Questions? Problems? Please call our customer help line: (888) 315-3080 M-F 8-5 CST or by email: partsandservice@greatlakestec.com Model 90239 Operating and Safety Instructions
Table of Contents Technical data.. 2 General safety rules. 3 Specific safety rules for router tables.. 5 Electrical information.. 7 Know your router table 9 Assembly and adjustments.. 10 Operation. 17 Maintenance. 21 Replacement parts 22 Warranty.. 24 Technical data Router/Table Combo Model 90239 Power source: Power cord: Double insulated: Net weight: 120 V AC, 60 Hz 6' (1.8 m), 2-prong, polarized Yes 22 lb (10 kg) 2
General safety rules Safety is a combination of common sense, staying alert and knowing how your router table works. SAVE THESE SAFETY INSTRUCTIONS. WARNING: To avoid mistakes that could cause serious injury, do not plug in the router table until the following steps have been read and understood. 1. READ and become familiar with this entire instruction manual. LEARN the tool s applications, limitations, and possible hazards. 2. AVOID DANGEROUS CONDITIONS. Do not use power tools in wet or damp areas or expose them to rain. Keep work areas well-lit. 3. DO NOT use power tools in the presence of flammable liquids or gases. 4. ALWAYS keep your work area clean, uncluttered, and well-lit. DO NOT work on floor surfaces that are slippery with sawdust or wax. 5. KEEP BYSTANDERS AT A SAFE DISTANCE from the work area, especially when the tool is operating. NEVER allow children or pets near the tool. 6. DO NOT FORCE THE TOOL to do a job for which it was not designed. 7. DRESS FOR SAFETY. Do not wear loose clothing, gloves, neckties, or jewelry (rings, watches, etc.) when operating the tool. Inappropriate clothing and items can get caught in moving parts and draw you in. ALWAYS wear non-slip footwear and tie back long hair. 8. WEAR A FACE MASK OR DUST MASK. WARNING: Dust generated from certain materials can be hazardous to your health. Always operate the router in a well-ventilated area and provide for proper dust removal. Use dust collection systems whenever possible. 9. ALWAYS remove the power cord plug from the electric outlet when making adjustments, changing parts, cleaning or working on the tool. 10. KEEP GUARDS IN PLACE AND IN WORKING ORDER. 11. AVOID ACCIDENTAL START-UPS. Make sure the power switch is in the OFF position before plugging in the power cord. 12. REMOVE ADJUSTMENT TOOLS. Always make sure all adjustment tools are removed from the router table before turning it ON. 3
General safety rules (continued) 13. NEVER LEAVE A RUNNING TOOL UNATTENDED. Turn the power switch to OFF. Do not leave the tool until it has come to a complete stop. 14. NEVER STAND ON A TOOL. Serious injury could result if the tool tips or is accidentally hit. DO NOT store anything above or near the tool. 15. DO NOT OVERREACH. Keep proper footing and balance at all times. Wear oil-resistant rubber-soled footwear. Keep the floor clear of oil, scrap, and other debris. 16. MAINTAIN TOOLS PROPERLY. ALWAYS keep tools clean and in good working order. Follow instructions for lubricating and changing accessories. 17. CHECK FOR DAMAGED PARTS. Check for alignment of moving parts, jamming, breakage, improper mounting, or any other conditions that may affect the tool s operation. Any part that is damaged should be properly repaired or replaced before use. 18. MAKE THE WORKSHOP CHILDPROOF. Use padlocks and master switches and ALWAYS remove starter keys. 19. DO NOT operate the tool if you are under the influence of drugs, alcohol, or medication that could affect your ability to use the tool properly. 20. USE SAFETY GOGGLES AT ALL TIMES that comply with ANSI Z87.1. Normal safety glasses only have impact resistant lenses and are not designed for safety. Wear a face or dust mask when working in a dusty environment. Use ear protection, such as plugs or muffs, during extended periods of operation. 4
Specific safety rules for router tables 1. Fully assemble and tighten all of the fasteners required for this table. Do not use the router table until it is fully assembled. Check the table and the router to make sure the fasteners are still tight before each use. 2. Make sure the router table is secured to a solid, flat, and level surface, and that it will not tip during use. 3. Make sure the router is not plugged into a power outlet when installing it on the table, making adjustments, or changing accessories. The router could start accidentally. 4. Make sure the router is fully and securely attached to the router table. Periodically check connections for tightness. The router motor can vibrate loose during use and fall from table. 5. Do not use the router table without the guard. The guard aids in keeping hands from unintended contact with the rotating bit. 6. Do not use the router dust collecting attachment when installing the router on the router table. 7. Ensure the collet, with the bit fully installed, is thoroughly tightened before operating the router. 8. Never place your fingers near a spinning bit or under the guard when the router is plugged in. Never hold the workpiece on the out-feed side of a bit. Pressing the workpiece against the outfeed side may cause material binding and possible kickback. 9. Use the router to cut and shape wood, wood-like products, and plastic or laminates. Do not cut or shape metals. Make sure each workpiece is free of nails or other obstructions. 10. Install the bit according to the instructions in the router manual. Make sure the bit is securely seated in the collet chuck before making any cuts. Do not use bits that have a cutting diameter that exceeds the clearance hole in the table insert or router sub base. 11. Do not use dull or damaged bits. Dull bits may cause the bit to break or the material to kick back. Damaged bits can snap during use. 12. Never start the tool when the bit is engaged in the material. The cutting edge may grab the material and cause you to lose control of the workpiece. 5
Specific safety rules for router tables (continued) 13. Use the router table to cut flat, straight, and squared materials. Do not cut warped, wobbly, or otherwise unstable material. If the material is slightly curved but otherwise stable, cut the material with the concave side against the table or fence. Cutting the material with the concave side up or away from the table may cause warped material to roll and kick back. 14. Feed the material against the rotation of the bit. The bit rotates counter-clockwise as viewed from the top of the table. Feeding the work in the wrong direction will cause the workpiece to climb up on the bit pulling the workpiece and possibly your hands into the rotating bit. 15. Guide the workpiece by the fence to maintain control. Do not place material between the router bit and fence while routing the edge. This will cause the material to become wedged, making kickback possible. 16. Use push sticks, vertical- and horizontally-mounted feather boards (spring sticks), and other jigs to hold down the workpiece. Push sticks, feather boards and jigs eliminate the need to hold the workpiece near the spinning bit. 17. Do not use the table as a workbench or work surface. Using it for purposes other than routing may cause damage and make it unsafe to use for routing. Do not stand on the table. 6
Electrical information WARNING: To avoid electrical hazards, fire hazards, or damage to the tool, use proper circuit protection. The router table and router are wired at the factory for 115 V operation. Connect to a 120 V, 15 A circuit and use a time delayed fuse or circuit breaker. If the power cord is worn, cut, or damaged, replace it immediately. Double insulated This router table has a plug that looks like the one shown in Fig. A. The router table is double insulated for additional user protection. All exposed metal parts are isolated from the internal metal motor components with protective insulation. WARNING: Double insulation does not take the place of normal safety precautions when operating this tool. WARNING: To avoid electrocution: Use only identical replacement parts when servicing a tool with double insulation. Servicing should be performed by a qualified technician. Do not use power tools in wet or damp areas or expose tools to rain. Grounding instructions In the event of a malfunction or breakdown, grounding provides the path of least resistance for electric current and reduces the risk of electric shock. This tool is equipped with an electric cord that has a polarized plug. The plug MUST be plugged into a matching outlet that is properly installed and grounded in accordance with ALL local codes and ordinances. DO NOT MODIFY THE PLUG PROVIDED. If it will not fit in the outlet, have the proper outlet installed by a licensed electrician. 7
Electrical information (continued) Guidelines for using extension cords WARNING: This router table is intended for indoor use only. Do not expose it to rain or use in damp locations. Make sure your extension cord is in good condition. 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 table below shows the correct size to be used according to 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 Extension Cords (AWG) (When using 120 V only) Ampere Rating Total Length of Cord in feet More Than Not More Than 25 50 100 150 0 6 18 16 16 14 6 10 18 16 14 12 10 12 16 16 14 12 12 16 14 12 Not Recommended Make sure your extension cord is properly wired and in good condition. Always replace a damaged extension cord or have it repaired by a qualified person before using it. Protect your extension cords from sharp objects, excessive heat and damp or wet areas. Use a separate electric circuit for your tools. This circuit must not be less than a #12 wire and should be protected with a 15 A time-delayed fuse. Before connecting the motor to the power line, make sure the switch is in the OFF position and the electric current is rated the same as the current stamped on the motor nameplate. Running at a lower voltage will damage the motor. WARNING: Although this tool is double insulated, the extension cord and receptacle must still be grounded while in use to protect the operator from electric shock. 8
Know your router table A Router table B Router C Switch with safety lock D Guard E Fence F Miter gauge WARNING: Do not use the router dust collecting attachment with the router table. When using the router dust collecting attachment with the router, do not use router bits larger than 1-1/2 (38 mm). 9
Assembly and adjustments Carefully unpack the router table and all of its parts. Compare the parts against the list below. Do not discard the carton or any packaging until the router table is completely assembled. WARNING: If a part is missing or damaged, do not plug in the router table until you have replaced the missing or damaged part. 1 Table top 16 Carriage bolts (1 large, 1 med, 4 small) 2 Table legs (3) 17 Flat washers for carriage bolts (6) 3 Power switch leg (1) 18 Lock knobs (2 large, 4 small) 4 Fence panels (2) 19 Socket head screws (16) 5 Fence (partially assembled) 20 Locking washers (16) 6 Switch box 21 Flat washers (16) 7 Guard 22 Screws (2) 8 Miter gauge 23 Machine screws (4) 9 Miter bar knob 24 Hex wrench (5 mm) 10 Miter bar 25 Router wrench 11 Table insert 1-1/4 (32 mm) 26 Router 12 Table insert 1-7/8 (47 mm) 27 Router dust collecting attachment* 13 Table insert 2 1/8 (55 mm) *Do not use when the router is installed 14 Starting pin on the router table. 15 Guard pin 10
Assembly and adjustments (continued) Assembly This router table must be assembled before use. The router is shipped assembled. Attach the legs to the table (Fig. 2) The right front leg has a rectangular cutout for the switch. The other three legs are identical and can be placed in any position. When the table is assembled, the switch faces the front for easy accessibility by the operator. 1. Place the router table upside down on a suitable work surface, so that the logo side (1) is closest to you. 2. Place the leg with the cutout (2) over the four holes to your left and align the holes in the leg over the threaded holes in the table. 3. Secure the leg with a flat washer (3), a locking washer (4), and a socket head screw (5) in each of the four holes. 4. Align the four holes of each of the other legs with the corresponding threaded holes in the table. 5. Secure each leg to the table with four flat washers, locking washers, and socket head screws. 6. Make sure all of the screws are securely fastened. 7. Place the router table right-side up on the work surface. 11
Assembly and adjustments (continued) WARNING: Do not plug the router table power cord into an outlet until the table is fully assembled and the router is installed. Attach the switch box to the front leg (Fig. 3 and 4) The switch box fits into the rectangular cutout on the right front leg so that the switch is easily accessible. The switch on the front of the switch box fits through the cutout in the leg. An electric cord and a double-insulated electric outlet for the router are located on the rear of the switch box. Note: If the cutout is not on the right front leg when the table is upright, reinstall the legs. 1. Place the switch box (1) through the cutout (2) on the front right leg. 2. Align the screw holes at the top and the bottom of the switch box with the 2 small openings above and below the cutout on the leg. 3. Secure the switch box to the leg with the two small Phillips head screws (3). 4. Flip the switch (4) up and down to make sure it moves freely. Note: The switch has a safety lock that must be in place before you will be able to flip the switch up or down. Secure the table to a work base (optional) Each table leg has an opening at the bottom for securing the assembled table to a suitable base. The work base should be level and strong enough to support the weight of the table and the router. In addition, the work base should be very stable to eliminate vibration and wobble when the router is operating. Select a suitable work base and use an appropriate fastener to secure each table leg to the work base. 12
Assembly and adjustments (continued) Assemble the table accessories The router table accessories include a moveable fence with a guard, a miter gauge, several table inserts, and a safety pin. Attach the fence to the table (Fig. 5) The plastic fence is moveable and attaches to the table through the two channel openings on the table. Two sliding panels and a guard attach to the fence. 1. Place the router table so that you are facing the rear of the table. 2. Align the fence (1) over the channel openings (2) in the table. The large round opening on the fence (3) should face the rear of the table. 3. Place the longest carriage bolt (4) through the channel opening (2) on the table and through the hole (5) on the right side of the fence. Secure the bolt with a flat washer (6) and a large lock knob (7). 4. Place the shorter carriage bolt (8) through the channel opening on the left side of the table and through the opening on the left side of the fence. Secure the bolt with a flat washer and a large lock knob. 13
Assembly and adjustments (continued) Attach the sliding panels to the fence (Fig. 6) 1. Place one sliding panel (1) along the front side of the fence (2) and align the channel openings on the panel with the holes along the front of the fence. 2. Place a carriage bolt (3) through each of the two openings on the panel and secure each bolt with a flat washer (4) and a small lock knob (5). 3. Repeat steps 1 and 2 to secure the second sliding panel to the fence. Attach the guard to the fence (Fig. 7) The guard protects the cutting edge of the router bit. A pin secures the guard to a support on the fence. The guard will move freely when it is attached properly to the fence. 1. Place the arm of the guard (1) over the support base (2) on the fence. 2. Align the openings (3) on each side of the guard arm with the openings on the support base. 3. Slide the pin (4) through both sides of the guard arm and the support base on the fence. Tap gently on the pin if needed to insert it through the support base. 14
Assembly and adjustments (continued) Attach the router to the table (Fig. 8 11) The plunge router attaches to the underside of the router table and is secured by four bolts. Once installed, the router power cord plugs into an outlet on the switch box. When properly installed, the router table switch turns the router on and off. Note: See the Plunge Router Instruction Manual for additional information on assembling and using the router. 1. Remove the four screws (1) that hold the plastic protective plate (2) to the router plate (3). 2. Make sure the dust collecting attachment is not installed on the router (Fig. 9). WARNING: Do not use the router dust collecting attachment when installing the router on the router table. 3. Place the router under the table and align the four openings (4) on the router plate with the four openings (5) on the table. Make sure the front of the router faces the front side of the router table (Fig. 10). 4. Secure the router to the table with four brass flat head Phillips screws (6). Make sure the router is securely attached to the table before continuing. 5. Make sure the switch on the front right leg is in the OFF (down) position. 6. Plug the router power cord into the outlet (7) on the rear of the switch box. Secure the router power cord so that it will not interfere with the operation of the router (Fig. 11). 15
Assembly and adjustments (continued) Install a table insert (Fig. 12) Three table inserts, each with a different size opening, are supplied with the router table. Change the table inserts as needed to accommodate the size of the router bit. The bit should not make contact with the table insert. WARNING: Do not use the router dust collecting attachment when installing the router on the router table. 1. Select a table insert (1) that has a clearance hole (2) that is larger than the diameter of the bit you will be using. 2. Align the table insert with the square depression (3) that surrounds the router opening in the table. 3. Press gently and evenly on the table insert to secure it in the depression. Assemble the miter gauge (Fig. 13 14) The miter gauge pivots on the miter bar and is secured in position by a lock knob that fits into a threaded opening on the bar. The small post on the bottom of the miter gauge fits into an unthreaded opening on the bar. 1. Remove the lock knob (1) from the miter bar (2). 2. Slide the front of the miter gauge (3) under the pointer (4) on the miter bar. 3. Insert the small post (5) on the bottom of the miter gauge into the unthreaded hole (6) on the bar. 4. Insert and tighten the lock knob bolt through the miter gauge and into the threaded hole (7) on the miter bar. 5. Place the assembled miter bar (8) into the channel (9) that runs the full length of the table. The bar should move freely in this channel. Adjust the miter gauge To change the angle of the miter gauge, loosen the lock knob and move the gauge to the desired angle. Tighten the lock knob to maintain the gauge at the selected position. 16
Operation With the router properly installed on the router table, you will be able to operate the router using the router table switch box. The switch on the router table has a switch lock safety feature. If the lock is not in place, the router table switch will not operate. Push the switch lock into the switch or pull on the switch lock to remove it from the switch. Plug in the router (Fig. 15) WARNING: Always wear safety goggles or safety glasses with side shields when operating your router. Failure to do so could result in objects being thrown into your eyes, resulting in serious injury. 1. Make sure the safety lock (1) is inserted in the router table switch and the switch is in the OFF (down) position. 2. Make sure the router switch is in the OFF (O) position. 2 3. Plug the router into the outlet (2) on the rear of the switch box. 4. Secure the router power cord so that it does not interfere with the operation of the router. 5. Plug the router table power cord into an AC power outlet. Turn on the router (Fig. 16) Once the router is properly installed and connected to the router table, you will be able to use the safety switch on the router table to turn the router on and off. 1. Make sure the safety lock is inserted in the router table switch and the router table switch is in OFF (down) position. 2. Make sure the switch (1) on the router is in the OFF (O) position. 3. Make sure the router is plugged into the outlet on the router table switch box. 4. Make sure the router table power cord into an AC wall outlet. 5. Slide the router switch to the ON (I) position. 6. Flip the router table switch to the ON (up) position to turn on and operate the router. 7. Flip the router table switch to the OFF (down) position to turn off the router. 17
Operation (continued) WARNING: Keep the router and the router table power cords away from the cutting area. Turn the router table switch to the OFF position if either cord interferes with the cutting area. Unplug the router and check the cords for damage. If there is no damage, re-position the cords to prevent them from interfering with the workpiece again. General Operating Instructions The type of material you are using and the type of cut you want to make will determine which of the router table features you will use. For example, small round pieces may require the use of a starting pin. The fence should be used with larger pieces. 1. Determine which accessories you will need for the piece. 2. Put a bit into the router collet and adjust the height of the bit. Use the wrench to make sure the bit is seated securely in the collet. See the Plunge Router Instruction Manual for more information. 3. Attach or install the appropriate accessories (fence, starting pin, etc.) to the router table. 4. Adjust the fence to support the uncut workpiece and adjust the out-feed side of the fence so it will support the workpiece after it is cut. 5. Double check all router and router table adjustments. Make sure the guard is in place. 6. Flip the router table switch (1) to the ON (up) position and feed the workpiece (2) from right to left. WARNING: Always feed the workpiece against the sharp edges of the bit and into the rotation of the cutter. Failure to heed this warning can result in serious personal injury. 18
Operation (continued) WARNING: Before operating the router, always install the appropriate router bit and adjust the height of the bit. For your safety and to avoid damage, turn the router ON and OFF only when the router bit is not in contact with the workpiece. Adjust the bit height and depth of cut (Fig. 18) The depth of cut affects the rate and quality of the cut. The recommended depth of cut for one pass is 1/8" (3 mm) and the recommended depth for the final pass is no more than 1/16" (1.5 mm). The plunge lock lever on the router holds the router at the desired height and depth of cut. 1. Make sure the router table switch is in the OFF position. 2. Release the plunge lever (1) on the router (Fig. 18). 3. Place your hand under the router and push up until the bit is at the desired height. 4. Move the lever to the locked position to set the depth of cut. Note: See the Plunge Router Instruction manual for more information on working with bits. Using the starting pin (Fig. 19) The starting pin is used to pivot a small workpiece. The fence does not need to be used with the starting pin. The starting pin (1) fits into a threaded opening (2) on the top of the table near the table insert. Turn the pin clockwise to insert it into the table. Turn the pin counterclockwise to remove it from the table. 19
Operation (continued) Adjust the Fence (Fig. 20 22) The fence can be adjusted in various ways to accommodate the size and shape of a particular workpiece. For example, you can: Loosen the lock knobs (1) that secure the fence to the table and slide the fence toward the front or rear of the table. This will set the in-feed (left) side of the fence to support the workpiece (Fig. 20). Loosen the lock knobs (2) on a fence panel and slide the panel to the left or the right (Fig. 21). Loosen the lock knob (3) that moves the left side of the fence forward or backward. Set this panel to support the workpiece after it is cut (Fig. 22). 20
Maintenance WARNING: Always turn off the router table and unplug the power cord from the outlet before maintaining the router table or router. General Keep your router clean and in good repair for maximum performance and machine longevity. Before each use inspect the router table, router, switches, and cords for damage. Check for damaged, missing, or worn parts. Check for loose screws, misalignment, moving parts that are jammed or any other conditions that may affect the operation. If abnormal vibration or noise occurs, turn off the tool immediately and have the problem corrected before further use. Do not use the router until it is properly repaired or replaced. Note: See the Plunge Router Instruction Manual for router maintenance information and instructions. WARNING: When servicing the router table, use identical replacement parts. Use of any other parts may create a hazard or cause product damage. Cleaning Use only mild soap and a clean damp cloth to clean the router table and router. Certain cleaning agents and solvents are harmful to plastic and other insulated parts. Do not use solvents to clean plastic parts. Many types of plastics may be damaged by their use. WARNING: To avoid fire or toxic reaction, do not use gasoline, naphtha, and acetone, lacquer thinner or similar highly volatile solvents to clean the router table or router. 21
Exploded view & parts list Item# Description Qty Item# Description Qty 1 Table leg A 3 11D Brass flat head screw 4 2 Rubber foot 4 12 Washer 6 3 Screw M6X12 16 13 Small lock knob 4 4 Spring washer 16 14 Fence panel (left) 1 5 Washer 16 16 Fence 1 6 Switch box 1 17 Large lock knob 2 6A ON/OFF switch 1 18 Guard pin 1 6B Safety lock 1 19A Table insert, 1-1/4" (32mm) 1 7 Screw ST4.2X9.5 2 19B Table insert, 1-7/8" (47mm) 1 8 Table leg B (switch on it) 1 19C Table insert, 2-1/8" (55mm) 1 9 Worktable 1 20 Guard 1 10 Miter gauge 1 22 Fence panel (right) 1 11A large bolt for fence 1 24 Starting pin 1 11B med bolt for fence 1 25 Hex wrench 5mm 1 11C Small bolt for fence panel 4 26 Router wrench 1 22
Warranty Performax router tables are warranted against faulty workmanship and material for a period of two (2) years from the date of purchase, with the exception of damage directly or indirectly due to abuse, misuse, consumer negligence, accidents, alterations, or use for purposes other than those for which the tool was designed. Any return must be preauthorized, so please contact our Customer Service Department with warranty claims at 888-315-3080 M-F 8-5 CST for further instructions. If it is determined that the product is within this warranty, replacement parts or complete product replacement will be made at our discretion. There are no warranties express or implied including fitness for a particular purpose and merchantability which extend beyond the description on the face hereof; no other warranty, written or oral, is authorized. This warranty gives you specific legal rights. You may also have other rights, which vary from state to state. 23