makita RP1100 Router Instruction Manual

Router
MODEL RP1100/RP1101

INSTRUCTION MANUAL
WARNING:
For your personal safety, READ and UNDERSTAND before using.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.

www.makitatools.com

SPECIFICATIONS

• Manufacturer reserves the right to change specifications without notice.
• Specifications may differ from country to country.

GENERAL SAFETY RULES

(For All Tools)
WARNING:
Read and understand all instructions. Failure to follow all instructions listed below, may result in electric shock, fire and/or serious personal injury.

SAVE THESE INSTRUCTIONS
Work Area

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

2. 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.

3. Keep bystanders, children, and visitors away while operating a power tool. Distractions can cause you to lose control.
   Electrical Safety

4. Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances.
   Never remove the grounding prong or modify the plug in any way.
   Do not use any adaptor plugs.
   Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded. If the tools should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user.

5. Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators.
   There is an increased risk of electric shock if your body is grounded.

6. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.

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

8. When operating a power tool outside, use an outdoor extension cord marked “W-A” or “W”. These cords are rated for outdoor use and reduce the risk of electric shock.
   Personal Safety

9. Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use tool while tired or under the influence of drugs, alcohol, or medication. A moment of inattention while operating power tools may result in serious personal injury.

10. Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts.

11. Avoid accidental starting. Be sure switch is off before plugging in. Carrying tools with your finger on the switch or plugging in tools that have the switch on invites accidents.

12. Remove adjusting keys or wrenches before turning the tool on. A wrench or a key that is left attached to a rotating part of the tool may result in personal injury.

13. Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the tool in unexpected situations.

14. Use safety equipment. Always wear eye protection. Dust mask, non-skid safety shoes, hard hat, or hearing protection must be used for appropriate conditions. Ordinary eye or sun glasses are NOT eye protection.
    Tool Use and Care

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

16. Do not force tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed.

17. Do not use tool if switch does not turn it on or off. Any tool that cannot be controlled with the switch is dangerous and must be repaired.

18. Disconnect the plug from the power source before making any adjustments, changing accessories, or storing the tool.
    Such preventive safety measures reduce the risk of starting the tool accidentally.

19. Store idle tools out of reach of children and other untrained persons. Tools are dangerous in the hands of untrained users.

20. Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools with sharp cutting edges are less likely to bind and are easier to control.

21. Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tools operation. If damaged, have the tool serviced before using.
    Many accidents are caused by poorly maintained tools.

22. Use only accessories that are recommended by the manufacturer for your model.
    Accessories that may be suitable for one tool, may become hazardous when used on another tool.

USE PROPER EXTENSION CORD: Use only three-wire extension cords that have threeprong grounding-type plugs and three-pole receptacles that accept the tool’s plug. Make sure your extension cord is in good condition. Replace or repair damaged or worn cord immediately. 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. Table 1 shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gage. The smaller the gage number, the heavier the cord.
Table 1: Minimum gage for cord

GROUNDING INSTRUCTIONS
This tool should be grounded while in use to protect the operator from electric shock. The tool is equipped with a three-conductor cord and three- prong grounding type plug to fit the proper grounding type receptacle. The green (or green and yellow) conductor in the cord is the grounding wire. Never connect the green (or green and yellow) wire to a live terminal.
Your unit is for use on 120 volts and has a plug that looks like Fig. “A”.
An adapter Fig. “B” and “C” is available for connecting Fig. “A” type plugs to two- prong receptacles. The green-colored rigid ear, lug, etc., extending from the adapter must be connected to a permanent ground, such as a properly grounded outlet box.

SPECIFIC SAFETY RULES

DO NOT let comfort or familiarity with product (gained from repeated use) replace strict adherence to router safety rules. If you use this tool unsafely or incorrectly, you can suffer serious personal injury.

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

2. Wear hearing protection during extended period of operation.

3. Handle the bits very carefully.

4. Check the bit carefully for cracks or damage before operation. Replace cracked or damaged bit immediately.

5. Avoid cutting nails. Inspect for and remove all nails from the workpiece before operation.

6. Hold the tool firmly with both hands.

7. Keep hands away from rotating parts.

8. Make sure the bit is not contacting the workpiece before the switch is turned on.

9. Before using the tool on an actual workpiece, let it run for a while.
   Watch for vibration or wobbling that could indicate improperly installed bit.

10. Be careful of the bit rotating direction and the feed direction.

11. Do not leave the tool running. Operate the tool only when hand-held.

12. Always switch off and wait for the bit to come to a complete stop before removing the tool from workpiece.

13. Do not touch the bit immediately after operation; it may be extremely hot and could burn your skin.

14. Always lead the power supply cord away from the tool towards the rear.

15. Do not smear the tool base carelessly with thinner, gasoline, oil or the like. They may cause cracks in the tool base.

16. Draw attention to the need to use cutters of the correct shank diameter and suitable for the speed of the tool.

17. Some material contains chemicals which may be toxic. Take caution to prevent dust inhalation and skin contact. Follow material supplier safety data.

SAVE THESE INSTRUCTIONS
WARNING:
MISUSE or failure to follow the safety rules stated in this instruction manual may cause serious personal injury.

SYMBOLS

The followings show the symbols used for tool.

V ………………….. volts
A ………………….. amperes
Hz ………………… hertz
…………….alternating current
n˚………………..no load speed
…/min…………….revolutions or reciprocation perminute

FUNCTIONAL DESCRIPTION

1. Lock lever
2. Adjusting knob
3. Depth pointer
4. Fast-feed button
5. Stopper pole
6. Fast-feed button
7. Stopper pole setting nut

Adjusting the depth of cut
Place the tool on a flat surface. Press the lock lever down and lower the tool body until the bit just touches the flat surface. Release the lock lever to hold the tool body down. Turn the stopper pole setting nut counterclockwise to loosen. While pressing the fast-feed button, lower the stopper pole until it makes contact with the adjusting hex bolt. Align the depth pointer with the “0” graduation. The depth of cut is indicated on the scale by the depth pointer. While pressing the fast-feed button, raise the stopper pole until the desired depth of cut is obtained. Minute depth adjustments can be obtained by turning the adjusting knob (1.6 mm (1/16”) per turn). After adjusting the depth of cut, turn the stopper pole setting nut clockwise to fasten the stopper pole firmly. Now, your predetermined depth of cut can be obtained by pressing the lock lever and then lowering the tool body until the stopper pole makes contact with the adjusting hex bolt of the stopper block.

Nylon nut
CAUTION:

• Do not lower the nylon nut too low or the bit will protrude dangerously.
  By turning the nylon nut, the upper limit of the tool body can be adjusted. When the tip of the bit is retracted more than required in relation to the base plate surface, turn the nylon nut to lower the upper limit.

CAUTION:

• Since excessive cutting may cause overload of the motor or difficulty in controlling the tool, the depth of cut should not be more than 15 mm (9/16”) at a pass when cutting grooves with an 8 mm (5/16”) diameter bit.
• When cutting grooves with a 20 mm (13/16”) diameter bit, the depth of cut should not be more than 5 mm (3/16”) at a pass.
• For extra-deep grooving operations, make two or three passes with progressively deeper bit settings.

1. Stopper pole
2. Adjusting hex bolt
3. Hex nut
4. Stopper block

Stopper block
The stopper block has three adjusting hex bolts which raise or lower 0.8 mm (1/32”) per turn. You can easily obtain three different depths of cut using these adjusting hex bolts without readjusting the stopper pole. Adjust the lowest hex bolt to obtain the deepest depth of cut, following the method of “Adjusting depth of cut”. Adjust the two remaining hex bolts to obtain shallower depths of cut. The differences in height of these hex bolts are equal to the differences in depths of cut. To adjust the hex bolts, first loosen the hex nuts on the hex bolts with the wrench and then turn the hex bolts. After obtaining the desired position, tighten the hex nuts while holding the hex bolts in that desired position. The stopper block is also convenient for making three passes with progressively deeper bit settings when cutting deep grooves.

Switch action
CAUTION:

• Before plugging in the tool, always check to see that the tool is switched off.
• Switch can be locked in “ON” position for ease of operator comfort during extended use. Apply caution when locking tool in “ON” position and maintain firm grasp on tool.
  To start the tool, move the switch lever to the I (ON) position.

Speed adjusting dial
For model RP1101 only
The tool speed can be changed by turning the speed adjusting dial to a given number setting from 1 to 6.
Higher speed is obtained when the dial is turned in the direction of number 6. And lower speed is obtained when it is turned in the direction of number

1. This allows the ideal speed to be selected for optimum material processing, i.e. the speed can be correctly adjusted to  suit the material and bit diameter.Refer to the table for the relationship between the number settings on the dial and the approximate tool speed.

CAUTION:

• If the tool is operated continuously at low speeds for a long time, the motor will get overloaded, resulting in tool malfunction.
• The speed adjusting dial can be turned only as far as 6 and back to 1. Do not force it past 6 or 1, or the speed adjusting function may no longer work.

Speed adjusting dial
For model RP1101 only
The tool speed can be changed by turning the speed adjusting dial to a given number setting from 1 to 6.
Higher speed is obtained when the dial is turned in the direction of number 6. And lower speed is obtained when it is turned in the direction of number

1. This allows the ideal speed to be selected for optimum material processing, i.e. the speed can be correctly adjusted to suit the material and bit diameter.
   Refer to the table for the relationship between the number settings on the dial and the approximate tool speed.
   CAUTION:
   • If the tool is operated continuously at low speeds for a long time, the motor will get overloaded, resulting in tool malfunction.
   • The speed adjusting dial can be turned only as far as 6 and back to 1. Do not force it past 6 or 1, or the speed adjusting function may no longer work.

ASSEMBLY

CAUTION:

• Always be sure that the tool is switched off and unplugged before carrying out any work on the tool.
  Installing or removing the bit
  CAUTION:

• Use always a collet which is suitable for the shank diameter of the bit.

• Do not tighten the collet chuck without inserting a bit, or the collet chuck will break.

• When using bit of bigger than 1-1/4” in diameter, install base plate with center hole diameter 2-1/2”, replacing the original base plate.
  Insert the bit all the way into the collet chuck and withdraw it very slightly ( approx. 2mm;1/16” ). Then tighten the collet chuck securely with the two wrenches. These routers accommodate the bits with 1/2” diameter shank. When using the 1/4” diameter  shank bit, replace the equipped collet chuck with the one for 1/4” diameter shank bit which is provided as the standard accessory. To remove the bit, follow the installation procedure in reverse.

OPERATION

Set the tool base on the workpiece to be cut without the bit making any contact. Then turn the tool on and wait until the bit attains full speed. Lower the tool body with pressing the lock lever down. Release the lock lever at the lowest position and push it further  to lock the tool body securely. Move the tool forward over the workpiece surface, keeping the tool base flush and advancing smoothly until the cutting is complete.
When doing edge cutting, the workpiece surface should be on the left side of the bit in the feed direction.

NOTE:

• Make sure that the tool raises automatically when the lock lever is loosened. The position of the bit must be higher than the tool base when not operating.

• Moving the tool forward too fast may cause a poor quality of cut, or damage to the bit or motor. Moving the tool forward too slowly may burn and mar the cut. The proper feed rate will depend on the bit size, the kind of workpiece and depth of cut. Before  beginning the cut on the actual workpiece, it is advisable to make a sample cut on a piece of scrap lumber. This will show exactly how the cut will look as well as enable you to check
  dimensions.

• When using the straight guide, be sure to install it on the right side in the feed direction. This will help to keep it flush with the side of the workpiece.

When cutting, move the tool with the straight guide flush with the side of the workpiece.

If the distance between the side of the workpiece and the cutting position is too wide for the straight guide, or if the side of the workpiece is not straight, the straight guide cannot be used. In this case, firmly clamp a straight board to the workpiece and use it as a  guide against the base.
Feed the tool in the direction of the arrow.
Templet guide (optional accessory)

The templet guide provides a sleeve through which the bit passes, allowing use of the tool with templet patterns.

Secure the templet to the workpiece. Place the tool on the templet and move the tool with the templet guide sliding along the side of the templet.

MAINTENANCE

CAUTIONCAUTION:

• Always be sure that the tool is switched off and unplugged before attempting to perform inspection or maintenance.
  Replacing carbon brushes
  Remove and check the carbon brushes regularly. Replace when they wear down to the limit mark. Keep the carbon brushes clean and free to slip in the holders. Both carbon brushes should be replaced at the same time. Use only identical carbon brushes. :

• Always be sure that the tool is switched off and unplugged before attempting to perform inspection or maintenance.
  Replacing carbon brushes
  Remove and check the carbon brushes regularly. Replace when they wear down to the limit mark. Keep the carbon brushes clean and free to slip in the holders. Both carbon brushes should be replaced at the same time. Use only identical carbon brushes.

Use a screwdriver to remove the brush holder caps. Take out the worn carbon brushes, insert the new ones and secure the brush holder caps.
To maintain product SAFETY and RELIABILITY, repairs, any other maintenance or adjustment should be performed by Makita Authorized or Factory Service Centers, always using Makita replacement parts.

ACCESSORIES

CAUTION:

• These accessories or attachments are recommended for use with your Makita tool specified in this manual. The use of any other accessories or attachments might present a risk of injury to persons. Only use accessory or attachment for its stated purpose.

If you need any assistance for more details regarding these accessories, ask your local Makita service center.
• Straight & groove forming bits
• Edge forming bits
• Laminate trimming bits
• Straight guide
• Templet guides
• Lock nut
• Clear base plate (Center hole 2-1/2”)
• Wrench 8
• Wrench 27
• Dust nozzle

Makita U.S.A., Inc.
14930 Northam Street
La Mirada, CA 90638-5753

WARNING

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 and cement and other masonry products, and
• 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.

MAKITA LIMITED ONE YEAR WARRANTY
Warranty Policy
Every Makita tool is thoroughly inspected and tested before leaving the factory. It is warranted to be free of defects from workmanship and materials for the period of ONE YEAR from the date of original purchase.
Should any trouble develop during this one year period, return the COMPLETE tool, freight prepaid, to one of Makita’s Factory or Authorized Service Centers. If inspection shows the trouble is caused by defective workmanship or material, Makita will repair (or  at our option, replace) without charge.
This Warranty does not apply where:

• repairs have been made or attempted by others:
• repairs are required because of normal wear and tear:
• the tool has been abused, misused or improperly maintained:
• alterations have been made to the tool.

IN NO EVENT SHALL MAKITA BE LIABLE FOR ANY INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES FROM THE SALE OR USE OF THE PRODUCT. THIS DISCLAIMER APPLIES BOTH DURING AND AFTER THE TERM OF THIS WARRANTY.
MAKITA DISCLAIMS LIABILITY FOR ANY IMPLIED WARRANTIES, INCLUDING IMPLIED WARRANTIES OF “MERCHANTABILITY” AND “FITNESS FOR A SPECIFIC PURPOSE,” AFTER THE ONE YEAR TERM OF THIS WARRANTY.
This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. Some states do not allow limitation on how long an implied warranty lasts, so the above limitation may not apply to you.

Makita Corporation of America
2650 Buford Hwy., Buford, GA 30518

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