OPERATOR'S MANUAL #4950300 ROUTER AND JIG SAW MOUNTING KIT (FOR USE WITH THE BT3000 TABLE SAW) CONGRATULATIONS AND THANK YOU FOR BUYING THIS RYOBI ROUTER AND JIG SAW MOUNTING KIT. Your new #4950300 Router and Jig Saw Mounting Kit has been designed for use with the RYOBI BT3000 Table Saw. It has been engineered and manufactured to Ryobi's high standards for dependability, ease of operation, and operator safety. This kit gives you the capability of mounting a router or jig saw on the accessory table of your BT3000. It also includes a circle cutting jig for cutting circular patterns in both large and small stock. Properly cared for, it will provide years of dependable, trouble-free performance. RULES FOR SAFE OPERATION 1. 2. 3. 4. 5. 6. READ THESE INSTRUCTIONS THOROUGHLY before assembling or using this router and jig saw mounting kit. READ THE INSTRUCTIONS FOR THE BT3000 TABLE SAW before operating your saw with this kit. KEEP ASSEMBLY AREA AND WORK AREA CLEAN. Cluttered areas and benches invite accidents. ALWAYS WEAR SAFETY GLASSES . Everyday eyeglasses have only impact-resistant lenses; they are NOT safety glasses. DO NOT USE THIS PRODUCT WITH OTHER EQUIPMENT OR FOR OTHER PURPOSES. ALWAYS DISCONNECT SAW FROM POWER SUPPLY BEFORE ASSEMBLING THIS KIT. Make sure switch is off when reconnecting saw to power supply. Save This Manual For Future Reference RULES FOR SAFE OPERATION (Continued) 7. 8. 9. 10. 11. 12. 13. 14. DO NOT MAKE ADJUSTMENTS UNTIL CUTTER OR BLADE HAS COME TO A COMPLETE STOP AND TOOL HAS BEEN DISCONNECTED FROM POWER SOURCE. FEED WORKPIECE AGAINST ROTATION OF CUTTER. DO NOT USE AWKWARD HAND POSITIONS. KEEP FINGERS AWAY FROM REVOLVING CUTTER, USE FIXTURES WHEN NECESSARY. WHENEVER POSSIBLE, ALWAYS USE DUST COVER FOR OVERHEAD GUARDING. DO NOT REMOVE JAMMED CUTOFF PIECES UNTIL CUTTER OR BLADE HAS STOPPED AND TOOL HAS BEEN DISCONNECTED FROM POWER SOURCE. HOLD WORKPIECE FIRMLY AGAINST THE TABLE. UNUSED SAW MAY CAUSE PERSONAL INJURY. DISCONNECT MOTOR CORD FROM THE RECEPTACLE ON YOUR SAW AND PLUG ACCESSORY POWER CORD INTO THE RECEPTACLE. ALWAYS USE THE SAW'S MASTER SWITCH TO TURN THE ACCESSORY "ON" AND "OFF". INTRODUCTION As mentioned previously, this kit gives you the capability of mounting a router or jig saw on the accessory table of your BT3000. A router mounted on the accessory table will provide expanded capabilities for making rabbets, grooves, chamfers, dovetails, and mortise and tenon joints. A jig saw mounted on the accessory table will provide expanded capabilities for cutting curves, scrollwork, and intricate patterns. The circle cutting jig included in this kit enables you to easily cut circular patterns in both large and small stock with either a router or jig saw. The additional versatility gained from use of this kit will turn your BT3000 table saw into a remarkable woodshaping center. CHECKING PARTS Separate all parts from packing materials. Check your parts with the parts list on page 3. Refer to Figure 1 if you are unsure about the description of any part. If any parts are missing, delay assembly of this kit until you have obtained the missing part(s). WARNING: Attempting to assemble the Router and Jig Saw Mounting kit or to use in any way without obtaining any missing parts and installing them correctly, could result in an accident resulting in possible serious injury. TOOLS NEEDED Tools needed for assembly of this kit are a phillips screwdriver, two slotted screwdrivers, and an adjustable wrench. Note: Adjustable wrench will be used to tighten threaded post into the special 5/16 in. T-nut provided. IMPORTANT NOTE This router kit has been specifically designed for use with the Ryobi Model RE600 Electronic Router Only. The hole pattern on the mounting plate has not been drilled to accommodate other routers on the market. This jig saw kit is used to mount a jig saw on the accessory table of your BT3000 table saw. Ryobi jig saws plus many other brands can be mounted using the parts supplied in this kit. Before operating the jig saw, make sure the front and rear clamping brackets properly secure the jig saw base to the mounting plate. Care must be taken to insure that the jig saw blade does not come in contact with the throat plate, accessory table, or any part of the assembly during operation. Visually inspect all areas of moving parts prior to connecting the jig saw to power supply. WARNING: Unplug the power supply cord of your BT3000 from electrical outlet before you begin mounting this kit. It should remain disconnected until the mounting operation is complete, all attachments are installed properly, and they have been checked to make sure they are secure. Failure to unplug your saw could result in accidental starting causing possible serious personal injury. UNPACKING Your new router and jig saw mounting kit includes two separate mounting plates, two guide fences with guide blocks, a dust cover assembly, a throat plate, plus the necessary brackets and connecting hardware required to mount a Ryobi Model RE600 Electronic Router to the accessory table of your BT3000 table saw. It also includes connecting hardware required to mount Ryobi jig saws to the accessory table of your BT3000 table saw . Page 2 5/16 in. WASHERS THROAT PLATE KNOB BOLTS GUIDE FENCE WITH GUIDE BLOCK #10-24 SCREWS JIG SAW MOUNTING PLATE TABLE CLAMPING BRACKET 5/16 in. T-NUTS KNOB BOLT 5/16 in. WASHER FRONT CLAMPING BRACKET #6 WOOD SCREW REAR CLAMPING BRACKET ROUTER MOUNTING PLATE CIRCLE CUTTING COLLAR SPACER #10 WASHER POST DUST COVER WITH PIVOT ASSEMBLY #1/4-20 SCREWS Fig. 1 LIST OF LOOSE PARTS Your #4950300 Router and Jig Saw Mounting Kit includes the following parts: DESCRIPTION QUANTITY DESCRIPTION QUANTITY Guide Fence with Guide Block ................................ 2 Knob Bolt (#5/16-18 x 1/2 in.) ................................. 4 5/16" Washer ........................................................... 5 5/16" T-Nut (Special) ............................................... 6 Spacer ..................................................................... 1 Post ......................................................................... 1 Dust Cover with Pivot Assembly ............................. 1 Throat Plate ............................................................. 1 Front Clamping Bracket for Jig Saw ....................... 1 Rear Clamping Bracket for Jig Saw ........................ 1 Page 3 Jig Saw Mounting Plate ........................................... 1 Screw (#10-24 x 3/4 in. Phillips Flat Hd.) ................ 4 Router Mounting Plate ............................................ 1 Screw (#1/4-20 x 1/2 in. Phillips Flat Hd.) ............... 4 Circle Cutting Collar with Slot.................................. 1 Washer (#10) ........................................................... 1 Screw (#10-24 x 1 in. Round Hd.) ........................... 1 Wood Screw (#6 x 1 in. Round Hd.) ....................... 1 Table Clamping Bracket .......................................... 1 Knob Bolt (#5/16-18 x 3/4 in.) ................................. 1 ASSEMBLY Read these instructions completely before beginning assembly of this kit. ROUTER MOUNTING WARNING: The saw's motor cord must be disconnected from the receptacle provided on the saw when using this kit with a Router or Jig Saw mounted to the accessory table. The power supply cord of the Router or Jig Saw must be plugged into the receptacle and the saw's master switch must be used to turn the Router or Jig Saw "ON" or "OFF". T-NUT SHOWN BETWEEN ADJUSTMENT SCREWS T-NUT ADJUSTMENT SCREW IMPORTANT This router kit has been specifically designed for use with the Ryobi Model RE600 Electronic Router Only. The hole pattern on the mounting plate has not been drilled to accommodate other routers on the market. Special mounting screws are provided with the RE600 to insure safe, secure mounting. WASHER TO INSTALL T-NUTS FOR GUIDE FENCE BRACKETS See Figure 2. This kit requires that five of the special 5/16 in. T-nuts provided fit in the top channel of the rip fence on your BT3000 table saw. The first T-nut is required between the two adjustment screws on top of the rip fence. TO INSTALL: 1. Place rip fence against saw blade as shown in figure 2 and lock in place. This will insure that rip fence remains square. 2. Using the appropriate allen wrench supplied with your BT3000 table saw, loosen and remove rear adjustment screw and washer on top of rip fence. 3. Slide one of the special 5/16 in. T-nuts into top channel of rip fence and place it between two adjustment screws. Note: T-nuts install from rear of rip fence. 4. Replace adjustment screw and washer. 5. Tighten adjustment screw securely. 6. Check rip fence for squareness with saw blade. RIP FENCE SHOWN LOCKED AGAINST SAW BLADE INSTALL T-NUTS FROM REAR OF RIP FENCE Fig. 2 T-NUT TO INSTALL REMAINING T-NUTS See Figure 3. 1. For ease of assembly, unlock rip fence and slide away from saw blade. See Figure 3. 2. Lock rip fence. 3. Slide four remaining 5/16 in. T-nuts in top channel of rip fence as shown in figure 3. Note: You should now have five T-nuts in the top channel of rip fence. Only one should be between adjustment screws. Page 4 Fig. 3 ROUTER MOUNTING (Cont'd) TO INSTALL GUIDE FENCE BRACKETS See Figure 4. 1. Align each guide fence bracket with two of the special 5/16 in. T-nuts in channel on top of rip fence. 2. Secure guide fences to rip fence with 5/16 in. washers and 5/16 in. x 1/2 in. knob bolts supplied. Note: As shown in figure 4, center T-nut is not used with guide fences. TO INSTALL POST See Figure 4. 1. Place spacer provided on threaded end of post. 2. Thread post thru spacer into remaining 5/16 in. T-nut in top channel of rip fence. 3. Tighten post securely with an adjustable wrench. Note: Adjustable wrench will fit flats on top of post. TO INSTALL DUST COVER AND PIVOT ASSEMBLY See Figure 4. 1. Place dust cover and pivot assembly on post as shown in figure 4. 2. It will slide up and down post as needed. When desired location is achieved, secure it in place by tightening knob nut attached to carriage bolt. DUST COVER AND PIVOT ASSEMBLY CARRIAGE BOLT (NOT SHOWN) KNOB NUT FLATS ON POST POST KNOB BOLTS SPACER 5/16 in. WASHERS GUIDE FENCE BRACKET T-NUTS RIP FENCE Fig. 4 Page 5 ROUTER MOUNTING (Cont'd) TO ASSEMBLE RE600 ELECTRONIC ROUTER TO ROUTER MOUNTING PLATE See Figures 5 and 6. 1. Remove the subbase screws and subbase from your router. 2. Figure 5 illustrates the correct orientation of parts and pieces for mounting your router to its mounting plate. 3. Place router upside down on a workbench and align mounting plate holes with tapped holes in the base of your router. 4. The switch handle of router should be facing the squared end of mounting plate. See Figure 5. 5. Using the 8 mm flat head screws provided with your router, secure mounting plate to router. 6. Once properly assembled, your router and mounting plate assembly should be similar to the illustration shown in figure 6. 7. Tighten screws securely. RE600 ELECTRONIC ROUTER 8 MILLIMETER SCREWS ROUTER MOUNTING PLATE FRONT OF ROUTER Fig. 5 TO ASSEMBLE MOUNTING PLATE WITH ROUTER ATTACHED TO ACCESSORY TABLE See Figure 7. 1. Place mounting plate under accessory table as shown in figure 7. Note: If desired you can remove accessory table, attach mounting plate with router, then reassemble complete assembly to your saw. 2. Secure mounting plate to accessory table using the four #1/4-20 x 1/2 in. flat head screws provided. 3. Tighten screws securely. INSTALLING ROUTER BIT Follow the instructions in the operator's manual of your router for this procedure. Install router bit and tighten securely in collet. Fig. 6 THROAT PLATE #1/4-20 SCREWS ACCESSORY TABLE CAUTION: Check to make sure it will not strike the accessory table or any metal surface. TO ASSEMBLE THROAT PLATE See Figure 7. Orient the throat plate as shown in figure 7, align tab with slot in accessory table, then place throat plate in recessed area of accessory table. Recheck router bit to make sure it will not strike the throat plate. SLOT TO ASSEMBLE TABLE CLAMPING BRACKET See Figure 8. The lever on the accessory table will tighten it securely to the front rail of your BT3000. However, the weight of your router and mounting plate, etc. may cause accessory table to be loose or have movement at the rear of the accessory table. To avoid this, install the table clamping bracket supplied with this kit. It can be used with a router mounted, with a jig saw mounted, or if desired it can be used with your BT3000 during normal use. Page 6 ROUTER WITH MOUNTING PLATE ATTACHED Fig. 7 ROUTER MOUNTING (Cont'd) TO ASSEMBLE TABLE CLAMPING BRACKET (Cont'd) 1. Remove end cap from rear rail as shown in figure 8. 2. Slide one of the special 5/16 in. T-nuts into channel of rear rail. 3. Orient table clamping bracket as shown and secure with a 5/16 in. washer and 5/16-18 x 3/4 in. knob bolt. Note: Table clamping brac ...