Craftsman 17540 - 9.5 Amp 1-3/4 HP Plunge Base Router User manual

Operator's Manual
ItenFT- .nN°l
9.5 Amp 13/4 Peak HP
Plunge Base Router
Model No.
320.17540
DOUBLE tNSULATED
Z_ CAUTION Read, understand andfollow
all Safety Rules andOperating Instructions
InthisManualbeforeusing this product,
Sears, Roebuck and Co_
Hoffman Estates, IL 60179 U°S°A.
Visit our Craftsman webslta: www.craftsman.com
• WARRANTY
• SAFETY
* UNPACKING
* DESCRIPTION
• ASSEMBLY
• OPERATION
=ADJUSTMENTS
=MAINTENANCE
9/11/06
4pm

Warranty.......................................................................................................... Page 2
Safety Symbols........................................................................................................Page 3
Safety instructions............................................................................................ Pages 4 +10
Unpacking................................................................................................... Pages 10-11
Description................................................................................................. Pages 11-14
Assembly,................................................................................................................Pages 14 - 17
Operation ....................................................................................................... Pages "t8+28
Mathtenance .....................................................................................................................Pages 29 - 30
Acceesodes ....................................................................................................................Pages 31 o32
RepatrPads,........................................................................................................... Pages 33- 36
Sears RepairParts Phone Numbers................................................................... Back Cover
ONE YEAR FULLWARRANTY ON CRAFTSMAN ePRODUCT
Ill th+sCraftsmanproductfartsdue to adefectIn matedar orworkmanshipwithinone year
from the date of purchase,RETURN IT TOTHE NEAREST SEARS STORE OR PARTS
AND REPAIR CENTER OR OTHER CRAFTSMAN OUTLET INTHE UNITED STATES
FOR FREE REPLACEMENT,
Thiswarrantydose not Include expendable partssuchas lamps, batteries, bits or blades,
If thisCraftsmanproductIsused for commercial or rentalpurposes,thiswarrantyapplies
for only g0 days from the date of purchase,
Thlswarrantygives you specific legaI dghts, and you may also have other dghts, whichvery
from e!ateto state+
Sears, Roebuckand Co,, Hoffman Estates,IL 60179
SAVETHESE INSTRUCTIONSI
READ ALL INSTRUCTIONS!

The pu_ose of safety symbols is to attract your attention !o possible dangers
The safety symbols, and the explanations with them,deserve your careful
attention and understanding The symbol warnings DO NOT by themselves
eliminate any danger. The instructionsand warningsthey give are no substitutes
for proper accident prevenlion measures.
WARNING: BE SURE to read end understand ell safety Instructions In
this manuel, Including all safety alert symbols such as "DANGER","WARNING"
end"CAUTION", BEFORE using this router, Failure to follow ell Instructions
Iletad below may result In electric shock,tire end/or serious personal tn]ury.
SYMBOL MEANING
/_ SAFETY ALERT SYMBOL: Indicates DANGER,WARNING,OR
CAUTION.May be used In conjunction wtth other symbols or plctogmphso
I_ ailure to obey this safety wernlngWILL result In death or
serious Injury to yourself or to others. Always follow the
safety precautions to reduce the risk of fire, electric shock
and personal Injury,
[[.,_ WARNINGiFailure to obey this safety warning CAN result tn death or
serious fnjury to yourself or to others. Always follow the
safety precautions to reduce the risk of fire, electric shock
end personal Injury.
[Z_ 1Failure to obey this safety warning MAY result In personal
CAUTION ]Injury to yourself or others or property damege, Always
follow the safety precautions to reduce the risk of fire,
electric shock and personal Injury,
DAMAGE PREVENTION AND INFORMATION MESSAGES
These informuser of Important Information and/or Instructions thatcouldlead to
equipment orotherpropertydamage If notfollowed Each message Is precededby the
word"NOTE:" as in theexample below:
FOTE: Equipment and/or property damage may result If these lnstroc'Jons
are not followed.
WEAR YOUR !_WARNING: The opemtlon of any muter can result In
foreign objects being thrown into your ayes, which can
result In severe eye damage, Before beginning power
tool operation, ALWAYSwear safety goggles or safety
glasses with side shield and a full-face shield when
needed. We recommend aWlde Vision Safety Mask for
use overeyeglasses or standard safety glasses with
side shletd, available at Sears Stores or other Craftsman
Outlets,

lL'i_tr;li4--i,I lI r.-i-i;-ti 1-_
Z_ WARNING: BE SURE to read and understand etl Instruotlons In this
meneel before using this router.Failure to follow all Instructions may result
electric shock, fire and/or sertoua personal lnlury.
WORK AREA SAFETY
1. Keep your work ares clean and well lit, Clutteredworkbenchesand dark areas
Invite accidents.
2. DO NOT operate power tools In explosive atmospheres, such as In the presence
of flammable Ilqulds_gases, or dust. Powertoolscreate sparks whichmay Ignite
the dustorfumes,
3. Keep bystanders, children and visitors sway while operating s power tool
Distractions can cause you to lose control
4, Make your workshop ¢hlldproof withpadlocksand masterswitches Locktools
away whennot Inuse°
5. MAKE SURE the work area has erupts lighting so you can see the work and that
there are no obstructionsthat will Interiorswithsafe operationBEFORE using
yourroutes
PERSONAL SAFETY
1. KNOW your power tool. Read this operator'smanual carefully. Learnthe router's
applicationsand limitations, aswell as thespecificpotsnllal hazards relaled to this
tool.
2, STAY ALERT, watchwhatyou aredoingand use commonsensewhenoperating
apowertool.
3 DO NOT use tool while ttredor underthe Influence el drugs, alcohol or medications
A moment of Inattention whileoperatingpower tools may resutl tn sedouapersonal
Injury.
4. DRESS properly, DO NOT wear loose clothingorlswslry, Pull back long haft, Keep
your half+clothlng,and glovesaway from moving parts,Looseclothing,or long hair
can becaughtIn moving parts,Air vents often cover moving paPs and should also
be avoided.
5. AVOID accidental starting Be sureswitch Is In"OFF" position before pluggingIn,
DO NOT carrytools withyour finger on the switch,Carryingtools with your finger
on the swiloh or pluggingIn toolsthai have the switchtn the "ON" peellton Invites
accidents
6. REMOVE adjusting keys or blade wrenchesbefore tumlng ths tool "ON". A wrench
thatts tstt attached to arotatingpart ofthe toolmay resultInpersonalInjury.
7. Do not overreach. Keep proper footing end balance at all times, Proper footing
and balance enables belier conlrel of the toolin unexpectedsituations.
B. ALWAYS SECUREYOUR WORK, Use clampsor s vise to hold workplacesecurely,
It ts safer Ihen using your handand freesbothhandsIo operate tool
9. USE SAFETY EQUIPMENT, Always wear eyeprotection, Dust mask, non-skid safety
shoes, hard hat,or hearing protection must be used forappropriate conditions.
10o DO NOT USE ON A LADDER or unsf_ble support. Stablefooting on s soIld surface
enables better controlof the toolIn unexpectedsituations.

TOOL USE AND CARE SAFETY
/_ WARNING: BE SURE to read and understand all Instructions before
operating this muter. Failure to foliow all Instructions nsted below may result
In electric shook, tire and/or serious personal Injury,
!o ALWAYS use clamps or other practical ways to secure and support the workplace
to astable platform° Hokilngthe workby handoragainst yourbody ls unstableand
may iead !o loss of control
2_ DO NOT force the tool Use the correct tool and bit for your application. The correct
tooland bit willdo the Jobbetter end safer at the rotefor whichit IsdesTgned.
3DO NOT usa the tool If switch does not turn It "On" or "Off". Any toolthat cannotbe
controlledwith the switchIsdangerousand mustbe repaired°
4. DISCONNECT the plug from the power source before making any adjustmsnts,
changing sccceeorlea or storing the tool Suchpreventivesafety measures reduce
the riskof startingthe toolaccldantaliy,
5, NEVER leave the tool running, ALWAYS turn It off.DO NOT leave the tool until it
comasto a complete atop,
6 STORE Idle tools out of the reach of children and other untrained persona, Tools
aredangerous Inthehands ofunlmlnsduaem.
7. MAINTAIN tools with care. Keep cutting tools sharp and clean. Propedy maintained
too_ewithsharp cuttingedges are less Ukelyto bindand ere eaefer to control
8. CHECK for mleallgnmsnt or binding of moving parts, breakage of parts, and any
otherconditionthat may effect the tool's operat_onrifdamaged, have the toolserviced
before using, Many accidentsare caused by poody maintained tooIso
9. USE ONLY accessories that ere recommended for this tool Accessoriesthat may be
suttablefor one toolmay become hazardous whenused on anothertool
ELECTRICAL SAFETY
L_ WARNING: Do not permit fingers to touch the terminals of plug whenInalaltlng or removing the plug from the ouUst,
_. Double Insulated tools are equipped with apolarized plug (one blade Is wider
than the other),Thle plug will fit In a polarized outlet only one way. If the plug
does not fitfuily Inthe outlet,reverse the plug,If Itstilldoes not fit, contactaquallfied
electrician to _netal]s polarized ouUet Donot change the ptugIn anyway,
2 DoubleInsulal_on_ eliminates the need for the three-wiregroundedpower
cord and groundedpowersupp;y system,Applicable only to Class II (double-Insulated)
tools.This router motor Is double Insulated,
L_ WARNING: Double Insulation DOES NOTtake the place of normal safety 1
precautions when operating this tool J

ELECTRICAL SAFETY cont.
3. BEFORE plugg{ngIn the tool,BE SURE that the out]etvoltage supplied tswithinthe
voltage marked on the tool'sdata plate DO NOT use "AC onI_ ratedtools withaDC
powersupply.
4. AVOID body contact with grounded surfaces, such aspipes, redfr_tors,ranges and
refrigerators. There Isan Increased risk of electric shockIfyour body Isgrounded°
5 DO NOT expose power tools to raln or wet oondlUona or use power tools tn wet
or damp locations, Water entedngapower toolwl_IIncrease the riskof eTec_c shack.
6. INSPECT too! cords for damage. Havedamaged locicordsrepaired at a Sear
Service Centare,BE SURE to stayconstantlyaware of Ihe cordlocation and keep
tlwell away fromthe movingrouter.
7, DO NOT abuse the cord, NEVER use the cord to carry the tool by or to pull the
plug from the outlet° Keep cordaway fromheat, o11,sharpedges ormov]ngparts
Replacedamaged cordsfmmsdlatafy. Damaged cords Increase the dskof elsctrtc shock.
EXTENSION CORDS
Use aproper extension cord. ONLY usecordslistedby UnderwritersLabomtorlss(UL).
Otherextensioncordscan causeadrop In Ilnsvoltage, resulting Ina loseof power end
overheatingof tool. Forthistool anAWG (AmericanWire Gauge) size of at least 14-gauge
isrecommended for an extensioncord of 25-fL ortessIn lengh_,Use 12-gaugefor an
extension cordof 50-fL FJdenstoncords 10IPIt. or longer are not recommended°
Remember,a smaller wire gauge size has greater capacity then a larger number
(14-gauge wirehas more capacitythan 16-gauge wire;12-gauge wirehas morecapactty
than 14..gauge).When In doubtuse the smallernumber. When operating apower loci
ouldoore, usa an outdoor extension cord marked "W-A" or "W', These cordsare rated
for outdoorusa and reducethe dskof elactr_ shock.
/_,CAUTION: Keep ths extensloncordclear of the working eras.Position the
cord sothat it will nat get caughton lumber,tools or other obslruotlonewhite you
are workingwith a powerloolo J
_WARNING: Cheek extensioncordsbefore each use. If damaged replace I
Immediately. Never use Iool with adamaged cord since touching the damaged area I
could causeelectrical shock,resulting in seriousinjury,
SAFETY SYMBOLS FORYOUR TOOL
The Isbel on your tool rosy Include the following symbols.
V............................................ Vol_
A............................... Amps
Hz..................................... Hertz
W.................................... Waits
rain.................................................... Minutes
............................ Alternating current
................................... Directcurrent
no .................................... No-loadspeed
................................. ,Class11conslrucllon.DoubleInsulated
]mtn ................................... Revolutionsor Strokespermin_
Z_' ................................. IndIcatesdanger, warningorcaution
t! means attentionl Yoa_"safetyis involved
6

SERVICESAFETY
1,ifanypertofthisrouter Is missing or should break, bend, or fall tn any way;
or should any electrical component fall to perform properly: SHUT OFF
the powerswitchand removethe routerplugfromthe powersourceand have the
missing, damagedor felledpads replaced BEFORE resumingeperaUon_
2, Tool service must be performed only at e Seers Parts and Repair Center.
Serviceormaintenance psdom_sdby unqualifiedpersonnelcouldresult Ina
riskof tnjUryr
3. When servicing atool, use only Identlcel replacement parts, Follow Instructions
In the maintenance seoifon of this manual. Usa of unauthorizedpads or failureto
followmaintenanceInstructions may creels a dak of elecldc shockorlnlury.
SAFETY RULES FOR REUTERS
Cutter bite coast after router Is switched off. 1
CAUTION: ]
1, HOLDTOOL by Insulated gripping surfaces (handles) when performing an
operation where the cutting tool may contact hidden _dng or Its own cord.
Contactwiths =l_ve*w_rewltfmake the exposedmetaf partsof the tool"live"end
shock theoperator.
2. Maintain sfirm gripon the muter withbothhands to resiststarting torque
3_ NEVER attempt to use the router motor without first installing It In an approved
afixed or plunge approved baee_ Failure to heed thlswarning couldresultinpersonal
_jury and damage to the motor.
4, MAKE SURE the motor hooalng does not move up or down when damped In the
plunge base. ffmotor ls not securely clamped fn bess, adjustments will
not be scourers.
5. DO NOT HAND_HOLDTHE ROUTER iN AN UPSIDE DOWN OR HORIZONTAL
POSITION. The motor can separatefrom the base tf notpropedyattached according
to the lnsltuctione_
6, TIGHTEN COLLETI NUT securely to prevent the cutter bit from sgpplng, if the
collar/nutts not securely tlghiened,the cutterbit me,y deL_chduringuse,causlngsedous
personalinjury,
7, NEVER lighten collet/nut without acutter bit Installed In the toilet InuL
8,, USE CLAMPS or other practical ways to secure and support the workplece to
e stable platform end hold the workplace rigidly In position, Holdlngthe work by
hand or against yourbodyIsunstable and may lead to loss of control
9, NEVER hold the piece being out In your hands or across your legs. It isImpodant
to support and clampthe workplaceproperlyin orderto minimize body exposure,
bitbinding, orlose of control,
10, ALWAYS keep chip shield clean and In place,
11, STAYALERT and clear the Router cutter bit path of any obstructions BEFORE
starting the motor_ Keep cutting area clear of ag foreign ob|ecte while motor Is
runnlngo
12, CHECK 'tO SEE that the cord will not "hang up'during routing operation,

SAFETYRULESFORROUTERSconL
13MAKESUREthecutterbitIsnotInoontsct with the workplace before the switch
Is turned on.The bit must ALWAYS be running st fuU speed before contacting
the workplace,
14_ KEEP HANDS CLEAR OF CUTTER BIT when motor Is running to prevent
personal InIury,
15 PROVIDE CLEARANCE under workplece for router cutter bit when through-cuttieg_
16., KEEP CUTTING PRESSURE CONSTANT_Do not ovsrIoedthe motor.
17, USE ONLY sharp cutter bits that are not chipped or ¢rsckad_Blunt cutter bits
will cause stalling and bum the workplace,
18, NEVER use this muter motor with e cutter bit larger than 3_/Plnch In diameter.
19, ALWAYS USE cutter bits that are designed for this router. Never usecutter bits
which are larger In diameter than the opening In the router sub-base, Cutterbits
thathavecutter diameterslargerthanthe openingcouldcause poselb_a_oeeo! central
orcreateolher hazardousconditionthat couldcause eedoue personalInjury
20, The eubbese on this plunge bass muter has an opening of 1_h-lnehoTo use cutter
bits w_tha larger diameter, [natslland usas eubbasewith a larger diameteropening
(sold separately) at Sears stores or otherCraltsman outlets
21. DO NOT use large router cutter bits for freehand routing. Use oflarge cutter btte
whenfreehand routingcouldcause lossof control or createhazardousconditionsthat
couldreeufl Inseriouspersonal injury
22,, BE SURE CUTTER BIT Is centered In template guide (sold eeperatsly) prior to
tamplsta guide applications to avoid personal Injury or damage to finished work.
23, DO NOT REMOVE more than l/e,tnch In a single pass. Excaesh,edepth of cut can
recultIntoss of control thatcouldresuitInpersonatInjury,
24, Aftercompletingecut,turn motor OFF and letit coma toacompletestop
BEFORE REMOVING muter from workplace,
25. Let the motor come to aCOMPLETE STOP before putting the muter dowm Cutter
bits coast uttsr power Isturned off,
26. DISCONNECTTHETOOL FROM POWER SOURCE before msldng any sdtL_stments
or changingcutter bits,
27_ If you are changing abit Immediately after usa, BE CAREFUL NOTTO1OUCH
the cotter/nut or cutter bit with your bends or fingers.The heat buildup from
cutting could cause severe burua_ALWAYS use the wrench provided.
28, AVOID "CLIMB CUTTING". See "OPERATION" (pages 0Oand 00) eecUon
In this manual "el}rob-cutting" increasesthechancefor lossel controlresultingin
possibleserious injury'

L_ WARNING: Use of this tool can generate duet contBlnlng chemicals
known to cause cancer, birth defects or other reproductive harm°
Some examples of these chemicals are:
.Lead from lead-basedpoints,
•Crystalline stiles from bricks end cement and other masonry producle.
•Arsen{c and chromlumofrom chemtca!lytreated lumber.
Your risk from these exposures varies, depending upon how often you
do this type of work.To reduce your exposure to these chemicals"
•Work In s wellwenttletedarea,
•Work withapproved safety equipment,such ea thosedust masks
thatere speclafly designed tofilterout microscopic paffJclea,
Avoid prolonged contact with duet from power sending, sewing, grinding
drilling end other construction activities.Wear protective clothing end wash
exposed apacewith soap and water. Allowing duet to get into your mouth,
eyes, or lay on the skin may promote absorption of harmful chemicals.
L_ WARNING: Use of this toot sen generate end/or disburse dust, which
may cause sedoue and permanent respiratory or other Injury. Always use
NIOSWOSHA approved respiratory protection apprepdate for the duet exposure.
Direct perOsles away from face end body.
ADDITIONAL RULES FOR SAFE OPERATION
Ak WARNING: BE SURE to road and understand ell Instructions. Failure to /
follow all Instructions listed below may result tn elecffrle shock, fire and/or J
eeffoue personal tnJury,
1. Know your power tool Read this operator's manual carefully, Learn the eppflcaUone
ertd limitations, as well as the apeclflcpotenllal hazards related to thistool. Following
thisrulewlllreduce the riskof electricshock,fireorserious Injury.
2o ALWAYSwear safety glasses or eye shields when using this router. Everyday
eyeglasseshaveonly tmpact-reslstant lenses; theyare NOT safetyglasses,,
3o PROTECT your lungs. Wear a face meek or dust meek ifthe operationIs dusty.
4, PROTECT your hearing. Wear sppropdalepersonalhearing protectiondudng use
Undersome conditionsnoisefrom thisproductmay contributeto hearingloss
5, ALL VISTORS AND BYSTANDERS MUST wear lhe same safety equipmentlhat the
operatorofthe routerwears,
6, INSPECT the tool cords periodically and If damaged have them rrepelredst your
nearest Sears Service Center, BE AWARE of the cord locetlon,

ADDITIONAL RULES FOR SAFE OPERATION cent.
7. ALWAYS check the tool for damaged perta, Beforeludhsr use of thetoo!,a guard or
other partthatIs damaged should be carefullychecked todetermine ffIt will operate
propedyand performIts Intended funstlon. Checkfor mlsallgnment or bindingof
moving parts,breakage of paris, and any other conditionthatmay affect the tool's
opera!Ion.A guard orother pertthat la damaged shouldbe properlyrepaired or roptacad
at e Sears ServiceCente_
8. INSPECT and remove all nails from lumber before routing.
g. SAVE THESE INSTRUCTIONS. Refer to them frequently and use them to Instruct
others who may use thls tool. If someone borrows this toot, make ours they have
these Instructions also=
Z_ WARNING: Your rreuter should NEVER be connected to the power source
when you are asssmb!lng parts, maldng adjustments, Installing or removing
collate /nuts,cutter bits, cleaning orwhen It Is not In use, Dfsconnsctlng the
muter will prevent accidental starting, which could cause serious personal
Injury,
When unpacking the box don't discardanypackingmaterials unltt all of thecontents are
accountedfor:.
1. Carefullylift the Router Motor and Plunge Base withthe li2-1n, collar/nut already
Installed, outof the cartonend place on a stableflat surfase.
2Open thepartsbag to locate the following:
•Sawdust Extraction Hood and 2 Screws usedto attachhood to base
•1/4-in. Col!st/Nut
•Conet/Nut wrench
& Inspect the Items carefutFyto makesurethat nobreakage ordamage hasoccurred
during ahlpplng Ifany of the llama mentioned are missing, (refer to "PARTS LIST"
IlIuslratlon on page 11), returnthe routerto your nearestSears store or Craftsman
outlet to have the muter replaced.
z_ WARNING: If any parts are broken or mlselng, DO NOT attempt to plug
In the power cord or operate muter until the broken or missing parts are
repfaced_Failure to do so could result In possible serious Injury.
10

PARTSLIST(Fig.1)
t.RouterMotorInPlungeBaseandv_V2._r_.Co_l_Nut(_
2_ Sawdust
Exttsctton Hood
3, 2 Screws
(for attaching Hood)
4_ 1/4-1n.Collar/Nut
5. Conet/Nut Wrench
KNOWYOUR PLUNGE ROUTER (Fig. 2)
INOTE:Before effemptlng to use your router, familiarize yourself with all of the
operating features and safety requirements,
Yourplungemuter haBaprecrslon-bulft electricmotor and It shouldonEybe connected
to e120-volt,60-Hz AC ONLY power supply (normal householdcurrant),DO NOT operate
on directcurrent(DO). Thislarge voltage dropwillcause aIo_e of powerend the motor
wiltoverheat, if the muterdoes not operate whenpluggedfntoacorrect120-volt,
60*Hz AC ONLY outlet, check the powersupply."131tsrouterhas en 8-ft, 2-wire power
cord (no adapterneeded).
11

I] :::b-_;11_ II[e)_l';T_i
KNOWYOUR PLUNGE ROUTERconL (Figo2)
This Plunge Router has the following features:
1. Powerful,9.5 Amp Soft Start Motor develops 13/4Peak HP to handle most
routing Jobs
2Single speed 2S 000 RPM (no-lsed speed) helpsprovidea quality finish
in mostmatarlals
3. Plunge Base features fineand microdepth mdadJuatmenls withturretstops
for predse set-ups and repetitivecutting,
4 Spindle Leek foreasy l-wrench bit changes.Includes 1/4-1n,end 1/2-1n.
self-releasing collate/nuts for use withawldavadety of I/4-1n,and 1/2-In.router
blts,soldseparately.
5_ 100% Bali Baarlnga foFsmooth,efficient operation and !ong Ilteo
6, Base features Ergonom!oally Deelgnod Handles forcomfort.
maximumcontrol.
7 Basefeatures Isrge base opening and large ¢hlp shield, combined with 3 LED
worldlghts on motor to provtdathe highestvlslbflltyof bit and workplecoo
8. Durable Non-marring Sub-base gfldcesmoothlyover workplace.Sub-bess has
culter-bltopeningof 1t/4.1nches.Do Not Use e bit withacutterdismetar larger than
1V4-in.as It WIUnot passthroughthe sub-base opentngl
9. Base constructed of Die-Cast Aluminum toprovidedurability and stabIlIty.
10. Motor Housing constructed of High Density Nylon end Precision Milled Cast
Aluminum for stranglh and exact fit into bess.
11. High.ImpactresistantMotor Houelng Top Cap and Handles on Base help
protecttoolfrom damage_
12. Convenientlylocated On/Off toggle switch, aide mounted for added visibility,
easy acoess.
13. Sawdust oxtl'aelJonhood atiowa base to hook up to 1V4-inchvachose attachment,
sold separateiy
14o "LIVETOOL INDICATOR" light Isgreen when saw tsp|uggadIntoa power
source. Light fs locatedon motorhousing topcap next to powercord IntaL
15. Rap|seeable Brushes (soldseparately) fordependable service.
12

I ; " lk ill
KNOWYOUR PLUNGE ROUTER conL (Fig, 2)
Motor housingpmcIs_oo
mlltedcastaluminumforexa_ fit
Super-fine
edJustrnsnt knob
Plungeeub.b_e
13

Rating
No4oad Speed
Peak HP
Inpul
Cogets!Nuleand Culler BitShank Otamators
Plunge Base Dtameler
Sub Base Opening (Dtameler forculter b|t use)
Sub BaseThickness
.................,,,, ,,, ,,,,,, ..... , , ,
PlungeBase Depth of Cut
9.5 Amps
2'5,000RPM
1_I_
12D-voile.6OHz.AC
lt4-tn, l12-tn,
6_llE-Inches
1t/_-|nches
o,23-=,_hesC6rnm)
2Ve-tnches(55ram)
NOTE=This tool Is ehlpped completely assembled.To Install or remove bits
or add accessories such as sawdust ejection hoods for hook-up to vscs, see
the following Instructions,
SELECTING THE CUTTER BIT
This router comes wilh1/4-In, and It24n. collate/nutsthataccept 1/4and ll2-lnch
diametershsnked ,,::tilterblte_
Z_ WARNING: Do not use router cutter bits that have a cutter bit dlsmstsr
larger than 1_h-lnchss as they will not fit through the sub-base openlng_and
will cause damage to the sub"base, the motor, and could cause serious personal
Injury to the operator.
NOTE=The sub-base Installed on this router has an opening of t_14.lnches,
To use cutting bits with a larger dlsmetsr, use s subbase with a larger opening,
sold separately at Sears stores or other Craftsman outlets.
Z_ WARNING: ALWAYS tum motor off and unplug router before maldng any
adjustments or Installing sccessorfes. Failure to unplug the router could result
In accidental starting which can cause serious peraonsl Injury.
14

INSTALLING AND REMOVING THE CUTTING BIT (Figs. 3,4 and 4a)
INSTALLING THE CUTTER BIT
1, Turn motoroffand unplugfrom powersource.
2. Removemotorhousingfrom plungebase.
_Fig°4
--Bit Shank
NOTE: See Instructions on removing and Installing the motor housing from the
plunge baseon page 17.
3. Set the molar upsidedown on Its topcap,withcofleVnutpotnUngup.
4. Pressspindlelock buttonto engage and lock the splndte shaft and caller!nut,(Fig. 3),
5. Placethe wrench on the coIlal/nutandturn countar-clockw|se and loosen colleVnut
eNghtlyto accept cutterbit shank,
6. Insert cutter bit shank lnlo coflel/nutassembly as far ae Itwillgo, thenback the shank
out untllthecuttersare approximately 1t8to 1/4-Inchaway fromthe face of the
coileVnut(Fig°4, 4a)
7. With culler bit Inserted and spindlelock bulton pressedIn engaging shaft,place wrench
on collet/nutand turnclockwiseunU[routercutter bit and cotlaVnutera firmlylightened.
WARNING: TIGHTEN COLLETiNUT SECURELY to prevent the cutter bit
from slipping, ffthe caller/nut Is not securely tightened, the cutter bit may detach
during use, causing serious personal injury
NOTE:To ensure proper gripping of cutter bit shank and minimize run-out_ the
shank ofthe cutter bit must be Inserted Into the caller/nut at least 5/8-inch,
/_ CAUTION'To prevent damage to tool, do not tighten coltet/nut without
acutter bit Installed°
15

REMOVING THE CUTTER BIT (Figs. 3 end 4 see page 15)
1+ Turnmotor offand unp|ugfrom power source
2 Remove motor from plungebase
3+ Set the motorupsidedown on _tetopcap,with co!let/nutpolnl+ngup+
4+ Pressspindle+ockbutton to engage and lockthe spindle shaft end colteVnut,(Rg, 3),,
5+ Place the wrench on thecotlet!nutand turn counter-clockwiseand loosen co_laVnut
s[IghUyand removecutterbit shank
COL.LET/NUT CARE
From time to time, Inspect the colleVnutto make sure it is cleanand Is grippingthe cutler
bit properly.
With the router cutter bit removed, lure the colleVnutcounterclockwise(with spindlelock
engaged) until it tefree from motor's spindleshaft.
Blowthe colletout wghcompressedsir, and cleanthe t_pered inside of the coIleVnutwith
a tissue orfine brush+
Always make sure the cutterbit shank,coital/nutand motor spindleare clean and freeof
wcodchlps,dust,residue, grease and rustbefore Installing.
Apply aslight amount of machine o11to spindle shaftIfit looksdry.
Replaceworn or damagedcollate/nutsimmediately+
NOTE:The collar/nut Is aalf-mleeelng; It Is NOTnecessary to strike the |
collar/nut to free the router cutter bit. If cutter bit seems stuck after use, loosen J
toilet/nut a little more until It releases.
CUTTER BITS
Get faster+more accurate cutting results by keeping cutterbits cleanand sharp+Remove
al_accumulated pitch and gumfromcutterbite aftereach use.
When sharpeningcutterbits, sharpen only the Inside of the culttngedge, Never grindthe
outsidediameter.Ba sure,whensharpeningthe end of acutterbit, to grind the clearance
angle the same as originally ground
INSTALLING ROUTER MOTOR IN BASE
Z_WARNING: NEVER use the muter motor without Installing It Into the
plunge base+Failure to do so could result In serious personal Injury and damage
to motor,
NOTE: Before Installing motor housing In fixed base, have the toilet/nut and
router cutter b.ltyou are going to use already Installed In motor housing+
See page 15' INSTALLING AND REMOVINGTHE CUTTER BIT".
Z_ WARNING: ALWAYS turn motor off and unplug muter from power source
before making any adjustments or Installing accessories. Failure to turn motor off
and unplug router could result in accidental starting which can cause sedoua
personal Injury+
16

INSTALLING ROUTER MOTOR
tNBASE (Rg,5)
1, Turnmotoroffandunplug
frompowersource,
2. Place plungebasson fiat surface.
3_ Withback ofplunge basefacing
you,open motor clamp (A) and
makesureplungeaction IsIn
"UP" poslt[on,with theplunge
lock laver (B) locked down.
4. Wtthmotor houslng'a kayatrlp (C)
aligned withptungabass ksystrlp
slot (D), lowermotorhousingInto
Fnlungebase engaging keyetdp
_okeyetdp-sloL
5, SlidethemotorIntothebase
asfarastlwittgo(E),
B, Close the motorclampsecurely.
Fig. 5
INOTE: When maldng depth adjustments on the plunge base, the motor clamp
should always be closed securely.
REMOVING MOTOR FROM BASE (see Fig_ 5)
1Turn motor off and unplug from power source
2 Place router (plunge base and meier housing) on ll_t surface
3With back of plunge base factng you, open motor clamp (A) and make sure plunge
action is in "UP" position, with the plunge lock lever (B) locked down
4 Liftmotor straight up oul of base, eliding motor houstng'e"keystrtp" (B) tree from
"keyetrlp slot" (C) in plunge base
5Set motor upside down on its top sap withso,let pointing up, remove bit, and slore
motor and base when not being used
Z_ WARNING: ALWAYS remove culler bits lrom colleb'nut when the router ]
Is not bethg used. Leaving bits installed could result in an accident causing I
sertous personal lnjury_
17

ADJUSTING DEPTH OF CUT
I_WARNING: ",'ourrouter should NEVER turned ON or be connected to
the power source when you are assembling parts, making adjustments,
Installing or removing toilets /nuts, cutter bite, cleaning or when it is not
in use. Disconnecting the router will prevent occidental starting, which could
cause serlous personal lnjury_
PLUNGING ACTION (Fig. 6)
The plungebasefeature slmplffles depth edtuatmentsand allows thecuttingblt to be
accurately |owered down Intothe workplacefor morepreciseset-ups.
To tower the cattingbit, release the ptunge_lockleverby movingit "Up"
to the unlocked posff!on.
Apply an evendownward preBsura on the plungeaction untilthe bit reaches the desired
depth, thenmovethe plunge-locklever "Down"to the locked position.
To raise the bitand the plungeeotlon
unlockthe plungetook Ieverend the
bitand plungeaction wlti
automatically retractfrom Fig. 6
the workplaceand returnto the
raisedposition.
Alwayshave the plungeaction
In the raisedpositionand locked
whenthe blt Is not cutltng
tn theworkplace.
S]otCutting
18

DEPTH-STOPRODANDDEPTH-STOPTURRET(Figs,,7andS)
TheDepth-StopRodandtheDepth-StopTurretareusedtocontrolthe
cuttingdepthasfollows:
tTurn motor off and unplug from power source
2 With the cutting bit already installed,Iowar the plungeaction until thecutter bit makes
contact withthe f_at,level surface the router is sitting on, Lock the plunge depth
locking lever (F}oThis positionisZERO - "0" lrom which furtherdepth adjustments
can be made
3 To set adesireddepth-el-cut, rotate depth-stop turretuntil theLowest step of the
turret (A) isaligned dlreegy under the Depth*Stop Rod (B) (see I]g 10),
Loosenthe Depth Rod Locking Knob and lower the depth-stop rod untilit
contactsthe lowest step on the turret
Slide the Clear Plastic Depth-tndlcstor (D) until the red line on the indicator is lined up
with ZERO - "0", marked in black on the bottom of the depth scale, (Thls is now the
indicating point at which the bit makes contact wi|h the workpiece)
To set a desired cutting depth, slide the Depth-Stop Rod up until lhe Red Line
on the Clear Plastic Depth-indicator points to your desired curling dep|h on Ihe
Depth Scale (E), Secure the
Depth-Stop Rod st thls (_
position by tighleniog the Depth
Rod Locking Knob
5 Unlock the Plunge Lock Lever(F) to
allow the bit to automatically retract
to theup position
The desired depth-of-cut may now be
achieved by plunging the router down
unltt the depth-stop rod conlacts the
selected step en the depth-stop turret
Fig- 7
NOTE,'When making depth adjustments on the plunge base_the motor clamp |
"1
should always be c!osed securely. !
19

MakingDeepCutswiththeDepth-StopTurret(Fig,8)
ere eastly broken bytoo much side thrust and torque. Larger cutter bits will
cause a rough cut and be difficult to guide and conlrot For these reasons,
DO NOT EXCEED 118-1N.DEPTH OF CUT in a single pass.
To produce deep cuts, always make severai progressively deeper cuts by starting wtlh
the Highest Step on the depth-slop turret, and after each cut rotate the turret to the next
towesl step until the linal Lowest or Last step is roached
Eaoh o! the 4 eleps progresses by "tt4th-tn. increments.The 4stepsrepresent e tota!
of "O"-in to 314-[n.with a fu}l360_rotation of th_ turret Repeat this process il necessary
Micro Adjustments with the Depth-Stop
Rod and Depth-Stop Turret
The Depth-Stop Rod has e Micro
Adjustment Knob (A) thatturnsescrew (B)
(_nsldethe rod) either clockwiseor
counterclockwise (lowedng or raising) the
depth=stoprod on the turret (C) formicro-fine
adiuslmenls of the p_nge depth
Each complete revolution of the Micro
Adjustment Knob adjusts the plunging depth
by 5f127th inch
A reference indicator tins is embossed inlo the
Depth-Stop Rod under lhe line-adjustment knob
to set "0",
When micro-adjusting the plunge depth,
before setting the Depth-Stop Rod end
Depth-Stop turret, always make sure the
micro adjustment screw has been turned
down (clockwise) several revolutions from
its top, or starting position, so It can be
adjusted upward.
Always set your micro adjustments with the plunge ectton in the RAISED,
(or up) positlon_ and locked down.
To use the micro adjustment knob once tile depth rodand turrethave been set. check
the final depth setting end micro ad}ust as foltows:
• Tomicro-increase the plunge depth, raise the micro adjustmentscrew by turning
the knob counlerclockwlse the desired amount
• Tomicro-reduce Ihe plungedepth, Iower the micro adjustmentscrewby turning
the knob clockwisethe desiredamount
211