Ozito Prr-1200 Manual 1c712n

SPECIFICATIONS MODEL NO. PRR-1200 Motor: Input: No load speed: Collet Size: Plunge Depth: Weight (tool only):

1200W 230-240V ~ 50Hz 10,000-28,000/min 6.35mm (1/4”) 40mm 3.75kgs

Know Your Product Front

Back

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Soft Grip Handles Variable Speed Dial Micro Depth Adjuster Knob On/Off Trigger Switch Lock-on Button Depth Lock Lever Parallel Guide Fence Guide Fence Rods Dust Extraction Adaptor

10. 11. 12. 13. 14. 15. 16. 17. 18.

Template Guide Spanner Circular Template Guide Parallel Guide Locking Knob Spindle Lock Button Collet Nut Adjustable Turret Depth Stop Micro Depth Gauge Micro Depth Locking Knob

TABLE OF CONTENTS SPECIFICATIONS…………………………………………. Page 2 TABLE OF CONTENTS…………………………………… Page 3 INTRODUCTION………………………………………….. Page 4 GENERAL SAFETY INSTRUCTIONS…………………….. Page 4 GENERAL SAFETY RULES……………………………….. Page 5 ADDITIONAL SAFETY INSTRUCTIONS FOR ROUTERS…… Page 7 ASSEMBLY.………………………………………………… Page 8 OPERATION…………………………………………………Page 11 MAINTENANCE…………………………………………… Page 15 TROUBLE SHOOTING…………………………………… Page 16 SPARE PARTS……………………………………………… Page 16 DESCRIPTION OF SYMBOLS……………………………. Page 17 CONTENTS………………………………………………… Page 18 WARRANTY………………………………………………… Page 19

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INTRODUCTION Congratulations on purchasing an Ozito Plunge Router. We aim to provide quality tools at an affordable price. We hope you will enjoy using this tool for many years. Your Plunge Router PRR-1200 has been designed for routing wood and wood products and is intended for DIY use only. ELECTRICAL SAFETY Warning! When using mains-powered equipment, basic safety precautions, including the following, should always be followed to reduce risk of fire, electric shock, personal injury and material damage. Read and understand the manual prior to operating this tool. Save these instructions and other documents supplied with this tool for future reference.

GENERAL SAFETY INSTRUCTIONS The electric motor has been designed for 230V and 240V only. Always check that the power supply corresponds to the voltage on the rating plate. Note: The supply of 230V and 240V on Ozito tools are interchangeable for Australia and New Zealand. This tool is double insulated in accordance with AS/NZS 60745; therefore no earth wire is required. If the supply cord is damaged, it must be replaced by a qualified electrician or a power tool repairer in order to avoid a hazard. Note: Double insulation does not take the place of normal safety precautions when operating this tool. The insulation system is for added protection against injury resulting from a possible electrical insulation failure within the tool. Using an Extension Lead Always use an approved extension lead suitable for the power input of this tool. Before use, inspect the extension lead for signs of damage, wear and ageing. Replace the extension lead if damaged or defective. When using an extension lead on a reel, always unwind the lead completely. Use of an extension lead not suitable for the power input of the tool or which is damaged or defective may result in a risk of fire and electric shock. It is recommended that the extension lead is a maximum of 25m in length. Do Not use multiple extension leads.

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GENERAL SAFETY RULES Warning! Read all instructions. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury. The term "power tool" in all of the warnings listed below refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool. Save these instructions 1) Work area a) Keep work area clean and well lit. Cluttered and dark areas invite accidents. b) Do not operate power tools in explosive atmospheres, such as in the presence of flammable 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 cause you to lose control. 2) Electrical safety a) Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock b) Avoid body with earthed or grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded. 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. e) When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock. 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 influence 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. Ensure the switch is in the off-position before plugging in. Carrying power tools with your finger 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.

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GENERAL SAFETY RULES (cont.) 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 jewellery. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts.

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 dust-related hazards. 4) Power tool use and care a) Do not force the power tool. Use the correct power tool for your application. The correct 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 supply and/or the battery pack from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally. 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 s. 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 instructions and in the manner intended for the particular type of power tool, taking into 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. 5) Service a) Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained. b) If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified persons in order to avoid a hazard.

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ADDITIONAL SAFETY INSTRUCTIONS FOR ROUTERS This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Recommendations for the use of a residual current device with a rated residual current of 30mA or less. Using an Extension Lead Always use an approved extension lead suitable for the power input of this tool. Before use, inspect the extension lead for signs of damage, wear and ageing. Replace the extension lead if damaged or defective. When using an extension lead on a reel, always unwind the lead completely. Use of an extension lead not suitable for the power input of the tool or which is damaged or defective may result in a risk of fire and electric shock. It is recommended that the extension lead is a maximum of 25m in length. Do Not use multiple extension leads. •

Wear safety glasses or goggles when operating this tool.

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Only use router bits with a shank diameter equal to the size of the collet installed in the tool.

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Only use router bits suitable for the no-load speed of the tool.

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Do not use the tool in an inverted position.

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Do not attempt to use the tool in a stationary mode.

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Take special care when routing MDF or surfaces coated with lead-based paint:

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Wear a dust mask specifically designed for protection against lead paint dust and fumes and ensure that persons within or entering the work area are also protected.

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Do not let children or pregnant women enter the work area.

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Do not eat, drink or smoke in the work area.

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Dispose of dust particles and any other debris safely.

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ASSEMBLY Assembly of the Parallel Guide Fence 1. Remove the two Phillips screws from the end of the guide fence rods (8) by rotating them anticlockwise (Fig.A).

Fig. A

2. Fix the two guide fence rods (8) onto the parallel guide fence (7) by inserting the Phillips screws through the holes in the guide fence (7) as shown in (Fig.B). 3. Tighten the two Phillips screws by rotating them clockwise. Fig. B

Assembly of the Circular Template Guide 1. Slide the circular template guide (12) onto one of the guide fence rods (8). (Fig.C). 2. Secure by tightening the wing nut clockwise (Fig.D).

Fig. C

Fig. D

Installing and Removing Collets CAUTION: Always ensure that the router is switched off and unplugged from the mains supply before installing or removing a collet or router bits. 1. The router is fitted with a 6.35mm (1/4”) collet (Fig.1). Note: It is recommended that you turn the router upside down and rest it on a table or bench when changing the router bits. This will assist when changing the router bits. Rest the upside down router on the lugs located on the top of the router assembly.

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Fig. 1

ASSEMBLY (cont.) 2. Depress and hold the spindle lock button (14) to stop the spindle from turning. 3. Whilst holding the spindle lock button (14), loosen the collet nut (15) by rotating it clockwise using the spanner (11) provided. Fig. 2

4. Remove the collet nut (15), followed by the collet (Fig.3). 5. Install the new collet into the assembly. 6. Install the collet nut (15) and tighten by hand, turning anti-clockwise. Warning! Do not tighten the collet nut without a bit in place or you may break the collet.

Fig. 3

Installing and Removing Router Bits 1. Ensure the correct collet size diameter is installed for the router bit shaft diameter you are using. 2. Loosen the collet nut (15) by depressing and holding the spindle lock button (14) and then rotating the collet nut (15) clockwise (Fig.4). Fig. 4

3. Insert a router bit into the collet, ensuring that the shaft of the bit is inserted all the way into the collet and then raise the bit approx 2mm (Fig.5).

Fig. 5

4. Tighten the collet nut (5) by depressing and holding the spindle lock button (14) and then tightening the collet nut (15) anti-clockwise (Fig.6). CAUTION: Ensure the bit is firmly secured before commencing operation.

Fig. 6

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ASSEMBLY (cont.) Adjusting the Cutting Depth CAUTION: Always ensure that the router is switched off and unplugged from the mains supply before adjusting the cutting depth. 1. The router has an adjustable turret depth stop (16). This turret stop (16) enables the router 0mm to have 5 preset depth of cut settings (Fig.7). Fig. 7 Fig. 8 Turn the adjustable turret depth stop (16) until the highest depth stop position, or 0mm, is facing the front of the router (Fig.8). 2. Place the router on a flat surface and loosen the micro depth locking knob (18) by rotating it anti-clockwise (Fig.9).

Fig. 9

3. Loosen the depth lock lever (6) by pushing the lever down and lowering the body of the router until the router bit just touches the flat surface (Fig.10). 4. Lower the micro depth gauge (17) allowing it to just make with the adjustable turret depth stop (16).

Router bit touching the flat surface. Fig. 10

5. The adjustable turret depth stop (16) has five steps. By rotating the adjustable turret depth stop it is possible to quickly and easily set the depth at five different cutting depths. This procedure is particularly useful when you wish to make a deep cut in a number of stages. 6. Use the micro depth adjuster knob (3) for precise setting of cutting depth. This will allow you to finely adjust the cutting depth to suit your requirements. Rotate the micro depth adjuster knob (3) clockwise to raise the router bit or anticlockwise to lower or increase the cutting depth of the router bit (Fig.11).

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Once you have made the required cutting depth adjustments, simply lower the depth lock lever (6) and then lower the router until the micro depth gauge (17) touches the adjustable turret depth stop (16). Release the depth lock lever (6) to lock the cutting depth.

Fig. 11

OPERATION Switching On and Off CAUTION: Before plugging in the router, always check that the on/off trigger switch engages and disengages properly. 1. Press the on/off trigger switch (4) to turn on the router (Fig.12). 2. To turn off the router, release the on/off trigger switch (4). 3. If you require the router to run continually without having to continue applying pressure to the on/off trigger switch, press the on/off trigger switch (4) and then depress the lock-on button (5) to lock the switch on (Fig.13).

Fig. 12

4. The router will now run in the “locked-on” condition. 5. If the switch is in the lock-on position, depress the on/ off trigger switch (4) to disengage the lock-on button (5) and then release the on /off switch (4) and the router will stop. Variable Speed Control

Fig. 13

The variable speed dial (2) is located in the left soft grip handle (1), depending on what direction the router is facing, for convenient speed adjustment and improved safety (Fig.14). 1. Adjust the variable speed dial (2) to suit different working materials. The tool cuts quicker and smoother at varying speeds when working in different timber materials or in plastic.

Fig. 14

2. Turn the variable speed dial (2) to a higher number, or Max for faster speed. Turn the dial to a lower number, or Min for slower speed. 3. Determine the optimum speed by making a trial cut in a scrap piece of material. NOTE: Using the correct speed for the job increases the life of the bit. CAUTION: Always use two hands to hold the router. CAUTION: Where possible, clamp the work piece to the bench. CAUTION: Moving the machine too fast may cause a poor quality of cut and can damage the bit or the motor. Moving the machine too slowly may burn or mar the cut. The proper feed rate will depend on the bit size, the type of material being cut and the cutting depth. Practice first on a scrap piece of material to gauge the correct feed rate and cut dimensions. Making a Cut Your router can be used to make specialty cuts and shapes in the surface and on the edge of wood. It accepts a wide range of bits that are each designed for a specific cut or shape. 1. Make all your adjustments as described in the previous sections.

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OPERATION (cont.) 2. Insert and secure your router bit. 3. Adjust the cutting depth as required for the application. 4. Ensure that the materials you are working on are fastened to the workbench or secured correctly. 5. Place the base plate on the work piece, ensuring that the bit is not in with the material to be cut. 6. Connect the router to the power supply. 7. Turn the router on. Ensure you have a firm grip on both handles. Wait for the bit to come to full speed. 8. Lower the router body and lock it in position at the desired cutting depth. 9. Follow the guide below to assist you when routing your workpiece. Direction of the router travel

When routering the outside of your workpiece

When routering the inside of your workpiece

10. Keep the cutting pressure constant, taking care not to overload the router, causing the motor to slow excessively. 11. On very hard woods or problem materials it may be necessary to make more than one at progressive cutting depths until the desired cutting depth is achieved. 12. To turn the router off, release the on/off trigger switch (4) or press and release the on/off trigger switch if in the “lock-on” position. Warning! When using this router to cut flat s such as kitchen work surfaces, before ing please ensure that you use an appropriate jig together with the correct guide bush. DO NOT use the curved part of the router base against a simple guide piece. Using the Parallel Guide Fence The parallel guide fence (7) is an effective aid to cutting in a straight line when chamfering or grooving. 1. Loosen the parallel guide locking knobs (13) by rotating them anti-clockwise (Fig.15).

Fig. 15

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OPERATION (cont.) 2. Feed the two bars on the parallel guide fence (7) through the holes in the router base, located on the right hand side of the router in the feed direction. This will assist in keeping the guide flush with the side of the work piece (Fig 16). 3. Adjust the distance between the router bit and parallel guide fence (7) by moving the guide until it is at the correct distance from the router bit and the cut you are making.

Fig. 16

4. Tighten the parallel guide locking knobs (13) by rotating clockwise, to hold the parallel guide fence (7) in position. Note: If the distance between the side of the work piece and the cutting position is too wide, or the side of the work piece is not straight, firmly clamp a straight board to the work piece and use this as a guide against the flat of the router base. Using the Dust Extraction Adaptor The dust extraction adaptor (9) will accept most standard vacuum cleaner nozzles allowing the dust to be efficiently removed when the tool is in use. Fit the dust extraction adaptor (9) into the base as shown in Fig.17. Ensure that the suction hose that will be used is a Fig. 17 reinforced hose such as a garden hose or a wire reinforced hose. If you use a non-reinforced hose, the hose can collapse and reduce the suction therefore limiting the extraction of debris and dust. Using the Copy Template Guide The copy template guide (10) can be used in various ways: •

Producing duplicates of a particular design of an original shape.

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In conjunction with a template, producing decorative features.

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Repetitive shape cutting.

1. To attach the template guide (10) turn the router upside down and remove the two fixing screws by rotating them anti-clockwise. These screws also hold the dust extraction shroud in place. The dust extraction shroud is the clear shroud located on the underside of the router base (Fig.8). 2. Insert the template guide (10) into the base of the router with the raised collar facing up or out from the base plate of the router (Fig.18). 3. You will need to hold the dust extraction shroud in it's position with your other hand prior to screwing the template guide (10) into position. Fig. 18

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OPERATION (cont.) 4. Secure the template guide (10) using the two fixing screws that you just removed by rotating them clockwise (Fig.19). If you wish to make your own templates, it is best to use a hardwood such as plywood. Use a piece that is just thicker than the depth of the copy template guide (10). Allow for the thickness of the guide in your template to ensure that the work piece is cut to the correct size.

Fig. 19

Consult woodworking forums or woodworking magazines for assistance in the use of circular or round template guide attachments . Using the Circular Template Guide 1. To use the circular template guide (12), insert a guide fence rod (8) with the circular template guide (12) attached into the holes, either side of the base plate of the router (Fig.20).

Fig. 20

2. Secure the guide fence rod (8) to the router at the required length be rotating the parallel guide locking knob (13) clockwise (Fig.21).

Fig. 21

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MAINTENANCE Warning! Always ensure that the tool is switched off and the plug is removed from the power point before making any adjustments or maintenance procedures. Always wear sturdy gloves when handling or changing bits as they can be very sharp. •

Keep the ventilation vents of the tool clean at all times, if possible, prevent foreign matter from entering the vents.

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After each use, blow air through the tool housing to ensure it is free from all dust particles which may build up. Build up of dust particles may cause the tool to overheat and fail.

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If the enclosure of the tool requires cleaning, do not use solvents but a moist soft cloth only. Never let any liquid get inside the tool; never immerse any part of the tool into a liquid.

Carbon Brushes When the carbon brushes wear out, the tool will spark and/or stop. Discontinue use as soon as this happens. They should be replaced prior to recommencing use of the tool. Carbon brushes are a wearing component of the tool therefore not covered under warranty. Continuing to use the tool when carbon brushes need to be replaced may cause permanent Carbon brushes damage to the tool. Carbon brushes will wear out after many uses but when the carbon brushes need to be replaced, take the tool to an electrician or a power tool repairer for a quick and low cost replacement. Always replace both carbon brushes at the same time. Note: Ozito Industries will not be responsible for any damage or injuries caused by the repair of the tool by an unauthorised person or by mishandling of the tool.

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TROUBLE SHOOTING SYMPTOM

POSSIBLE CAUSE

REMEDY

No supply of power.

Check that power is available at source.

Blunt or damaged router bits.

Re-sharpen or replace router bits.

Variable speed set low.

Increase variable speed setting.

Motor is overloaded.

Reduce excessive load or force on router.

Excessive vibration.

Bent router bit shaft.

Replace router bit.

Heavy sparking occurs inside motor housing.

Brushes not moving freely.

Disconnect power, remove brushes, clean or replace.

Router will not operate. Router runs slowly.

SPARE PARTS Limited spare parts are available subject to availability. Please your local Bunnings Special Orders Desk to order the required spare parts. Most common spare parts listed below

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Spare Part

Part No.

Brush Holder

SPPRR1200-06

Carbon Brushes (set)

SPPRR1200-07

Variable Speed Switch

SPPRR1200-16

On/Off Switch

SPPRR1200-26

Collet Spring

SPPRR1200-31

Collet 6.35mm (1/4”)

SPPRR1200-38

Collet Nut

SPPRR1200-39

Depth Lock Lever

SPPRR1200-50A

DESCRIPTION OF SYMBOLS V

Volts

Hz

Hertz

~

Alternating current

W

Watts

/min

Revolutions or reciprocation per minute

ø

Diameter Warning

Double insulated

no

No load speed Regulator compliance mark

Read instruction manual

CARING FOR THE ENVIRONMENT Power tools that are no longer usable should not be disposed of with household waste but in an environmentally friendly way. Please recycle where facilities exist. Check with your local council authority for recycling advice. Recycling packaging reduces the need for landfill and raw materials. Reuse of recycled material decreases pollution in the environment. Please recycle packaging where facilities exist. Check with your local council authority for recycling advice.

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CONTENTS 1 x Plunge Router (PRR-1200)

1 x Template Guide

1 x Collet 6.35mm (1/4”)

1 x Circular Template Guide

1 x Spanner

1 x Assembly Nuts & Screws

1 x Parallel Guide Fence

1 x Instruction Manual

1 x Dust Extraction Adaptor

OZITO INDUSTRIES PTY LTD AUSTRALIA (Head Office) 1 - 23 Letcon Drive, Bangholme, Victoria, Australia 3175 Telephone: 1800 069 486 Facsimile: +61 3 9238 5588 Website: www.ozito.com.au Email: [email protected]

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WARRANTY THIS WARRANTY FORM AND CONFIRMED BUNNINGS RECEIPT SHOULD BE RETAINED BY THE CUSTOMER AT ALL TIMES

The warranty is only made available by returning the product to your nearest Bunnings Warehouse with a confirmed Bunnings receipt.

YOUR WARRANTY FORM SHOULD BE RETAINED BY YOU AT ALL TIMES. SHOULD YOU HAVE ANY QUESTIONS PRIOR TO RETURNING YOUR PRODUCT FOR WARRANTY OR REPAIR PLEASE TELEPHONE OUR CUSTOMER SERVICE HELPLINE:

Australia 1800 069 486 New Zealand 0508 069 486 TO ENSURE A SPEEDY RESPONSE PLEASE HAVE THE MODEL NUMBER AND DATE OF PURCHASE AVAILABLE. AN OZITO CUSTOMER SERVICE REPRESENTATIVE WILL TAKE YOUR CALL AND ANSWER ANY QUESTIONS YOU MAY HAVE RELATING TO THE WARRANTY POLICY OR PROCEDURE.

PURCHASED FROM:_________________________________________________ DATE PURCHASED: _________________________________________________ 3 YEAR REPLACEMENT WARRANTY Your Ozito tool is guaranteed for a period of 36 months from the original date of purchase and is intended for DIY (Do it yourself) use only. WARNING The following actions will result in the warranty being void. •

Trade, Industrial or high frequency use.

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If the tool has been operated on a supply voltage other than that specified on the tool.

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If the tool shows signs of damage or defects caused by or resulting from abuse, accidents or alterations.

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If the tool is disassembled or tampered with in any way.

Note: Warranty excludes consumable parts such as carbon brushes, grinding or cutting wheels/discs, diamond wheels, paper washers, allen keys, pin spanners and other accessories.