Chicago Electric 37793 Installation manual

PLUNGE ROUTER

Model

37793

SET UP AND OPERATING INSTRUCTIONS

Diagrams within this manual may not be drawn proportionally.

Due to continuing improvements, actual product may differ slightly from the product described herein.

Distributed exclusively by Harbor Freight Tools®.

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our website at: http://www.harborfreight.com

Read this material before using this product.

Failure to do so can result in serious injury.

SAVE THIS MANUAL.

manual or any artwork contained herein may be reproduced in any shape or form

without the express written consent of Harbor Freight Tools.

For technical questions or replacement parts, please call 1-800-444-3353.

REV 07j

Page 2SKU 37793 For technical questions, please call 1-800-444-3353.

SPECIFICATIONS

Motor 23,000 RPM, electrical brake

Power 2.5 HP

Power Consumption 15 Amps @ 120VAC, 60 Hz, single phase

Power Cord 8 foot, 14 AWG

Collet Capacity 1/4, 1/2, and 3/4 inch

Maximum Plunge 2-1/2 inches; 3 adjustable plunge settings

SAVE THIS MANUAL

You will need this manual for the safety warnings and precautions, assembly,

operating, inspection, maintenance and cleaning procedures, parts list and assembly

diagram. Keep your invoice with this manual. Write the invoice number on the inside of the

front cover. Keep this manual and invoice in a safe and dry place for future reference.

GENERAL SAFETY RULES

WARNING!

READ AND UNDERSTAND ALL INSTRUCTIONS. Failure to follow

all instructions listed below may result in electric shock, re, and/or

serious injury.

SAVE THESE INSTRUCTIONS

WORK AREA

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

accidents.

Do not operate power tools in explosive atmospheres, such as in the

presence of ammable liquids, gases, or dust. Power tools create sparks which

may ignite the dust or fumes.

Keep bystanders, children, and visitors away while operating a power tool.

Distractions can cause you to lose control. Protect others in the work area from

debris such as chips and sparks. Provide barriers or shields as needed.

Use tool in a well ventilated area.

ELECTRICAL SAFETY

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 adapter plugs. Check with a qualied

electrician if you are in doubt as to whether the outlet is properly grounded. If the

Page 3SKU 37793 For technical questions, please call 1-800-444-3353.

tools should electrically malfunction or break down, grounding provides a low resistance

path to carry electricity away from the user.

Double insulated tools are equipped with a polarized plug (one blade is wider than

the other). This plug will t in a polarized outlet only one way. If the plug does

not t fully in the outlet, reverse the plug. If it still does not t, contact a qualied

electrician to install a polarized outlet. Do not change the plug in any way. Double

insulation eliminates the need for the three wire grounded power cord and grounded

power supply system.

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.

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

increase the risk of electric shock.

Do not abuse the Power Cord. Never use the Power Cord to carry the tools or pull

the Plug from an outlet. Keep the Power Cord away from heat, oil, sharp edges, or

moving parts. Replace damaged Power Cords immediately. Damaged Power Cords

increase the risk of electric shock.

When operating a power tool outside, use an outdoor extension cord marked “W-A”

or “W”. These extension cords are rated for outdoor use, and reduce the risk of electric

shock.

PERSONAL SAFETY

Stay alert. Watch what you are doing, and use common sense when operating

a power tool. Do not use a power tool while tired or under the inuence of

drugs, alcohol, or medication. A moment of inattention while operating power

tools may result in serious personal injury.

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.

Avoid accidental starting. Be sure the Power Switch is off before plugging

in. Carrying power tools with your nger on the Power Switch, or plugging in power

tools with the Power Switch on, invites accidents.

Remove adjusting keys or wrenches before turning the power tool on. A

wrench or a key that is left attached to a rotating part of the power tool may result

in personal injury.

Do not overreach. Keep proper footing and balance at all times. Proper footing

and balance enables better control of the power tool in unexpected situations.

Use safety equipment. Always wear eye protection. Dust mask, non-skid safety

shoes, hard hat, or hearing protection must be used for appropriate conditions.

Page 4SKU 37793 For technical questions, please call 1-800-444-3353.

TOOL USE AND CARE

Use clamps (not included) or other practical ways 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.

Do not force the 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.

Do not use the power tool if the Power Switch does not turn it on or off. Any tool that

cannot be controlled with the Power Switch is dangerous and must be replaced.

Disconnect the Power Cord 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.

Store idle tools out of reach of children and other untrained persons. Tools

are dangerous in the hands of untrained users.

Maintain tools with care. Keep cutting tools sharp and clean. Properly

maintained tools with a sharp cutting edge are less likely to bind and are easier

to control. Do not use a damaged tool. Tag damaged tools “Do not use” until

repaired.

Check for misalignment or binding of moving parts, breakage of parts, and any

other condition that may affect the tool’s operation. If damaged, have the tool

serviced before using. Many accidents are caused by poorly maintained tools.

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.

SERVICE

Tool service must be performed only by qualied repair personnel. Service or

maintenance performed by unqualied personnel could result in a risk of injury.

When servicing a tool, use only identical replacement parts. Follow instructions

in the “Inspection, Maintenance, And Cleaning” section of this manual. Use of

unauthorized parts or failure to follow maintenance instructions may create a risk of electric

shock or injury.

SPECIFIC SAFETY RULES FOR THE PLUNGE ROUTER

Hold tool by the insulated gripping handles when performing an operation

where the cutting tool may contact hidden wiring or its own cord. Contact with

“live” wire will make exposed metal parts of the tool “live” and shock the operator.

This Router has sharp, fast-moving parts. Misuse can cause severe injury.

Follow the safety instructions.

Page 5SKU 37793 For technical questions, please call 1-800-444-3353.

Under no circumstance is the Router base ever to be removed from the Router

in order to use bits that are too large to use with the base assembly attached.

Removal of the Router base, and using the Router “free hand” can lead to serious

bodily injury.

Never touch the bit, collet, or any other moving parts while the Router is in

operation.

Never lay the Router down until it has stopped rotating completely.

Hold the Router firmly when starting, as startup rotation creates significant

torque.

Never hold workpiece by hand. Secure the workpiece by clamping, or with other

holding devices.

Make sure the workpiece is free of nails and other obstacles. These can interfere with

the cutting process, and possibly cause damage and injury.

Hold the tool rmly while cutting. The action of the bit against the workpiece can cause it

to “kick out”, jumping rapidly away from the workpiece. This can be caused by an improper

type, or dull bit being used.

Do not handle the Router bit immediately after cutting. It may be very hot, potentially

causing burns or injury.

Avoid overloading the tool. If the speed drops abnormally, decrease the pressure on the

bit immediately. Do not apply excessive pressure to the router while cutting.

Always use sharpened bits. If the bit stops abruptly, or the bit becomes blocked, remove

the Router from the workpiece and shut it off.

Never start the Router while the bit is in contact with workpiece. Allow the tool to

reach its normal operating speed before applying the bit to the workpiece.

Maintain labels and nameplates on the Router. These carry important information. If

unreadable or missing, contact Harbor Freight Tools for a replacement.

Always wear ANSI-approved safety impact eye glasses, full face shield and

heavy-duty work gloves when using the Router. Using personal safety devices

reduce the risk for injury. Safety impact eye goggles and heavy work gloves are

available from Harbor Freight Tools.

Maintain a safe working environment. Keep the work area well lit. Make sure

there is adequate surrounding workspace. Always keep the work area free of

obstructions, grease, oil, trash, and other debris. Do not use a power tool in areas

near ammable chemicals, dusts, and vapors. Do not use this tool in a damp or

wet locations.

Avoid unintentional starting. Make sure you are prepared to begin work before

turning on the Router.

10.

11.

12.

13.

14.

15.

16.

17.

Page 6SKU 37793 For technical questions, please call 1-800-444-3353.

Do not force the Router. This tool will do the work better and safer at the speed

and capacity for which it was designed.

Always unplug the Router from its electrical outlet before performing any

inspection, maintenance, or cleaning procedures.

Never leave the Router unattended while running. Turn power off if you have

to leave the Router.

Before each use, check all nuts, bolts, and screws for tightness. Vibration

during mixing may cause these to loosen.

Keep extension cord off the ground and away from water.

Always connect the Line Cord (or extension cord) to a Ground Fault Circuit

Interrupter (GFCI) protected electrical outlet.

If this Plunge Router is to be mounted on a router table, it must be an approved

router table and must have all appropriate holding devices and safety shields.

Never use a router table which is not specically designed for use with this

Plunge Router.

People with pacemakers should consult their physician(s) before use. Electromagnetic

ﬁelds in close proximity to heart pacemaker could cause pacemaker interference

or pacemaker failure.

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 or 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. (California Health & Safety

Code § 25249.5, et seq.)

GROUNDING

Improperly connecting the grounding wire can result in electric

shock.

Check with a qualied electrician if you are in doubt as to

whether the outlet is properly grounded. Do not modify the

power cord plug provided with the tool. Never remove the

grounding prong from the plug. Do not use the tool if the

18.

19.

20.

21.

22.

23.

24.

25.

26.

WARNINGWARNING

Page 7SKU 37793 For technical questions, please call 1-800-444-3353.

power cord or plug is damaged. If damaged, have it repaired

by a service facility before use. If the plug will not t the outlet,

have a proper outlet installed by a qualied electrician.

Grounded Tools: Tools with Three Prong Plugs

Note: This product has a line cord with a 3-prong, grounded plug.

Tools marked with “Grounding Required” have a three wire cord and three prong

grounding plug. The plug must be connected to a

properly grounded outlet. If the tool should

electrically malfunction or break down, grounding

provides a low resistance path to carry electricity

away from the user, reducing the risk of electric

shock. (See 3-Prong Plug and Outlet.)

The grounding prong in the plug is connected

through the green wire inside the cord to the

grounding system in the tool. The green wire in the

cord must be the only wire connected to the tool’s

grounding system and must never be attached to an electrically “live” terminal. (See

3-Prong Plug and Outlet.)

The tool must be plugged into an appropriate outlet, properly installed and grounded

in accordance with all codes and ordinances. The plug and outlet should look like

those in the following illustration.

(See 3-Prong Plug and Outlet.)

Extension Cords

Grounded tools require a three wire extension cord. Double Insulated tools can

use either a two or three wire extension cord.

As the distance from the supply outlet increases, you must use a heavier gauge

extension cord. Using extension cords with inadequately sized wire causes a serious

drop in voltage, resulting in loss of power and possible tool damage.

(See Table A.)

The smaller the gauge number of the wire, the greater the capacity of the cord. For

example, a 14 gauge cord can carry a higher current than a 16 gauge cord.

(See Table A.)

When using more than one extension cord to make up the total length, make sure

each cord contains at least the minimum wire size required. (See Table A.)

3-Prong Plug and Outlet3-Prong Plug and Outlet

Page 8SKU 37793 For technical questions, please call 1-800-444-3353.

If you are using one extension cord for more than one tool, add the nameplate

amperes and use the sum to determine the required minimum cord size.

(See Table A.)

If you are using an extension cord outdoors, make sure it is marked with the sufx

“W-A” (“W” in Canada) to indicate it is acceptable for outdoor use.

Make sure the extension cord is properly wired and in good electrical condition.

Always replace a damaged extension cord or have it repaired by a qualied

electrician before using it.

Protect the extension cords from sharp objects, excessive heat, and damp or wet

areas.

RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS* (120/240 VOLT)

NAMEPLATE

AMPERES

(at full load)

EXTENSION CORD LENGTH

25 Feet 50 Feet 75 Feet 100 Feet 150 Feet

0 – 2.0 18 18 18 18 16

2.1 – 3.4 18 18 18 16 14

3.5 – 5.0 18 18 16 14 12

5.1 – 7.0 18 16 14 12 12

7.1 – 12.0 18 14 12 10 -

12.1 – 16.0 14 12 10 - -

16.1 – 20.0 12 10 - - -

TABLE A * Based on limiting the line voltage drop to ve volts at 150% of the rated amperes.

Symbology

Double Insulated V~ Volts Alternating Current

Canadian Standards Association AAmperes

Underwriters Laboratories, Inc. n0xxxx/min. No Load Revolutions per Minute

(RPM)

Page 9SKU 37793 For technical questions, please call 1-800-444-3353.

UNPACKING

When unpacking, check to make sure the following parts are included. Refer to the

Assembly Section, and the Assembly Drawing and Parts List at the end of this manual.

If any parts are missing or broken, please call Harbor Freight Tools at the number

on the cover of this manual as soon as possible.

OPERATING INSTRUCTIONS

Installing Bits

Caution: Turn router power Off and unplug. Bits are sharp. Handle with care. Check

the bit for cracks or damage before using. Use only router bits.

Lock Lever (26)

Collet Nut (20)

Loosen to left

Tighten to right

Bit

Screw (32) Stopper

Pole

Hex Bolt (65)

Stopper (57)

Half Nut (18)

Push down on the shaft Lock Lever (26) to keep the shaft stationary. See photo

above.

Using Wrench (5A), loosen the Collet Nut (20).

Insert the bit all the way into the Collet Cone (21).

When using smaller shank bits, insert the Collet Sleeve (2A) into the Collet Cone,

then the bit through the Cone.

Securely tighten Collet Nut (20).

Do not tighten the Collet Nut without inserting a bit or Collet Cone with bit. Damage

can occur.

Pull up the Lock Lever (26) to free the shaft.

Cutting Depth Adjustment

Place the router on a at surface.

Loosen the Lock Lever (26).

Lower router body until the bit just touches the at surface.

Page 10SKU 37793 For technical questions, please call 1-800-444-3353.

Tighten the Lock Lever.

Turn Stopper (57) turret to select the desired Hex Bolt (65) height.

Lower the Screw (32) stopper pole until it touches the adjustable Hex Bolt (65).

Press and hold the Half Nut (18) fast feed button to lower stopper pole rapidly.

Raise the Screw (32) stopper pole in ne increments to desired depth of cut.

Note: The depth of cut is equal to the distance between the end of the Screw (32) and

the top of the Hex Bolt (65).

Loosen Lock Lever (26) and lower router body until Screw (32) stopper pole makes

contact with the Hex Bolt (65). The depth of cut can now be seen.

Upper Limit Adjustment

The upper limit adjustment should be set so that the bit clears the stock material

by approximately 1/2 inch.

Turn the Knob (68) to the correct upper limit and clamp in place using the Lock

Lever (26).

Screw the Nut (70) down the screw shaft until it seats rmly against the motor

housing (5).

Loosen the Lock Lever.

Using the Straight Guide

The Straight Guide (4A) and Guide Holder (6A) are used for chamfering or grooving

cuts.

Guide Holder (6A)

Guide (4A)

Fine Adjustment

Screw (A)

Wing Nut (B)

Wing Nut (C) Wing Nut (C)

Place the Straight Guide on the Guide Holder with the Wing Nut (B).

Insert Guide Holder into the holes in the router base.

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