Makita M3602 900W 8mm Router Instruction Manual

makita M3602 900W 8mm Router

SPECIFICATIONS

• Due to our continuing program of research and development, the specifications herein are subject to change without notice.
• Specifications may differ from country to country.
• Weight according to EPTA-Procedure 01/2014

Symbols
The followings show the symbols which may be used for the equipment. Be sure that you understand their meaning before use.

Read the instruction manual.

Wear safety glasses.

DOUBLE INSULATION

Only for EU countries

Due to the presence of hazardous components in the equipment, used electrical and electronic equipment may have a negative impact on the environment and human health.
Do not dispose of electrical and electronic appliances with household waste!
In accordance with the European Directive on waste electrical and electronic equipment and its adaptation to national law, used electrical and electronic equipment should be collected separately and delivered to a separate collection point for municipal waste, operating in accordance with the environmental protection regulations.
This is indicated by the symbol of the crossed-out wheeled bin placed on the equipment.

Intended use
The tool is intended for flush trimming and profiling of wood, plastic and similar materials.

Power supply
The tool should be connected only to a power supply of the same voltage as indicated on the nameplate, and can only be operated on single-phase AC supply. They are double-insulated and can, therefore, also be used from sockets without earth wire.

General power tool safety warnings
WARNING: Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.

The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

Work area safety

1. Keep work area clean and well lit. Cluttered or 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 children and bystanders away while operating a power tool. Distractions can cause you to lose control.

Electrical safety

1. 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.
2. Avoid body contact 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.
3. Do not expose power tools to rain or wet conditions.
   Water entering a power tool will increase the risk of electric shock.
4. 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.
5. 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.
6. If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.
7. Use of power supply via an RCD with a rated residual current of 30 mA or less is always recommended.
8. Power tools can produce electromagnetic fields (EMF) that are not harmful to the user.
   However, users of pacemakers and other similar medical devices should contact the maker of their device and/or doctor for advice before operating this power tool.
9. Do not touch the power plug with wet hands.
10. If the cord is damaged, have it replaced by the manufacturer or his agent in order to avoid a safety hazard.

Personal safety

1. 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.
2. Use personal protective equipment. Always wear eye protection. Protective equipment such as a dust mask, non-skid safety shoes, hard hat or hearing protection used for appropriate conditions will reduce personal injuries.
3. Prevent unintentional starting. Ensure the switch is in the off-position before connecting to a power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.
4. 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.
5. Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
6. Dress properly. Do not wear loose clothing or jewelry. Keep your hair and clothing away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
7. If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards.
8. Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.
9. Always wear protective goggles to protect your eyes from injury when using power tools. The goggles must comply with ANSI Z87.1 in the USA, EN 166 in Europe, or AS/NZS 1336 in Australia/New Zealand. In Australia/New Zealand, it is legally required to wear a face shield to protect your face, too.It is an employer’s responsibility to enforce the use of appropriate safety protective equip-ments by the tool operators and by other persons in the immediate working area.

Power tool use and care

1. 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.
2. 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.
3. Disconnect the plug from the power source and/or remove the battery pack, if detachable, 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.
4. 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 users.
5. Maintain power tools and accessories. Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
6. Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
7. Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account 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.
8. Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.
9. When using the tool, do not wear cloth work gloves which may be entangled. The entanglement of cloth work gloves in the moving parts may result in personal injury.

Service

1. 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.
2.  Follow instructions for lubricating and changing accessories.

Router safety warnings

1. Hold the power tool by insulated gripping surfaces only, because the cutter may contact its own cord. Cutting a “live” wire may make exposed metal parts of the power tool “live” and could give the operator an electric shock.
2. Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by your hand or against the body leaves it unstable and may lead to loss of control.
3. The cutter bit shank must match the designed collet chuck.
4. Only use a bit that is rated at least equal to the maximum speed marked on the tool.
5. Wear hearing protection during extended periods of operation.
6. Handle the router bits very carefully.
7. Check the router bit carefully for cracks or damage before operation. Replace cracked or damaged bit immediately.
8. Avoid cutting nails. Inspect for and remove all nails from the workpiece before operation.
9. Hold the tool firmly with both hands.
10. Keep hands away from rotating parts.
11. Make sure the router bit is not contacting the workpiece before the switch is turned on.
12. Before using the tool on an actual workpiece, let it run for a while. Watch for vibration or wobbling that could indicate an improperly installed bit.
13. Be careful of the router bit rotating direction and the feed direction.
14. Do not leave the tool running. Operate the tool only when hand-held.
15. Always switch off and wait for the router bit to come to a complete stop before removing the tool from the workpiece.
16. Do not touch the router bit immediately after operation; it may be extremely hot and could burn your skin.
17. Do not smear the tool base carelessly with thinner, gasoline, oil or the like. They may cause cracks in the tool base.
18. Some material contains chemicals that may be toxic. Take caution to prevent dust inhalation and skin contact. Follow material supplier safety data.
19. Always use the correct dust mask/respirator for the material and application you are working with.
20. Place the tool on a stable area. Otherwise falling accident may occur and cause an injury.
21. Keep cord away from your foot or any objects. Otherwise, an entangled cord may cause a falling accident and result in personal injury.

WARNING: DO NOT let comfort or familiarity with the product (gained from repeated use) replace strict adherence to safety rules for the subject product. MISUSE or failure to follow the safety rules stated in this instruction manual may cause serious personal injury.

FUNCTIONAL DESCRIPTION

CAUTION: Always be sure that the tool is switched off and unplugged before adjusting or checking the function on the tool.

Adjusting the depth of cut
Place the tool on a flat surface. Loosen the lock lever and lower the tool body until the router bit just touches the flat surface. Tighten the lock lever to lock the tool body. While pressing the fast-feed button, move the stopper pole up or down until the desired depth of cut is obtained. Minute depth adjustments can be obtained by turning the stopper pole (1.5 mm (1/16″) per turn).
Fig.1: 1. Nylon nut 2. Stopper pole 3. Fast-feed button 4. Adjusting hex bolt 5. Stopper block 6. Lock lever

CAUTION: The depth of cut should not be more than 20 mm (13/16″) at a pass when cutting grooves. For extra-deep grooving operations, make two or three passes with progressively deeper router bit settings.

Nylon nut

For tool without the knob
The upper limit of the tool body can be adjusted by turning the nylon nut. Do not lower the nylon nut too low. The router bit will protrude dangerously.

For tool with the knob
By turning the knob, the upper limit of the tool body can be adjusted. When the tip of the router bit is retracted more than required in relation to the base plate surface, turn the knob to lower the upper limit. Fig.2: 1. Knob

CAUTION: Since excessive cutting may cause an overload of the motor or difficulty in controlling the tool, the depth of cut should not be more than 20 mm (13/16″) at a pass when cutting grooves. When you wish to cut grooves more than 20 mm (13/16″) deep, make several passes with progressively deeper router bit settings.
CAUTION: Do not lower the knob too low. The router bit will protrude dangerously.

Stopper block

As the stopper block has three adjusting hex bolts that raise or lower 0.8 mm per turn, you can easily obtain three different depths of cut without readjusting the stopper pole. ► Fig.3: 1. Stopper pole 2. Adjusting hex bolt
3. Stopper block

Adjust the lowest adjusting hex bolt to obtain the deep-est depth of cut, following the method of “Adjusting depth of cut”. Adjust the two remaining adjusting hex bolts to obtain shallower depths of cut. The differences in height of these adjusting hex bolts are equal to the differences in depths of cut To adjust the adjusting hex bolts, turn the adjusting hex bolts with a screwdriver or wrench. The stopper block is also convenient for making three passes with progres- sively 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.
CAUTION: Make sure that the shaft lock is released before the switch is turned on.

To start the tool, move the switch lever to the I position. To stop the tool, move the switch lever to the O position. Fig.4: 1. Switch lever
CAUTION: Hold the tool firmly when turning off the tool, to overcome the reaction.

Electronic function

The tool is equipped with the electronic functions for
easy operation.

Indication lamp
Fig.5: 1. Indication lamp

The indication lamp lights up green when the tool is plugged. If the indicator lamp does not light up, the main cord or the controller may be defective. The indication lamp is lit but the tool does not start even if the tool is switched on, the carbon brushes may be worn out, or the controller, the motor or the ON/OFF switch may be defective.

Unintentional restart proof
The tool does not start with the switch lever is in the I position even when the tool is plugged. At this time, the indication lamp blinks in red and shows the unintentional restart proof device is on function. To cancel the unintentional restart proof, move the switch lever to the O position. Soft start feature

Soft-start feature
minimizes start-up shock and makes the tool start smoothly.

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 router bit
Insert the router bit all the way into the collet cone. Press the shaft lock to keep the shaft stationary and use the wrench to tighten the collet nut securely. When using router bits with smaller shank diameter, first insert the appropriate collet sleeve into the collet cone, then install the router bit. To remove the router bit, follow the installation proce dure in reverse. Fig.6: 1. Shaft lock 2. Wrench 3. Loosen 4. Tighten

CAUTION: Install the router bit securely. Always use only the wrench provided with the tool. A loose or overtightened router bit can be dangerous.
NOTICE: Do not tighten the collet nut without inserting a router bit or install small shank bits without using a collet sleeve. Either can lead to breakage of the collet cone.

OPERATION

CAUTION:

• Before the operation, always make sure that the tool body automatically rises to the upper limit and the router bit does not protrude from the tool base when the lock lever is loosened.
• Before the operation, always make sure that the chip deflector is installed properly.
• Always use both grips and firmly hold the tool by both grips during operations. Fig.7: 1. Chip deflector

Set the tool base on the workpiece to be cut without the router bit making any contact. Then turn the tool on and wait until the router bit attains full speed. Lower the tool body and 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 router bit in the feed direction. ► Fig.8: 1. Workpiece 2. Bit revolving direction 3. View from the top of the tool 4. Feed direction

NOTE:

• Moving the tool forward too fast may cause a poor quality of cut, or damage to the router bit or motor. Moving the tool forward too slowly may burn and mar the cut. The proper feed rate will depend on the router bit size, the kind of workpiece and the 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 or the trimmer 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. ► Fig.9: 1. Feed direction 2. Bit revolving direction
  3. Workpiece 4. Straight guide

Straight guide

The straight guide is effectively used for straight cuts when chamfering or grooving.

Straight guide (Type A)
Optional accessory
Install the straight guide on the guide holder with the thumbscrew (B). Insert the guide holder into the holes in the tool base and tighten the thumbscrew (A). To adjust the distance between the router bit and the straight guide, loosen the thumb screw (B) and turn the fine adjusting screw. At the desired distance, tighten the thumbscrew (B) to secure the straight guide in place. ► Fig.10: 1. Guide holder 2. Fine adjusting screw
3. Straight guide

Straight guide (Type B)
Optional accessory
Insert the straight guide into the holes in the tool base and tighten the thumbscrew. To adjust the distance between the router bit and the straight guide, loosen the thumbscrew. At the desired distance, tighten the thumbscrew to secure the straight guide in place. Fig.11: 1. Thumbscrew 2. Straight guide When cutting, move the tool with the straight guide flush with the side of the workpiece. A wider straight guide of desired dimensions may be made by using the convenient holes in the guide to bolt on extra pieces of wood. When using a large diameter router bit, attach pieces of wood to the straight guide which have a thickness of more than 15 mm (5/8″) to prevent the router bit fro striking the straight guide. Fig.12: 1. Straight guide 2. Wood

• A=55 mm (2-3/16″)
• B=55 mm (2-3/16″)
• C=15 mm (5/8″) or thicker

Templet guide

Optional accessory
The templet guide provides a sleeve through which the router bit passes, allowing use of the router with templet patterns. Fig.13

1. Loosen the screws on the base, insert the templet guide and then tighten the screws. ► Fig.14: 1. Screws 2. Templet guide
2. 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. ► Fig.15: 1. Router bit 2. Base
3. Baseplate
4. Templet
5. Workpiece
6. Templet guide

NOTE: The workpiece will be cut a slightly different size from the templet. Allow for the distance (X) between the router bit and the outside of the templet guide. The distance (X) can be calculated by using the following equation:
Distance (X) = (outside diameter of the templet guide – router bit diameter) / 2

Trimmer guide

Trimming, curved cuts in veneers for furniture and the like can be done easily with the trimmer guide. The guide roller rides the curve and assures a fine cut.

Trimmer guide (Type A)
Optional accessory
Install the trimmer guide on the guide holder with the thumbscrew (B). Insert the guide holder into the holes in the tool base and tighten the thumbscrew (A). To adjust the distance between the router bit and the trimmer guide, loosen the thumbscrew (B) and turn the fine adjusting screw. When adjusting the guide roller up or down, loosen the thumbscrew (C). After adjusting, tighten all the thumb screws securely.

1. Guide holder
2. Fine adjusting screw
3. Trimmer guide
4. Guide roller

Trimmer guide (Type B)
Optional accessory
Install the trimmer guide onto the straight guide using
the thumbscrews (B). Insert the straight guide into the holes in the tool base and tighten the thumbscrew (A). To adjust the distance between the router bit and the trimmer guide, loosen the thumbscrews (B). When adjusting the guide roller up or down, loosen the thumbscrew (C). After adjusting, tighten all the thumb screws securely. Fig.17: 1. Guide roller 2. Trimmer guide When cutting, move the tool with the guide roller riding the side of the workpiece. Fig.18: 1. Router bit 2. Guide roller 3. Workpiece

Dust cover (For tool with the knob)

Optional accessory
Dust cover prevents sawdust from being drawn into the tool in the inverted position. Install the dust cover as illustrated when using the tool with a router stand available in the market. Remove it when using the tool in the normal position.

1. Screw
2. Dust cover

Spacer (For tool with the knob)

Optional accessory
The spacer prevents the router bit from dropping into the chuck when replacing the router bit in the inverted position. Insert the spacer as illustrated when using the tool with a router stand available in the market. Fig.20: 1. Collet nut 2. Collet cone 3. Spacer

Dust extraction

Optional accessory
Use the dust nozzle for dust extraction. Fig.21: 1. Dust nozzle

Installing the dust nozzle

1. Support
2. Lock lever
3. Raise the lock lever of the dust nozzle.
4. Place the dust nozzle onto the tool base so that its top will be caught in the hook on the tool base.
5. Insert the supports on the dust nozzle into the hooks on the front of the tool base.
6. Push down the lock lever onto the tool base.
7. Connect a vacuum cleaner to the dust nozzle. Fig.23

Removing the dust nozzle

1. Raise the lock lever.
2. Pull the dust nozzle out of the tool base while holding the supports between thumb and finger.

MAINTENANCE

CAUTION: Always be sure that the tool is switched off and unplugged before attempting to perform inspection or maintenance.
NOTICE: Never use gasoline, benzene, thinner, alcohol or the like. Discoloration, deformation or cracks may result.

Replacing carbon brushes
Limit mark Check the carbon brushes regularly. Replace them 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.

1. Use a screwdriver to remove the brush holder caps.
2. Take out the worn carbon brushes, insert the new ones, and secure the brush holder caps. Fig.25: 1. Brush holder cap

For tool with the knob
CAUTION: Be sure to re-install the knob after inserting a new carbon brush.
Release the lock lever and remove the knob by turning it counterclockwise. Fig.26: 1. Knob
NOTE: The compression spring will come out of the knob, so be careful not to lose the compression spring.

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.

OPTIONAL ACCESSORIES

Router bits
Straight bit Fig.27

“U” Grooving bit Fig.28

“V” Grooving bit Fig.29

Dovetail bit Fig.30

Drill point flush trimming bit Fig.31

Drill point double flush trimming bit Fig.32

Slotting cutter Fig.33

Board-jointing bit Fig.34

Corner rounding bit Fig.35

Chamfering bit Fig.36

Fig.37

Beading bit Fig.38

Cove beading bit Fig.39

Ball-bearing flush trimming bit Fig.40

Ball bearing corner rounding bit Fig.41

Ball bearing chamfering bit Fig.42

Ball bearing beading bit Fig.43

Ball bearing cove beading bit Fig.44

Ball bearing roman ogee bit Fig.45

Double ball bearing round corner bitFig.46