RYOBI ROUTER MODEL NO. RE180PL1 REPAIR SHEET
RYOBI ROUTER MODEL NUMBER RE180PL1
WARNING: Improper repair of a double insulated tool can result in damages to the double insulation system possibly causing electrical shock or electrocution. Any repairs requiring disassembly of your tool requires safety testing and should only be performed by a Ryobi Authorized Service Center. For the service center nearest you call 1-800-525-2579. 2
The model number will be found on a plate attached to the motor housing. Always mention the model number in all correspondence regarding your ROUTER or when ordering repair parts.

PARTS LIST

Key No. Part Number Description Qty. Key No. 43 Part Number 983000448 983000448R 03-30-05 Description Qty.
SCREW (8-10 X 5/8 in. PAN HD.).. 9 SPEED CONTROL COVER.. 1 SCALE LABEL... 1 LOGO PLATE.. 1 SCREW (8-10 X 1-1/4 in. PAN HD.).. 1 SPEED CONTROL ASSEMBLY.. 1 CORD.. 1 ROCKER SWITCH.. 1 LEAD... 1 HOUSING ASSEMBLY.. 1 STATOR PAD.. 1 DATA PLATE.. 1 FIELD.. 1 BRUSH TUBE.. 2 BRUSH SET.. 1 BRUSH CAP.. 2 BALL BEARING... 1 ARMATURE... 1 O RING... 2 RETAINING RING.. 1 SPRING WASHER.. 1 BEARING FRAME.. 1 PLUNGE LOCK SCREW.. 1 PLUNGE LOCK LEVER.. 1
SCREW (6-32 X 1/4 in. PAN HD.). 1 SCREW (1/4-15 X 1-3/4 in. PAN HD.). 4 COLLET ASSEMBLY (1/2 in.).. 1 COLLET ADAPTOR (1/4 in.). 1 SHAFT LOCK PIN.. 1 SHAFT LOCK SPRING.. 1 SHAFT LOCK COVER PLATE.. 1 SCREW (10-32 X 3/8 in. WAFER HD.).. 2 LOCK KNOB... 1 STOP BAR... 1 POINTER... 1 DEPTH ADJUSTING ROD.. 1 HEX NUT (3/8-16).. 3 BELLOWS ASSEMBLY.. 2 DEPTH STOP KNOB.. 1 GAGE CAP... 1 BASE ASSEMBLY.. 1 SUBBASE.. 1 CHIP SHIELD.. 1 WRENCH... 1 OPERATOR'S MANUAL (960931002) REPAIR SHEET (REV:01)

POWER CORD

WHITE LEAD BLACK (SWITCH) LEAD BROWN (SWITCH) LEAD SWITCH SPEED CONTROL CIRCUIT BOARD BLUE (MOTOR) LEAD YELLOW LEAD BRUSH ASSEMBLY BLACK (MOTOR) LEAD

MOTOR FIELD

RED LEAD BRUSH ASSEMBLY

WIRING DIAGRAM

Make sure your extension cord is in good condition. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. A wire gage size (A.W.G.) of at least 16 is recommended for an extension cord 100 feet or less in length. A cord exceeding 100 feet is not recommended. If in doubt, use the next heavier gage. The smaller the gage number, the heavier the cord. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. Inspect for and remove all nails from lumber before routing. Following this rule will reduce the risk of serious personal injury. Drugs, alcohol, medication. Do not operate tool while under the influence of drugs, alcohol, or any medication. Following this rule will reduce the risk of electric shock, fire, or serious personal injury. Save these instructions. Refer to them frequently and use them to instruct others who may use this tool. If you loan someone this tool, loan them these instructions also.
Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known 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 chemicallytreated 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.

SYMBOLS

Important: Some of the following symbols may be used on your tool. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to operate the tool better and safer. SYMBOL V A Hz W min NAME Volts Amperes Hertz Watt Minutes Alternating Current n0 No Load Speed Class II Construction DESIGNATION/EXPLANATION Voltage Current Frequency (cycles per second) Power Time Type or a characteristic of current Rotational speed, at no load Designates double-insulated construction tools Revolutions, strokes, surface speed, orbits etc. per minute Indicates danger, warning or caution. It means attention!!! Your safety is involved. Do not expose to rain or use in damp locations.
Revolutions or Reciprocation Per Minute

Safety Alert

Wet Conditions Alert
The purpose of safety symbols is to attract your attention to possible dangers. The safety symbols, and the explanations with them, deserve your careful attention and understanding. The safety warnings do not by themselves eliminate any danger. The instructions or warnings they give are not substitutes for proper accident prevention measures.

SYMBOL MEANING DANGER: Failure to obey a safety warning will result in serious injury to yourself or to others. Always
follow the safety precautions to reduce the risk of fire, electric shock and personal injury.
WARNING: Failure to obey a safety warning can result in serious injury to yourself or to others.
Always follow the safety precautions to reduce the risk of fire, electric shock and personal injury.
CAUTION: Failure to obey a safety warning may result in property damage or personal injury to yourself or to others. Always follow the safety precautions to reduce the risk of fire, electric shock and personal injury. NOTE:
Advises you of information or instructions vital to the operation or maintenance of the equipment.

SPECIFICATIONS

Plunge Depth Collet Adaptor Peak Horsepower Input No Load Speed Power Cord Net Weight 0 - 2 in. (0 - 5.08 cm) 1/2 in. (12.7 mm) 1/4 in. (6.35 mm) Volts, 60 Hz, AC Only, 10.0 Amperes 15,000 - 23,000 RPM 10 ft. (3 m) 8.5 lbs. (3.86 kg.)

UNPACKING

INSTRUCTIONS
Your router has been shipped completely assembled. Carefully remove the tool and accessories from the box. Make sure that all items listed in the packing list are included. Inspect the tool carefully to make sure no breakage or damage occurred during shipping. Do not discard the packing material until you have carefully inspected and satisfactorily operated the tool. If any parts are damaged or missing, please call 1-800-525-2579 for assistance.

PACKING LIST

Plunge Router Collet Adaptor 15/16 in. (23.8 mm) Wrench 5/16-18 UNC-2A Flathead Screws (2) Operators Manual NOTE: The screws and the optional depth control knob must be used when mounting your router to a router table. They are the only screws that will secure your router to a router table properly.
If any parts are missing do not operate your tool until the missing parts are replaced. Failure to do so could result in possible serious personal injury.

APPLICATIONS

Use your router only for the purposes listed below: Routing grooves, shaping edges, freehand designs, etc. in wood. Chamfering, rabbeting, dadoing, and dovetailing in wood. Routing edges on laminates.

FEATURES

Your plunge router is a versatile woodworking tool that will give you years of trouble-free performance. It is engineered with the professional in mind, but its ease of operation allows the amateur to produce work that is beautiful and precise. As the name implies your plunge router can be used for making plunge cuts in workpieces, routing grooves, edge routing, routing circles, and freehand routing. When used with recommended accessories, such as a UL listed router table, depth adjusment knob, and straight guide; it becomes even more versatile. Various types of cutters, both with and without roller bearings as guides, also add to the versatility of this tool.

HEAVY DUTY MOTOR

Your router has a powerful 10 amp motor with sufficient power to handle tough routing jobs. It delivers 2 horsepower for heavy duty performance. The motor also has externally accessible brushes for ease of servicing.
Speed can be set according to the approximate cutter diameter you will be using and to the hardness of the material being cut. The best cuts are made when the cutter is fed through material at the proper rate of feed.

PLUNGE LOCK LEVER

Your router has a plunge lock lever that allows for free plunging. This feature is very useful for table mounted operations on UL listed router tables when used with the optional depth control knob. Unlocking the plunge lock lever allows for a smooth, precise plunging action. Once you reach the desired depth of cut, simply lock the plunge lock lever. The cutter will then be secured at the desired depth of cut.

SWITCH

To turn the router ON, toggle the switch to the I position. To turn the router OFF, toggle the switch to the O position.

DEPTH STOP SYSTEM

The Accu-Stop Micro-Adjustable depth stop located on the base of your router provides precise stops for repetitive depth of cut changes. A depth adjustment scale makes quick adjustments to depth of cut changes possible.

ERGONOMIC DESIGN

The design of this tool provides for easy handling. It is designed for comfort and ease of grasp when operating in different positions and at different angles.

OPERATION

HANDLE

LOCK KNOB SPINDLE LOCK STOP BAR
ACCU-STOPTM MICRO-ADJUSTABLE DEPTH STOP
EACH 90O ROTATION OF DEPTH STOP KNOB EQUALS 1/64 in. (0.4 mm) CHANGE IN DEPTH OF CUT
EACH COMPLETE ROTATION (360O) OF DEPTH STOP KNOB EQUALS 1/16 in. (1.6 mm) CHANGE IN DEPTH OF CUT

Fig. 1 8

REAR VIEW OF ROUTER

POWER CORD

PLUNGE LOCK LEVER HEX NUT(S)

COLLET NUT

ROUTER BASE

SUBBASE

1/4 in. (6.35 mm) ADAPTOR 15/16 in. (23.8 mm) WRENCH Fig. 2
Do not attempt to modify this tool or create accessories not recommended for use with this tool. Any such alteration or modification is misuse and could result in a hazardous condition leading to possible serious personal injury. 9

ADJUSTMENTS

Your router should never be connected to power supply when you are assembling parts, making adjustments, installing or removing cutters, or when not in use. Disconnecting your router will prevent accidental starting that could cause serious injury. SPINDLE LOCK

TO LOOSEN COLLET NUT

CUTTER INSTALLATION
See Figures 3 and 4. UNPLUG YOUR ROUTER.
Failure to unplug your router could result in accidental starting causing serious injury. COLLET NUT TO TIGHTEN COLLET NUT

CAUTION:

To prevent damage to the spindle or spindle lock, always allow motor to come to a complete stop before engaging spindle lock. Remove chip shield from router base. Depress spindle lock. See Figure 3. Lay router down on workbench in order to gain easy access to collet nut. See Figure 3. Place the wrench provided through front of router base onto collet nut and turn counterclockwise to loosen. See Figure 3. CUTTER 15/16 in. (23.8 mm) WRENCH COLLET NUT COLLET NUT COLLET Fig. 3
If you are changing a cutter immediately after use, be careful not to touch the cutter or collet with your hands or fingers. They will get burned because of the heat buildup from cutting. Always use the wrench provided. Install cutter once collet nut is loose. If changing cutters, cutter will easily slip from collet after loosening collet nut. NOTE: The collet is machined to precision tolerances to fit cutters with 1/2 in. (12.7 mm) diameter shanks. To use cutters with 1/4 in. (6.35 mm) diameter shanks, insert the 1/4 in. (6.35 mm) adaptor into the 1/2 in. (12.7 mm) collet. Insert shank of cutter until shank bottoms out, then pull it out 1/16 in. (1.6 mm) to allow for expansion when the bit gets hot. Tighten the collet nut securely by turning clockwise with the wrench provided. Release spindle lock. Replace chip shield.

1/4 in. (6.35 mm) ADAPTOR CUTTER WITH 1/4 in. (6.35 mm) SHANK DIAMETER Fig. 4
If the collet nut is not securely tightened, the cutter may detach during use causing serious personal injury.
Do not use cutters with undersized shanks. Undersized shanks will not tighten properly and could be thrown from the tool causing injury. TO UNLOCK TO LOCK HEX NUTS
Do not use cutters that are larger in diameter than the opening in router base. Use of such cutters will come in contact with the router base and damage both the cutter and router base. This situation could also cause possible loss of control or create other hazardous conditions that could cause possible serious personal injury.

DEPTH OF CUT

See Figures 5, 6 and 7. When routing a groove that is too deep to safely cut in one pass, it is best to make the cut in several passes. We recommend that cuts be made at a depth not exceeding 1/8 in. (3.2 mm) and that several passes be made to reach deeper cuts. Proper depth of cut depends on several factors: horsepower of router motor, type of cutter being used, and type of wood being routed. A lightweight, low horsepower router is designed for making shallow cuts. A router with high horsepower rating can safely cut deeper. Small bits, such as veining bits with 1/16 in. (1.6 mm) cutting diameters, are designed to remove only small amounts of wood. Large bits, such as straight-flute bits, are made to remove larger amounts of wood in a single pass. Cuts can be made deeper in soft woods, such as white pine, than in tough hardwoods, like oak or maple. Based upon these considerations, choose a depth of cut that will not place excessive strain on router motor. If you find that extra force is needed or that the motor speed slows down considerably, turn off router and reduce the depth of cut. Then, make the cut in two or more passes. TO ADJUST DEPTH OF CUT UNPLUG YOUR ROUTER.
CUTTER INSIDE SUBBASE SCALE ZERO RESET INDICATOR WITH RED LINE

Fig. 5

LOCK KNOB STOP BAR
TIP OF CUTTER TOUCHING WORKPIECE = ZERO DEPTH OF CUT

Fig. 6

Failure to unplug your router could result in accidental starting causing serious injury. Raise cutter by unlocking plunge lock lever. See Figure 5. Adjust hex nuts on threaded post until cutter is inside router subbase. Place router on a flat surface. Lower router until tip of cutter barely touches flat surface. See Figure 6. 11

Relacing optional depth control knob without compression spring could result in depth control knob and hex nut vibrating off depth adjustment rod. This situation could cause motor to separate from router base, resulting in possible serious injury.

STOP FLANGE

Fig. 8 12
TO ADJUST DEPTH OF CUT USING OPTIONAL DEPTH CONTROL KNOB See Figure 9. UNPLUG YOUR ROUTER.
Failure to unplug your router could result in accidental starting casuing serious injury. Loosen lock knob and raise stop bar. Unlock plunge lock lever and raise cutter to its uppermost position. Plunge router until cutter reaches the approximate desired depth of cut. Lock plunge lock lever, temporarily locking cutter at desired depth of cut. Turn depth control knob clockwise until hex nut seats against stop flange. Do not overtighten. Unlock plunge lock lever. Always unlock plunge lock lever before setting depth of cut with depth control knob. Turn depth control knob until cuter reaches desired depth of cut. Lock plunge lever. Always lock cutter in place before routing. Loosen lock knob and adjust stop bar until it touches depth stop. Tighten lock knob securely.
PLUNGE LOCK LEVER DEPTH ADJUSTMENT ROD COMPRESSION SPRING HEX NUT Fig. 9

DEPTH STOP KNOB

LOCK KNOB
STOP BAR ACCU-STOPTM MICRO-ADJUSTABLE DEPTH STOP EACH 90 ROTATION OF DEPTH STOP KNOB EQUALS 1/64 in. (0.4 mm) CHANGE IN DEPTH OF CUT Fig. 10 SCALE ZERO RESET INDICATOR WITH RED LINE LOCK KNOB

DEPTH STOP

See Figures 10 and 11. The depth stop is located on the base of your router and makes it possible to make deep or heavy cuts in successive passes by use of the Accu-Stop MicroAdjustable Depth Stop System. Alignment marks make depth of cut changes quick and easy. A preset cutting depth is achieved by plunging router until stop bar comes in contact with depth stop. The micro-adjusting feature provides alignment marks at each 90 rotation of the depth stop knob. Each 90 rotation of the knob changes depth of cut setting 1/64 in. (0.4 mm). See Figure 10. A complete rotation (360) of the depth stop knob changes the depth of cut setting 1/16 in. (1.6 mm). See Figure 11. The Accu-Stop Micro-Adjustable Depth Stop System provides for depth of cut changes to be made from 0 to 1/2 in. (12.7 mm) from the initial setting of the stop bar. This initial setting of the stop bar can be "zero" depth of cut, or it can be any depth of cut setting that you choose as a starting point for a particular job to be performed.

The zero reset indicator allows you to use the scale provided on the housing to make quick depth of cut changes to existing depth of cut settings. Simply choose a reference point on the scale and slide the zero reset indicator up or down the scale the distance required for new depth of cut. Then change stop bar position by loosening lock knob and adjusting stop bar until red line on zero reset indicator moves back to reference point. Tighten lock knob securely to lock stop bar in new position. The cutter position will now increase or decrease the exact distance the stop bar was adjusted. NOTE: Each mark on the inch scale indicates 1/16 in. (1.6 mm).
See Figure 13. To turn the router ON, toggle the switch to the I position. To turn the router OFF, toggle the switch to the O position.

MOTOR HOUSING

I = ON O = OFF
We suggest that you practice with your router before installing a cutter and making cuts in wood.

ROUTING

See Figure 14. For ease of operation and maintaining proper control, your router has two handles, one on each side of the router base. When using your router hold it firmly with both hands. Before starting the router, unplug it and make sure the cutter is securely tightened in collet nut and that depth of cut is properly set. Plug router into power supply, turn it on, and let motor build to its full speed, then gradually plunge or feed cutter into workpiece. Do not let the cutter contact workpiece before turning on router and allowing it to develop full speed. Remain alert and watch what you are doing. Do not operate router when fatigued or under the influence of drugs, alcohol, or any medication.
ROUTING GROOVES See Figure 15. When routing across the face of boards, set router at desired depth of cut, place the edge of router base against workpiece, and turn on the router. Slowly feed the cutter into the workpiece along desired line of cut.

Fig. 13

Fig. 14
If desired depth of cut is greater than can be safely cut in one pass, make cuts in two or more passes. When routing straight cuts across stock, clamp a straight edge to the workpiece to use as a guide. Position the straightedge parallel to the line of cut and offset the distance between the cutting edge of the cutter and the edge of the router base. Hold the router base against the straightedge and rout the groove. When routing a groove wider than the diameter of the cutter, clamp a straightedge on both sides of the cutlines. Position both guides parallel to the desired line of cut and spaced equal distances from the desired edges of the groove. Rout along one guide; then, reverse direction and rout along the other guide. Clean out any remaining waste in the center of the groove freehand. Fig. 15 15
ROUTING BY FREEHAND See Figure 16. When used freehand, your plunge router becomes a flexible and versatile tool. This flexibility makes it possible to easily rout signs, relief sculptures, etc. There are two basic techniques for freehand routing: Routing letters, grooves, and patterns into wood. Routing out the background, leaving the letters or pattern raised above the surface. When freehand routing, we suggest the following: Draw or layout the pattern on workpiece. Choose the appropriate cutter. NOTE: A core box or V-groove bit is often used for routing letters and engraving objects. Straight bits and ball mills are often used to make relief carvings. Veining bits are used to carve small, intricate details. Rout the pattern in two or more passes. Make the first pass at 25% of the desired depth of cut. This process will provide better control as well as being a guide for the next pass. Do not rout deeper than 1/8 in. (3.2 mm) per pass or cut. Follow these directions when routing by freehand: Choose the appropriate cutter, set desired depth of cut, carefully check set-up, and secure workpiece. Make a test cut in a scrap piece of wood from the same workpiece if possible. Unlock plunge lock lever to raise cutter from any preset depth of cut. This also permits raising cutter inside router subbase. Place router on workpiece inside pattern to be routed. Grasp handles securely and press the switch to start your router. Let motor build to full speed, then gradually plunge cutter into workpiece until stop bar comes into contact with depth stop. Lock plunge lock lever to secure depth of cut setting. Begin routing out the pattern, continuing until a complete pass at this depth of cut has been made.

Fig. 16 Several cuts that require repositioning of router may be needed for a particular job. If this situation exists, unlock plunge lock lever to raise cutter inside router subbase after each cut, reposition router for next cut, gradually plunge cutter into workpiece until stop bar contacts depth stop, lock plunge lock lever and continue routing. After all cuts have been made, unlock plunge lock lever, raise cutter inside router subbase, remove router from workpiece, turn off the router, and allow cutter to come to a complete stop. ROUTING EDGES Place router on workpiece, making sure the router bit does not contact workpiece. Turn router on and let the motor build to its full speed. Begin your cut, gradually feeding cutter into workpiece.
Keep a firm grip on router with both hands at all times. Failure to do so could result in loss of control leading to possible serious injury. Upon completion of cut, turn motor off and let it come to a complete stop before removing router from work surface.
Do not use large router bits for freehand routing. Use of large router bits when freehand routing could cause loss of control or create other hazardous conditions that could cause possible serious personal injury.
Never pull router out of work and place upside down on work surface before the cutter stops.

PILOT BIT EDGING

See Figure 17. Rabbets and molded edges can be cut using piloted cutters. The pilot extends below the cutter. Some pilots are solid extensions of the cutter. Others are ball bearing guides that are fastened to the end of the cutter. The pilots allow the cutters to turn while the pilot follows the edge of the workpiece. Arbor-type bits with pilots are excellent for quick, easy, edge shaping. They will follow workpiece edges that are either straight or curved. The pilot prevents the bit from making too deep a cut; and holding the pilot firmly in contact with the workpiece edge throughout prevents the cut from becoming too shallow. Whenever the workpiece thickness together with the desired depth of cut (as adjusted by router depth setting) are such that only the top part of the edge is to be shaped (leaving at least a 1/16 inch (1.6 mm) thick uncut portion at bottom), the pilot can ride against the uncut portion, which will serve to guide it. See Figure 17. However, if the workpiece is too thin or the bit set too low so that there will be no uncut edge to ride the pilot against, an extra board to act as a guide must be placed under the workpiece. This guide board must have exactly the same contour straight or curve as the workpiece edge. If it is positioned so that its edge is flush with the workpiece edge, the bit will make a full cut (in as far as the bit radius). On the other hand, if the guide is positioned as shown in Figure 17 (out from the workpiece edge), the bit will make less than a full cut which will alter the shape of the finished edge. NOTE: When edge shaping with guides, any of the piloted bits can be used without a pilot. Also, the size (diameter) of the pilot that is used determines the maximum cut width that can be made with the pilot against the workpiece edge (the small pilot exposes all of the bit; the large one reduces this amount by 1/16 inch (1.6 mm). When routing all the edges of a panel or board, rout the end grain first. Any splintering that occurs at the corners will then be removed when routing the edge. Start each side 1/4 in. (6.35 mm) away from the end. Feed the cutter into the wood until the pilot contacts the uncut edge. Then, slowly back the router to shape the corner. Next, move the router forward to shape the rest of the edge. Be careful to keep the pilot pressed against the uncut edge. Repeat this procedure on each side of the panel. Figure 18 shows the proper sequence of cuts to make when edge routing four sides of a panel.

TOO FAST

TOO SLOW Fig. 21
As previously mentioned, the depth of cut is important because it affects the rate of feed that, in turn, affects the quality of the cut (and, also, the possibility of damage to your router motor and bit). A deep cut requires a slower feed than a shallow one, and a too deep cut will cause you to slow the feed so much that the bit is no longer cutting, it is scraping, instead. Making a deep cut is never advisable. The smaller bits especially those only 1/16 inch (1.6 mm) in diameter are easily broken off when subjected to too much side thrust. A large enough bit may not be broken, but if the cut is too deep a rough cut will result and it may be very difficult to guide and control the bit as desired. For these reasons, we recommend that you do not exceed 1/8 in. (3.2 mm) depth of cut in a single pass, regardless of the bit size or the softness or condition of the workpiece. See Figure 22. To make deeper cuts it is therefore necessary to make as many successive passes as required, lowering the bit 1/8 in. (3.2 mm) for each new pass. In order to save time, do all the cutting necessary at one depth setting, before lowering the bit for the next pass. This will also assure a uniform depth when the final pass is completed. See Figure 23. DEPTH OF CUT WIDTH OF CUT

Fig. 22

2ND. PASS

1ST. PASS

Fig. 23

MAINTENANCE

When servicing use only identical Ryobi replacement parts. Use of any other parts may create a hazard or cause product damage. Electric tools used on fiberglass material, wallboard, spackling compounds, or plaster are subject to accelerated wear and possible premature failure, as the fiberglass chips and grindings are highly abrasive to bearings, brushes, commutators, etc. Consequently, we do not recommended that this tool be used for extended work on these types of materials. If, however, you do work with any of these materials, it is extremely important that you clean the tool frequently by blowing it with an air jet.

GENERAL

Avoid using solvents when cleaning plastic parts. Most plastics are susceptible to damage from various types of commercial solvents and may be damaged by their use. Use clean cloths to remove dirt, carbon dust, etc.

Do not at any time let brake fluids, gasoline, petroleum-based products, penetrating oils, etc. come in contact with plastic parts. They contain chemicals that can damage, weaken, or destroy plastic.
Always wear safety goggles or safety glasses with side shields during power tool operation or when blowing dust. If operation is dusty, also wear a dust mask.

LUBRICATION

All of the bearings in this tool are lubricated with a sufficient amount of high grade lubricant for the life of the unit under normal operating conditions. Therefore, no further lubrication is required. BRUSH ASSEMBLY BRUSH ASSEMBLY

CUTTERS

Get faster and more accurate cutting results by keeping cutters clean and sharp. Remove all accumulated pitch and gum from cutters after each use. When sharpening cutters, sharpen only the inside of the cutting edge. Never grind the outside diameter. Be sure when sharpening the end of a cutter to grind the clearance angle the same as originally ground. BRUSH CAP BRUSH CAP

COLLET

Dust and chips may collect on the collet from time to time, making it necessary to clean the collet. To do so, remove the collet assembly and wipe it with a clean dry rag. Clean the taper in the shaft in the same manner. Never immerse the collet or end of the shaft in a solvent or in water. Before replacing the collet assembly, put a drop of SAE30 motor oil on the inside of the nut, on the threads of the shaft, and on the taper in the shaft. Replace the collet assembly onto the shaft by hand only. Never tighten the collet nut without a bit in the collet. This action could permanently damage the collet.

Fig. 24

BRUSH ASSEMBLIES
See Figure 24. Your router has externally accessible brush assemblies that should periodically be checked for wear. TO REPLACE BRUSH ASSEMBLIES UNPLUG YOUR ROUTER.
Failure to unplug your router could result in accidental starting causing serious injury. Remove brush cap with a screwdriver. Brush assembly is spring loaded and will pop out when you remove brush cap. Remove brush assembly (brush and spring). Check for wear. If worn, always replace in pairs. Do not replace one side without replacing the other. Reassemble using new brush assemblies. Make sure curvature of brush matches curvature of motor and that brush moves freely in brush tube. Make sure brush cap is oriented correctly (straight) and replace. Tighten brush cap securely. Do not over torque.

See Figures 25, 26, and 27. After extended use, the plunge lock may wear. If this happens, you can easily adjust the lever. TO ADJUST PLUNGE LOCK LEVER UNPLUG YOUR ROUTER.

TO LOOSEN

Failure to unplug your router could result in accidental starting causing serious injury. Make sure lever is in locked position. Remove the screw supporting the plunge lock lever. Remove the lever. Place the lever back in the original locked position.

SCREW TO TIGHTEN

Fig. 26
Replace the screw. Check for free plunge with lever rotated to unlocked position. If router does not plunge freely, reposition lever.
PLUNGE LOCK LEVER SHOWN IN ORIGINAL LOCKED POSITION PLUNGE LOCK LEVER SHOWN AFTER EXTENDED WEAR

Fig. 27

Fig. 25

HELPFUL HINTS

Always clamp workpiece securely before routing. A safe operator is one who thinks ahead. Always wear eye protection when routing. Make setup adjustments carefully. Then double check. Measure twice and cut once. Keep cutters clean and properly sharpened. Dont let familiarity make you careless. Study all safety rules and do the job safely. NEVER place your hands in jeopardy. Make certain clamps cant loosen while in use. Test difficult setups on scrapDont waste lumber. Plan each operation before you begin. Clean your router frequently. Shake router or blow with an air jet to remove sawdust buildup. DO NOT ABUSE POWER TOOLS. Abusive practices can damage tool as well as workpiece. THINK SAFETY BY THINKING AHEAD. 22

ACCESSORIES

OPTIONAL STRAIGHT GUIDE
An optional straight guide, part number 6090080, is available and may be purchased for use with your router.
When using a UL listed router table, large router bits should be used for edging only. Do not use router bits that are larger in diameter than the opening in the router base for any purpose. Failure to heed this warning could result in serious personal injury.
An optional depth control knob, part number 4830175, is available, which allows you to easily adjust the depth of cut when using the router mounted upside down to a router table.

ROUTER TABLE

When mounting your router to a router table, use the two 5/16-18 UNC-2A flathead screws supplied. These screws will secure your router to the router table properly. Use of any other type and size screws could result in an accident causing possible serious injury. Do not use 8 mm screws.
Do not use with router tables that are not UL listed and that fail to conform to safe woodworking practices and offer proper guarding for the cutter. Failure to comply can result in an accident causing possible serious injury.

The use of this router in table mounted applications requires the use of the optional depth control knob. Failure to use this optional depth control knob could result in an accident and possible serious personal injury.

EXTENSION CORD CAUTION

When using a power tool at a considerable distance from a power source, be sure to use an extension cord that has the capacity to handle the current the tool will draw. An undersized cord will cause a drop in line voltage, resulting in overheating and loss of power. Use the chart to determine the minimum wire size required in an extension cord. Only round jacketed cords should be used. When working with a tool outdoors, use an extension cord that is designed for outside use. This is indicated by the letters "WA" on the cord's jacket. Before using any extension cord, inspect it for loose or exposed wires and cut or worn insulation.
**Ampere rating (on tool faceplate)

2.1-3.4

3.5-5.0

5.1-7.0

7.1-12.0 12.1-16.0

Cord Length

Wire Size (A.W.G.)

25' 50' 100'

CAUTION: Keep the extension cord clear of the working area. Position the cord so that it will not get caught on lumber, tools or other obstructions while you are working with a power tool.
**Used on 12 gauge - 20 amp circuit.

SERVICE

Now that you have purchased your tool, should a need ever exist for repair parts or service, simply contact your nearest Ryobi Authorized Service Center. Be sure to provide all pertinent facts when you call or visit. Please call 1-800-525-2579 for your nearest Ryobi Authorized Service Center. You can also check our Web site at www.ryobitools.com for a complete list of Authorized Service Centers.

MODEL NO. AND SERIAL NO.

The model number of this tool will be found on a plate attached to the motor housing. Please record the model number and serial number in the space provided below.
HOW TO ORDER REPAIR PARTS
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE FOLLOWING INFORMATION: MODEL NUMBER SERIAL NUMBER RE180PL1

RYOBI TECHNOLOGIES INC.

1428 Pearman Dairy Road Anderson, SC 29625 Post Office Box 1207 Anderson, SC 29622 www.ryobitools.com Phone 1-800-525-2579

983000-448 6-04