1 H.P. VARIABLE SPEED
PLUNGE ROUTER
MODEL H2854
INSTRUCTION MANUAL
COPYRIGHT ?? NOVEMBER, 2001 BY GRIZZLY INDUSTRIAL, INC.
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE
OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.
PRINTED IN CHINA.
WARNING
Some dust created by power sanding, sawing, grind- ing, 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
???Crystalline silica from bricks, cement, and other masonry products.
???Arsenic and chromium from chemically treated lumber.
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to fil- ter out microscopic particles.
SECTION 1: SAFETY
For Your Own Safety Read Instruction Manual Before Operating This Equipment
The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series of symbols and signal words which are intended to convey the level of importance of the safety messages. The progression of symbols is described below. Remember that safety messages by themselves do not eliminate danger and are not a substitute for proper accident prevention measures.
Safety Instructions For Power Tools
1.KEEP GUARDS IN PLACE and in working order.
2.REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see that keys and adjusting wrenches are removed from tool before turning on.
3.KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents.
4.DO NOT USE IN DANGEROUS ENVI- RONMENT. Do not use power tools in damp or wet locations, or where any flam- mable or noxious fumes may exist. Keep work area well lighted.
5.KEEP CHILDREN AND VISITORS AWAY. All children and visitors should be kept a safe distance from work area.
6.MAKE WORKSHOP CHILD PROOF with padlocks, master switches, or by removing starter keys.
7.DO NOT FORCE TOOL. It will do the job better and safer at the rate for which it was designed.
8.USE RIGHT TOOL. Do not force tool or attachment to do a job for which it was not designed.
Safety Instructions For Power Tools
9.USE PROPER EXTENSION CORD. Make sure your extension cord is in good condi- tion. Conductor size should be in accor- dance with the chart below. The amperage rating should be listed on the motor or tool nameplate. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. Your extension cord must also contain a ground wire and plug pin. Always repair or replace exten- sion cords if they become damaged.
Minimum Gauge for Extension Cords
10.WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry which may get caught in moving parts.
11.ALWAYS USE SAFETY GLASSES. Also use face or dust mask if cutting operation is dusty. Everyday eyeglasses only have impact resistant lenses, they are NOT safety glasses.
12.SECURE WORK. Use clamps or a vise to hold work when practical. It???s safer than using your hand and frees both hands to operate tool.
13.DO NOT
14.MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best and safest performance. Follow instructions for lubri- cating and changing accessories.
15.USE RECOMMENDED ACCESSORIES.
Consult the owner???s manual for recom- mended accessories. The use of improper accessories may cause risk of injury.
16.REDUCE THE RISK OF UNINTENTION- AL STARTING. On machines with magnet- ic contact starting switches there is a risk of starting if the machine is bumped or jarred. Always disconnect from power source before adjusting or servicing. Make sure switch is in OFF position before reconnecting.
17.MANY WOODWORKING TOOLS CAN ???KICKBACK??? THE WORKPIECE toward the operator if not handled properly. Know what conditions can create ???kickback??? and know how to avoid them. Read the manual accom- panying the machine thoroughly.
18.CHECK DAMAGED PARTS. Before fur- ther use of the tool, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment of moving parts, bind- ing of moving parts, breakage of parts, mounting, and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced.
19.NEVER LEAVE TOOL RUNNING UNAT- TENDED. TURN POWER OFF. Do not leave tool until it comes to a complete stop.
20.NEVER OPERATE A MACHINE WHEN
TIRED, OR UNDER THE INFLUENCE OF DRUGS OR ALCOHOL. Full mental alert- ness is required at all times when running a machine.
21.NEVER ALLOW UNSUPERVISED OR
UNTRAINED PERSONNEL TO OPER- ATE THE MACHINE. Make sure any instructions you give in regards to machine operation are approved, correct, safe, and clearly understood.
22.IF AT ANY TIME YOU ARE EXPERIENC- ING DIFFICULTIES performing the intend- ed operation, stop using the machine! Then contact our service department or ask a qualified expert how the operation should be performed.
SECTION 2: CIRCUIT REQUIREMENTS
110V Operation
The Model H2854 is wired for 110/120V operation only. The 1 H.P. motor will safely draw 2.6 amps at 110V. If you operate this machine on any circuit that is already close to its capacity, it might blow a fuse or trip a circuit breaker. However, if an unusual load does not exist, and the circuit break- er still trips, contact a qualified electrician or our service department.
Extension Cords
If you find it necessary to use an extension cord with the Model H2854, make sure the cord is rated Hard Service (grade S) or better. Refer to the chart in the standard safety instructions to determine the minimum gauge for the extension cord. Always repair or replace extension cords when they become worn or damaged.
SECTION 3: INTRODUCTION
Commentary
We are proud to offer the Grizzly Model H2854 1 H.P. Variable Speed Plunge Router. The Model H2854 is part of a growing Grizzly family of fine woodworking machinery. When used according to the guidelines set forth in this manual, you can expect years of
The Model H2854 is a 1 H.P. variable speed plunge router that features 11,000 to 26,000 R.P.M.
A number of router bits for the Model H2854 are available through the Grizzly catalog.
We are also pleased to provide this manual with the Model H2854. It was written to guide you through assembly, review safety considerations, and cover general operating procedures. It repre- sents our effort to produce the best documenta- tion possible. If you have any comments regard- ing this manual, please write to us at the address below:
Grizzly Industrial, Inc.
C/O Technical Documentation
P.O. Box 2069
Bellingham, WA
Most importantly, we stand behind our machines. If you have any service questions or parts requests, please call or write us at the location listed below:
Grizzly Industrial, Inc.
1203 Lycoming Mall Circle
Muncy, PA 17756
Phone: (570)
Fax: (800)
The specifications, drawings, and photographs illustrated in this manual represent the Model H2854 as supplied when the manual was pre- pared. However, owing to Grizzly???s policy of con- tinuous improvement, changes may be made at any time with no obligation on the part of Grizzly. Whenever possible, though, we send manual updates to all owners of a particular tool or machine. Should you receive one, we urge you to insert the new information with the old and keep it for reference.
Read the manual before assembly and opera- tion. Become familiar with the machine and its operation before begin- ning any work. Serious personal injury may result if safety or opera- tional information is not understood or followed.
Unpacking
The Model H2854 is shipped from the manufac- turer in a carefully packed case. If you discover the machine is damaged after you have opened it, immediately call Customer Service for advice.
When you are completely satisfied with the con- dition of your shipment, you should inventory its parts.
Some metal parts may have sharp edges on them after they are formed. Please examine the edges of all metal parts before handling them. Failure to do so could result in injury.
Make your shop ???child safe.??? Ensure that your workplace is inaccessible to youngsters by closing and locking all entrances when you are away. Never allow visitors in your shop when assembling, adjust- ing or operating equip- ment.
Piece Inventory
After all the parts have been removed from the case, you should have:
???Router Assembly
???Handle Knobs (2)
???Collet Wrench
???Collet
???Collet Nut
???Standard and Metric Depth Gauge
???Edge Guide Assembly
???Guide Bushing
???Curve Guide
???Pivot Pin
???Dust Collection Attachment
???Centering Gauge
???Allen?? Wrench
???Case
In the event that any nonproprietary parts are missing (e.g. a nut or a washer), we would be glad to replace them, or for the sake of expediency, replacements can be obtained at your local hard- ware store.
Figure 1. Parts layout.
NOTICE
A full parts list and breakdown can be found toward the end of this manual. For easier assembly, or to identify specific parts, please refer to the detailed illustrations at the end of the manual.
SECTION 4: ASSEMBLY
Beginning Assembly
!Disconnect power to the machine when perform-
ing any maintenance, assembly or adjust- ments. Failure to do this may result in serious personal injury.
Keep loose clothing rolled up and out of the way of machinery and keep hair pulled back.
Wear safety glasses dur- ing the entire assembly process. Failure to com- ply may result in serious personal injury.
Some metal parts may have sharp edges on them after they are formed. Please examine the edges of all metal parts before handling them. Failure to do so could result in injury.
Most of your Model H2854 has been assembled at the factory, but some parts must be assembled or installed after delivery. We have organized the assembly process into steps. Please follow along in the order presented here.
TOOLS REQUIRED: Phillips?? and flat head screw driver, 4mm Allen?? wrench (supplied), 19mm open end wrench (supplied).
Handles
The two handles supplied with your router come unattached from the main unit. You will need to thread them into the mounting holes located on both sides of the upper router base as shown in Figure 2. When you want to store the router in its case, the handles will need to be removed and threaded back into the case mounting locations.
NOTICE
Be careful not to
Figure 2. Installing handles.
Installing Bits
!Disconnect power to the machine when perform-
ing any maintenance, assembly or adjust- ments. Failure to do this may result in serious personal injury.
The Model H2854 is supplied with a 1???4" collet for use with all 1???4" router bits. To install a bit:
1.Remove the collet nut from the spindle shaft using the supplied
2.Once the collet nut is removed, you will be able to insert the 1???4" collet into the spindle shaft as shown in Figure 3.
3.Be careful not to let the collet fall onto the floor. Damage to the collet could occur.
4.Press the spindle shaft lock pin and thread the collet nut onto the spindle shaft as shown in Figure 4. The router bit should not be inserted into the collet at this time. Be sure not to cross the threads when starting the col- let nut onto the spindle shaft. Do not tighten the collet nut more than several turns at this time.
5.Insert the shaft of a 1???4" router bit into the col- let. Be sure to follow the router bit manufac- turer???s directions regarding how far the bit shaft must be inserted into the collet for safe operation.
6.Once the bit is inserted into the collet, press the spindle shaft lock pin and continue to tighten the collet nut with the supplied open- end collet wrench as shown in Figure 5.
NOTICE
When the collet nut is removed from the spindle shaft, take care to prevent the collet from dropping onto the floor. The collet may become damaged if it is dropped, causing it to not secure router bits properly.
Collet
Figure 3. Inserting collet.
Collet Nut
Spindle Shaft
Lock Pin
Figure 4. Threading collet nut onto spindle.
Figure 5. Tightening bit into router.
H2854 1 H.P. Variable Speed Plunge Router
The Model H2854 is supplied with a dust collec- tion attachment. Routing produces large amounts of wood dust that can be both damaging to your lungs as well as messy around your worksite. We recommend connecting a vacuum system to the dust collection attachment to keep wood dust to a minimum. Use a tapered hose end to ensure a tight connection to the dust collection attachment. To mount the dust collection attachment to the router base:
1.The dust collection attachment has a long lip on one side and two small lips on the other side. Line up the lips with the slots in the router base and snap into place as shown in Figure 6.
2.Using two Phillips?? head screws, secure the dust collection assembly to the base of the router.
Figure 6. Installing dust port.
The Model H2854 is supplied with both standard and metric depth stops. To attach the depth stop:
1.Loosen the lock knob located on the front of the router base and slide the desired stop into the
2.Tighten the lock knob until the stop is held securely in place. Be sure not to overtighten the knob. Depth adjustment will be dis- cussed later in the manual.
Figure 7. Installing depth stop.
SECTION 5: ADJUSTMENTS
!Disconnect power to the machine when perform-
ing any maintenance, assembly or adjust- ments. Failure to do this may result in serious personal injury.
Keep loose clothing rolled up and out of the way of machinery and keep hair pulled back.
Wear safety glasses during the entire adjust- ment process. Failure to comply may result in serious personal injury.
The Model H2854 is capable of a wide variety of routing operations. The key to successful use of the Model H2854 is understanding how to proper- ly adjust the tool for maximum performance.
Spindle R.P.M.
Using the correct spindle R.P.M. is critical to achieving the smoothest, safest cuts from your router. The general rule is the larger the diameter router bit, the lower the spindle R.P.M. should be. The Model H2854 is equipped with a speed adjustment dial as shown in Figure 8. Setting ???1??? is the slowest R.P.M. at 11,000. ???6??? is the highest R.P.M. setting at 26,000.
Figure 8. Spindle R.P.M. dial.
Depth Stop
The Model H2854 has a maximum spindle plunge depth of 11???2". To set the depth stop:
1.Install the desired router bit into the collet.
2.Without turning the router on, plunge the bit so that it extends below the base plate the same amount as the final depth of cut you desire to make.
3.While holding the desired depth, press the plunge lock lever located on the right back corner of the upper router base as shown in Figure 9. This will lock the router in the pre- sent position. Recheck to make sure the bit is still extending below the base plate the desired amount.
4.Loosen the depth scale lock knob on the front of the upper router base. Let the depth gauge drop down to the shortest peg on the round depth stop turret.
Plunge
Lock Lever
Figure 9. Plunge lock lever.
5.Release the plunge lock lever and rotate the round depth stop turret to the highest of the three pegs. Your first routing pass will remove approximately 1???3 of the final depth of cut. Rotate the turret to the next highest peg and perform the second routing pass. This pass will remove the next 1???3 of the material. Finally, turn the turret to the small- est peg (Figure 10) and perform the third routing pass. This will complete the routing operation to the final desired depth of cut.
By performing your routing operations in three successive passes, you will get smoother results with less chance of ???chip out??? and burning of the workpiece. You will also reduce the possibility of the router jerking out of your hands from trying to remove too much material in one pass.
Smallest
Turret Peg
Figure 10. Depth stop set for third and final pass that results in final depth of cut.
SECTION 6: OPERATIONS
Test Run
!Disconnect power to themachine when perform-
ing any maintenance, assembly or adjust- ments. Failure to do this may result in serious personal injury.
Keep loose clothing rolled up and out of the way of machinery and keep hair pulled back.
Wear safety glasses dur- ing the entire operation process. Failure to com- ply may result in serious personal injury.
Always wear a dust mask when operating the H2854. Using this machine produces saw- dust which may cause allergic reactions or res- piratory problems.
Once assembly is complete and adjustments are done to your satisfaction, you are ready to test run the machine.
Turn on the power supply at the main panel. Press the START button. The machine should run smoothly, with little or no vibration or rubbing nois- es. Strange or unnatural noises should be investi- gated and corrected before operating the machine further.
If you cannot easily locate the source of an unusual noise or vibration, contact our service department for help.
General
There are an endless number of operations that can be performed with the use of this router. The Model H2854 is supplied with several attach- ments that can greatly increase the productive- ness of the tool. These will be explained further along in the manual.
Once the bit has been selected and installed properly, and the depth stop has been set cor- rectly (see Section 5: Adjustments), you need to determine the proper feed direction of the router across the workpiece:
1.Examine the top face of workpiece you intend to route and determine the direction of the grain. Always feed the router so the bit is cutting with the grain (cutting along the growth rings as shown in Figure 11). Cutting against the grain chips the wood rather than cutting it, and makes for a rougher surface with more ???chip out???.
2.It is very important to pass the router across the workpiece so the bit is rotating opposite the feed direction as shown in Figure 11. If the cutters are moving in the same direction you are feeding the router, you are perform- ing a ???climb cut.??? This is a very dangerous operation because the router could lunge forward out of your hands, causing serious personal injury.
Figure 11. Proper feed direction and grain orientation when viewed from bottom.
3.Finally, it is important to remove material in multiple passes at incrementally deeper depths. The depth stop and round depth stop turret are designed to perform this func- tion efficiently.
Attachments
Discussing every possible procedure that can be perform with a router is beyond the scope of this manual. We recommend seeking out your local library or newsstand for trade books, instructional videos or magazine articles that go further into depth on the uses for a router.
Guide Bushing
The guide bushing allows the router to follow a precut template pattern that has been attached to the top of the workpiece. When the bushing is installed onto the base of the router, the lip that protrudes from the bottom of the router base rides along the edge of a template while the 1???4" straight router bit routes the edge of the workpiece. The template must be at least as thick or thicker than the distance the bushing lip protrudes from the base. Adjust the depth of the bit so you achieve the desired depth of cut when taking into consid- eration the thickness of the template. Remember to make multiple passes if you are removing a lot of material.
Figure 12. Guide bushing attachment.
Bit Centering Gauge
The bit centering gauge is designed to keep the vertical
Figure 13. Bit centering gauge attachment.
Edge Guide
The edge guide is designed for dado and plow operations that need to be parallel and equidistant from a workpiece edge. The maximum distance from the edge that a dado or plow operation can be performed is 6 inches.
Figure 15. Flush trim guide attachment.
Circle Cutter
The circle cutter consists of a pivot pin that attach- es to the edge guide. The edge guide must be installed in the inverted position as compared to its position when you are edge routing. Fasten the pivot bolt to one of the holes located on the cen- ter of the edge guide. Adjust the pivot bolt so it is set to the desired height. Place the pivot pin on the desired center location of the circle. Adjust the edge guide so that the distance between the inside edge of the bit and the pivot pin equals the radius of the desired circle. Set the depth of the router bit and you are ready to route a circle.
Figure 14. Edge guide attachment.
Flush Trim Guide
The flush trim guide is designed to keep a router bit flush against a subsurface edge, similar to a bit with a flush guide bearing. This guide is used when trimming laminate flush with a subsurface edge. Adjust the guide so that it is flush with the cutting edge of the bit and rides along the subsur- face edge. The router bit and guide follow along the edge of the subsurface, trimming the laminate flush. Be sure the guide does not come into con- tact with the bit.
Pivot Bolt
Figure 16. Circle cutter attachment.
SECTION 7: MAINTENANCE
!Disconnect power to the machine when perform- ing any maintenance,
assembly or adjust- ments. Failure to do this may result in serious personal injury.
Keep loose clothing rolled up and out of the way of machinery and keep hair pulled back.
Wear safety glasses during the entire mainte- nance process. Failure to comply may result in serious personal injury.
General
Regular periodic maintenance of your Model H2854 will ensure its optimum performance. Make a habit of inspecting your machine each time you use it. Check for the following conditions and repair or replace when necessary:
1.Loose screws and bolts.
2.Worn switch.
3.Worn or damaged cords and plugs.
4.Damaged collet.
5.Any other condition that could hamper the safe operation of this machine.
Lubrication
Since all bearings are sealed and permanently lubricated, simply leave them alone until they need to be replaced. Do not lubricate them.
SECTION 8: CLOSURE
The following pages contain general machine data, parts diagrams/lists, a troubleshooting guide and Warranty/Return information for your Model H2854.
If you need parts or help in assembling your machine, or if you need operational information, we encourage you to call our Service Department. Our trained service technicians will be glad to help you.
If you have comments dealing specifically with this manual, please write to our Bellingham, Washington location using the address in Section 3: Introduction.
We have included some important safety mea- sures that are essential to this machine???s opera- tion. While most safety measures are generally universal, each workshop is different and safety rules should be considered as they apply to your specific situation.
Operating this equipment creates the poten- tial for flying debris to cause eye injury. Always wear safety glasses or goggles when operating equipment. Everyday glass- es or reading glasses only have impact resistant lenses, they are not safety glasses. Be certain the safety glasses you wear meet the appropriate standards of the American National Standards Institute (ANSI).
We recommend you keep a copy of our current catalog for complete information regarding war- ranty and return policy. If you need additional technical information relating to this machine, or if you need general assistance or replacement parts, please contact the Service Department list- ed in Section 3: Introduction.
Additional information sources are necessary to realize the full potential of this machine. Trade journals, woodworking magazines, and your local library are good places to start.
The Model H2854 was specifically designed for routing operations. DO NOT MODIFY
AND/OR USE THIS MACHINE FOR ANY OTHER PURPOSE. Modifications or improper use of this tool will void the war- ranty. If you are confused about any aspect of this machine, DO NOT use it until all your questions have been answered or serious personal injury may occur.
Like all power tools, there is danger asso- ciated with the Model H2854. Accidents are frequently caused by lack of familiarity or failure to pay attention. Use this tool with respect and caution to lessen the possibility of operator injury. If normal safety precautions are overlooked or ignored, serious personal injury may occur.
Notes
WARRANTY AND RETURNS
Grizzly Industrial, Inc. warrants every product it sells for a period of 1 year to the original purchaser from the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence, accidents, repairs or alterations or lack of maintenance. This is Grizzly???s sole written warranty and any and all warranties that may be implied by law, including any merchantability or fitness, for any par- ticular purpose, are hereby limited to the duration of this written warranty. We do not warrant or represent that the merchandise complies with the provisions of any law or acts unless the manufacturer so warrants. In no event shall Grizzly???s liability under this warranty exceed the purchase price paid for the product and any legal actions brought against Grizzly shall be tried in the State of Washington, County of Whatcom.
We shall in no event be liable for death, injuries to persons or property or for incidental, contingent, spe- cial, or consequential damages arising from the use of our products.
To take advantage of this warranty, contact us by mail or phone and give us all the details. We will then issue you a ???Return Number,??? which must be clearly posted on the outside as well as the inside of the car- ton. We will not accept any item back without this number. Proof of purchase must accompany the mer- chandise.
The manufacturers reserve the right to change specifications at any time because they constantly strive to achieve better quality equipment. We make every effort to ensure that our products meet high quality and durability standards and we hope you never need to use this warranty.
Please feel free to write or call us if you have any questions about the machine or the manual.
Thank you again for your business and continued support. We hope to serve you again soon.
WARRANTY CARD
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MODEL # H2854 1 H.P. Variable Speed Plunge Router Order______________________________________
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