Craftsman 320.27669 User manual

Operator's Manual
12.0 Amp, Variable Speed,
2Peak HP Digital Plunge Base
Router
Model No. 320.27669
!i
WARNING: To reduce the risk of
injury, the user must read and
understand the Operator's manual
before using this product.
00°s
• WARRANTY
• SAFETY
• UNPACKING
• DESCRiPTiON
•OPERATION
• MAINTENANCE
• TROUBLESHOOTING
•ESPANOL
Sears Brands Management Corporation, Hoffman Estates, iL 60179 U.S.A.
www,craftsman,com

Warranty page 2
Safety Symbols page 3-4
Safety Instructions page 5-10
Unpacking Page 10-11
Description page 12-14
Operation page 15-31
Maintenance page 32-33
Troubleshooting page 34-36
Exploded View and Part List page 37-43
Sears Repair Parts Phone Number Back Cover
CRAFTSMAN ONE YEAR LIMITED WARRANTY
FOR ONE YEAR from the date of purchase, this product is warranted
against any defects in material or workmanship. With proof of
purchase, defective product will be replaced free of charge.
For warranty coverage details to obtain free replacement, visit the
web site: www.craftsman.com
This warranty is void if this product is ever used while providing
commercial services or if rented to another person.
This warranty gives you specific legal rights, and you may also have
other rights which vary from state to state.
Sears Brands Management Corporation, Hoffman Estates, IL 60179
A
AI& WARNING: Some dust created by using power tools contains chemicals
known to the state of California to cause cancer and birth defects or other
reproductive harm.
SAVE THESE INSTRUCTIONS!
READ ALL INSTRUCTIONS!
This router has many features for making its use more pleasant and enjoyable.
Safety, performance, and dependability have been given top priority in the
design of this product making it easy to maintain and operate.
27669 ManuaLRevised_11 0215 Page 2

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 symbol warnings do not, by themselves,
eliminate any danger. The instructions and warnings they give are no
substitutes for proper accident prevention measures.
WARNING: Be sure to read and understand all safety instructions in this
manual, including all safety alert symbols such as "DANGER," "WARNING,"
and "CAUTION," before using this router. Failure to follow all instructions listed
in this manual may result in electric shock, fire and/or serious personal injury.
SYMBOL SIGNAL MEANING
,_ SAFTY ALERT SYMBOL: Indicates DANGER, WARNING, OR CAUTION.
May be used in conjunction with other symbols or pictographs
,_ DANGER: Indicates a hazardous situation which, if not avoided, will result
in death or serious injury. This signal word is to be limited to the most extreme
situations .Always follow the safety precautions to reduce the risk of fire,
electric shock, and personal injury.
_, WARNING: Indicates a hazardous situation which, if not avoided, could
result in death or serious injury. Always follow the safety precautions to reduce
the risk of fire, electric shock, and personal injury.
,_ CAUTION: Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury. It may also be used without the safety alert
symbol as an alternative to "NOTICE"2 Always follow the safety precautions to
reduce the risk of fire, electric shock, and personal injury.
NOTICE: "NOTICE" is the preferred signal word to address practices not
related to personal injury. The safety alert symnol not be used with this signal
word. As an alternative to "NOTICE", the word "CAUTION" without the safety
alert symbol may be used to indicate amessage not related to personal injury.2
Damage Prevention and Information Messages
These inform the user of important information and/or instructions that could
lead to equipment or other property damage if they are not followed. Each
message is preceded by the word "NOTE," as in the example below:
NOTE: Equipment and/or property damage may result if these instructions are
not followed.
,_ WARNING: To ensure safety and reliability, all repairs should be performed
at a Sears Parts & Repair Service Center.
WARNING: The operation of any power tools can result in
foreign objects being thrown into your eyes, which can result in
severe eye damage. Before beginning power tool operation,
always wear safety goggles or safety glasses with side shield
and a full face shield when needed. We recommend a Wide
Vision Safety Mask for use over eyeglasses or standard safety
glasses with side shields. Always use eye protection which is
marked to comply with ANSI Z87.1
27669 ManuaLRevised_11 023_5 Page 3

SAVE THESE iNSTRUCTiONS
Some of the following symbols may be used on this tool. Please study them
and learn their meaning. Proper interpretation of these symbols will allow you to
operate the tool better and more safely.
SYMBOL NAME DESIG NATION/EXPLANATION
V Volts Voltage
A Amperes Current
Hz Hertz Frequency (cycles per second)
W Watt Power
min Minutes Time
Alternating Current Type of current
Direct Current Type or a characteristic of current
n o No Load Speed Rotational speed, at no load
] Class II Construction Double-insulated construction
.../min Per Minute Revolutions, strokes, surface speed,
orbits, etc., per minute
Wet Conditions Alert Do not expose to rain or use in damplocations.
To reduce the risk of injury, user must
Read The Operator's Manual read and understand operator's manual
before using this product.
O Always wear safety goggles or safety
Eye Protection glasses with side shields and a full face
shield when operating this product.
_1_ Alert Precautions that involve
Safety your safety.
No Hands Symbol Failure to keep your hands away from theblade will result in serious personal injury.
Failure to keep your hands away from the
No Hands Symbol blade will result in serious personal injury.
Failure to keep your hands away from the
No Hands Symbol blade will result in serious personal injury.
No Hands Symbol Failure to keep your hands away from the
blade will result in serious personal injury.
Hot Surface To reduce the risk of injury or damage,
avoid contact with any hot surface.
27669 ManuaLRevised_11 0215 Page 4

GENERAL POWER TOOL SAFETY WARNINGS
,_ WARNING: Read all safety warnings and instructions. Failure to follow
the warnings and instructions may result in electric shock, fire and/or serious
injury.
= Know your power tool. Read the operator's manual carefully. Learn the
applications, as well as the specific potential hazards related to this tool.
Following this rule will reduce the risk of electric shock, fire or serious injury.
= Save these instructions. Refer to them frequently and use them to instruct
others who may use this tool. if someone borrows this tool, make sure they
have these instructions also.
=The term "power tool" in the warnings refers to your mains-operated
(corded} power tool or battery-operated (cordless) power tool.
WORK AREA SAFETY
= Keep the work area clean and well lit. Cluttered or dark areas inviteaccidents.
=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.
=Keep children and bystanders away while operating a power tool.
Distractions can cause you to lose control.
ELECTRICAL SAFETY
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
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.
Do not expose power tools to rain or wet conditions. Water entering a
power tool will increase the risk of electric shock.
Inspect the tool cords periodically and, if damaged, have them repaired
at your nearest Sears Service Center. Be aware of the cord location.
Do not abuse the cord. Never use the cord for carrying, pulling or
unplugging the power tool. Keep the cord away from heat, oil, sharp
edges or moving parts. Damaged or entangled cords increase the risk of
electric shock.
= 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.
27669 ManuaLRevised_11 0215 Page 5

• If operating a power tool in a damp location is unavoidable, use a
ground fault circuit interrupter (GFCl} protected supply. Use of a GFCI
reduces the risk of electric shock.
PERSONAL SAFETY
®
®
Stay alert, watch what you are doing and use common sense when
operating a power tool. Do not use the tool while tired or under the
influence of drugs, alcohol, or medication. A moment of inattention while
operating power tools may result in serious personal injury.
Know your power tool. Read the operator's manual carefully. Learn the
applications, as well as the specific potential hazards related to this tool.
Following this rule will reduce the risk of electric shock, fire or serious injury.
Always wear safety glasses or eye shields when using this router. Everyday
eyeglasses have only impact-resistant lenses; they are not safety glasses.
Protect your lungs. Wear a face mask or dust mask if the operation is dusty.
Protect your hearing. Wear appropriate personal hearing protection during
use. Under some conditions noise from this product may contribute to
hearing loss.
All visitors and bystanders must wear the same safety equipment that the
operator of the router wears.
Prevent unintentional starting. Ensure that the switch is in the OFF-position
before connecting to a power source and/or battery, 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.
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.
Do not overreach. Keep proper footing and balance at all times. This
enables better control of the power tool in unexpected situations.
Dress properly. Do not wear loose clothing or jewelry. Keep your hair,
clothing and gloves away from moving parts. Loose clothes, jewelry or
long hair can be caught in moving parts.
If devices are provided for the connection of dust extraction and
collection facilities, ensure that these are connected and properly used.
Use of these devices can reduce dust-related hazards.
POWER TOOL USE AND CARE
• Do not force the power tool. Use the correct power tool for your
application. The correct power tool will do the job better and more safely at
the rate for which it was designed.
27669 ManuaLRevised_11 0215 Page 6

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.
Always check the tool for damaged parts before use. Before further
use of the tool, a guard or other part that is damaged should be carefully
checked to determine if it will operate properly and perform its intended
function. Check for misalignment or binding of moving parts, breakage of
parts, and any other condition that may affect the tool's operation. A guard
or other part that is damaged should be properly repaired or replaced at a
Sears Service Center.
Disconnect the plug from the power source and/or the battery 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.
=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.
Maintain power tools. Check for misalignment or binding of moving
parts, breakage of parts and any other condition that may affect the
power tool operation. If damaged, have the power tool repaired before
use. Many accidents are caused by poorly maintained power tools.
• Keep cutting tools sharp and clean. Properly maintained cutting tools with
sharp cutting edges are less likely to bind and are easier to control.
•Use the power tool, accessories, 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.
_, WARNING: When using power tools, basic safety precautions should always
be followed to reduce the risk of fire, electric shock, and personal injury.
_. WARNING: The operation of any tool can result in foreign objects being
propelled into your eyes, resulting in severe eye damage. When operating
power tool, always wear safety goggles or safety glasses with side shields and
a full face shield when needed.
WARNING: if any parts are missing, do not operate the tool until the missing
parts have been replaced. Doing so could result in serious personal injury.
SERVICE SAFETY
• Nave 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.
27669 ManuaLRevised_11 0215 Page 7

If any part of this router is missing or should break, bend, or fail in any
way; or should any electrical component fail to perform properly: shut off
the power switch and remove the plug from the power source and have the
missing, damaged, or failed parts replaced before resuming operation.
• Tool service must be performed only at a Sears Parts & Repair Service
Center. Service or maintenance performed by unqualified personnel could
result in a risk of injury.
Use only identical replacement parts when servicing a tool. Follow the
instructions in the maintenance section of this manual. Use of unauthorized
parts or failure to follow maintenance instructions may create a risk of
electric shock or injury.
SPECiFiC SAFETY RULES FOR ROUTER
®
®
Hold power tools by insulated gripping surfaces when performing an
operation where the cutting tool may contact hidden wiring or its own cord.
Contact with a "live" wire will make exposed metal parts of the tool" live" and
shock the operator.
Use clamps or another practical way to support and secure the
workpiece to a stable platform. Holding the work by hand or against your
body leaves it unstable and may lead to loss of control.
Maintain a firm grip o the router with both hands to resist starting torque.
Never attempt to use the router motor without first installing it in an
approved fixed base. Failure to heed this warning could result in personal
injury and damage to the motor.
Make sure that the motor housing does not move up or down when
clamped in the fixed base. If the motor is not securely clamped into the
base, injury could result and adjustments will not be accurate.
Do not hand=hold the router in an upside down or horizontal position.
The motor can separate from the base if not properly attached according to
the instructions.
®
®
®
®
Tighten the coliet/nut securely to prevent the cutter bit from slipping, if
the collet/nut is not securely tightened, the cutter bit may detach during use,
causing serious personal injury.
Never tighten collet/nut without a cutter bit installed in the collet/nut.
Never hold the piece being cut in your hands or across your legs. it is
important to support and clamp the workpiece properly in order to minimize
body exposure, bit binding, or loss of control.
Always keep the chip shield clean and in place.
Stay alert and clear the router cutter bit path of any obstructions before
starting the motor. Keep cutting area clear of all foreign objects while the
motor is running.
27669 ManuaLRevised_11 0215 Page 8

= Inspect and remove a[[ nails from lumber before routing.
= Check to see that the cord wi[[ not "hang up" during routing operation.
= Make sure that the cutter bit is not in contact with the workpiece before
the switch is turned on. The bit must always be running at full speed before
contacting the workpiece.
= Keep hands clear of the cutter bit when the motor is running to prevent
personal injury.
= Provide clearance under the workpiece for the router cutter bit when
through-cutting.
= Keep cutting pressure constant. Do not overload the motor.
= Use only sharp cutter bits that are not chipped or cracked. Blunt cutter bits
will cause stalling and burn the workpiece.
= Never use this router motor with a cutter bit larger than 3=1/2 inches in
diameter.
Always use cutter bits that are designed for this router. Never use cutter
bits which are larger in diameter than the opening in the router sub-
base. Cutter bits that have cutter diameters larger than the opening could
cause possible loss of control or create other hazardous condition that could
cause serious personal injury.
The sub-base on this fixed base router has an opening of 1=1/4 inches.
To use cutter bits with a larger diameter, install and use a sub-base with a
larger diameter opening (sold separately at Sears stores or other Craftsman
outlets).
Do not use large router cutter bits for freehand routing. Use of large
cutter bits when freehand routing could cause loss of control or create
hazardous conditions that could result in serious personal injury, if using a
router table, large bits should be used for edging only.
Be sure that the cutter bit is centered in a template guide (sold
separately) prior to template guide applications to avoid personal injury or
damage to finished work.
Do not remove more than 1/8 inch in a single pass. Excessive depth of
cut can result in loss of control that could result in personal injury.
After completing a cut, turn the motor OFF and let it come to complete
stop before removing router from workpiece.
Let the motor come to a complete stop before putting the router down.
Cutter bits coast after the power is turned off.
Only use router tables with on=board switch=controlled receptacles.
Failure to use router tables with all the appropriate safety features could
result in serious personal injury.
27669 ManuaLRevised_11 0215 Page 9

Disconnect the tool from the power source before making any
adjustments or changing cutter bits.
if you are changing a bit immediately after use, be careful not to touch
the collet/nut or cutter bit with your hands or fingers. The heat buildup
from cutting could cause severe burns. Always use the wrench provided.
Avoid "climb cutting;" see "OPERATION" section in this manual "Climb cutting"
increases the chance for loss of control resulting in possible serious injury.
,_ WARNING: Your router should never be connected to the power source
when you are assembling parts, making adjustments, installing or removing bits,
cleaning, or when it is not in use. Disconnecting the router will prevent accidental
starting, which could cause serious personal injury.
When unpacking the box, do not discard any packing materials until all of the
contents are accounted for:
1.
2.
Carefully lift the router out of carton and place it on a stable, flat surface.
Open the carton to locate the following:
• Vacuum port and 2 screws used to attach it to the base
Chip shield ( already installed on router )
1/4 inch .collets/nut ( (the 1/2 in. collet/nut is already installed on router )
Collet/nut wrench
Depth-Adjustment Wrench
• Edge Guide
Manual
3. Inspect the items carefully to make sure that no breakage or damage has
occurred during shipping. If any of the items mentioned is missing, (refer to
"PARTS LIST" illustration), return the router to your nearest Sears store to
have the router replaced.
WARNING: If any part is broken or missing, do not attempt to assemble the
router, plug in the power cord, or operate the router until the broken or missing
part is replaced. Failure to do so could result in possible serious injury.
27669 ManuaLRevised_11 0215 Page 10

CARTON CONTENTS/LOOSE PARTS (Fig.l)
Plunge Base and Digital Router motor with 1/2 inch Collet/
Nut
Vacuum Port
Chip shield ( already installed on router )
2 screws (for attaching vacuum port)
1/4 inch Collet/Nut
Edge guide
Depth-adjustment wrench
@_ Collet/Nut wrench
27669 ManuaLRevised_11 0215 Page 11

KNOW YOUR DiGiTAL ROUTER (Fig. 2)
NOTE: Before attempting to use your router, familiarize yourself with all of the
operating features and safety requirements.
Your plunge base router has a precision-built electric motor and it should only
be connected to a 120-volt, 60-Hz AC only power supply (normal household
current). Do not operate on direct current (DC). This large voltage drop will cause
a loss of power and the motor will overheat. If the router does not operate when
plugged into a correct 120-volt, 60-Hz AC only outlet, check the power supply.
This router has an 8-ft., 2-wire power cord (no adapter needed).
Fig. 2
Motor housing precision
milled cast aluminum for exact fit Digital display
housing
Super-fine
adjl
Depth indicators
Toggle Switch
base
Depth rod
knob
_indle lock
Depth rod Non-marring
Super-fine sub-base
adjustment screw
Depth sto_ and
construction
"Live Tool ght
_-ft. Power Cord
Ergonomic handles
Self-releasing
Collet/Nuts System :
1/4 and 1/2-inch collets/nuts
Quick Lever
Vacuum port
Plunge depth
locking lever
27669 ManuaLRevised_11 0215 Page 12

,_ WARNING: Do not allow familiarity with the router to cause a lack of alertness. A
fraction of a second of carelessness is enough to cause severer injury
PRODUCT SPECiFiCATiONS
Rating 12.0Amps
No Load Speed 10000-25000 RPM
Peak HP 2
Input 120-volt, 60Hz AC
Collets/Nuts and Cutter bit Shank 1/4 in. and 1/2 in.
Diameters
Plunge Base Diameter 6-11/16"
Sub Base Opening (Diameter for 1-1/4 inches
cutter bit use)
Sub Base Thickness 0.23 inch (6mm)
Plunge Base Depth of Cut 2-1/8 inches (55mm)
WARNING: The safe use of this product requires an understanding of the
information on the tool and in this operator's manual, as well as knowledge of
the project you are attempting. Before use of this product, familiarize yourself
with all operating features and safety rules.
This Plunge Router has the following features:
1.
2.
3.
4.
Powerful, 12.0 Amp soft start motor develops 2 Peak HP to handle most
routing jobs.
Bectronic Feedback Circuitry provides soft starts for longer motor life,and
maintains constant speed under load to help produce a quality finish in all materials.
Variable=Speed Motor runs at 10,000 to 25,000 RPM (no-load speed).
Variable=Speed allows matching proper speed to material and cutter bit
size.
5. Quick=clamp System allows motor to be changed from fixed to plunge base
without use of tools.
6. Plunge Base features Fine and Micro Depth Rod Adjustments with Turret
Stops for precise set-ups and repetitive cutting.
7. Smooth Plunge Action lowers bit into workpiece at 90°for more accurate cutting.
8. Protective Plunge Post Bellows protect guideposts from woodchips, dust,
and moisture.
27669 Manual_Revised_11 0215 Page 13

9. Spindle Lock for easy 1 wrench bit changes. Includes 1/4 and 1/2 inch
Self-Releasing Collets/Nuts for use with a wide variety of 1/4 in. and 1/2 in.
router bits, sold separately.
10. 100% Ball Bearings for smooth, efficient operation and long life.
11. Base Features Large Base Openings and Large Chip Shield, combined with 3
LED Worklights on motor to provide high visibility of bit and workpiece.
12. Durable Non=marring Sub-base glides smoothly over workpiece. The sub-
base installed on this router has an opening of 1-1/4 inches. To use cutter
bits with larger diameters, please disassembly vaccum port and use
sub-bases with larger openings, sold separately at Sears stores or other
Craftsman outlets.
13. Motor Housing constructed of High Density Nylon and Precision Milled
Cast Aluminum for strength and exact fit into bases.
14. High-impact resistant Motor Housing Top Cap and Handles on Bases help
protect tool from damage.
15. Conveniently located ON/OFF toggle switch, side mounted for added
visibility, easy access.
16. Vacuum Port allows base to attach to 1-1/4 inches vac hose attachment,
sold separately.
17. Large 1" X1-1/2" LCD Screen provides digital readings of motor speed and
suggests bits selection
18. "Live Tool Indicator" light is green when router is plugged into a power
source. Light is located on motor housing top cap next to power cord inlet.
19. Replaceable Brushes (sold separately) for dependable service.
20. Includes carry bag for easy carrying and storage.
27669 ManuaLRevised_11 0215 Page 14

NOTE: This tool is shipped completely assembled. To change the router motor
from one base to another, install or remove cutter bits or add accessories such
as vacuum ports for hook-up to vacs, see the following instructions.
SELECTING THE CUTTER BiT
This router comes with 1/4 in. and 1/2 in. collets/nuts that accept 1/4 inch and
1/2 inch shanks.
WARNING: The sub-base installed on this router has an opening of 1-1/4
inches. To use cutter bits with larger diameters, please disassembly vaccum port
and use sub-bases with larger openings, sold separately at Sears stores or other
Craftsman outlets.
WARNING: Always turn the motor off and unplug the router before making
any adjustments or installing accessories. Failure to unplug the router could
result in accidental starting, which can cause serious personal injury.
INSTALLING AND REMOVING THE CUTTER BIT
iNSTALLiNG THE CUTTER BiT
1. Turn motor off and unplug from power source.
2. Remove motor housing from the plunge base.
NOTE: See the instructions for installing and removing on the motor housing
from the plunge base.
3. Set the motor upside down on its top cap, with collet/nut pointing up.
4. Press the spindle-lock button to engage and lock the spindle shaft and
collet/nut. (Fig. 3)
5. Place the wrench on the collet/nut and turn it counterclockwise to loosen the
collet/nut slightly so it can accept cutter bit shank.
6. l Fig. 3
Insert the cutter bit shank into
the collet/nut assembly as
far as it will go, then back the
shank out until the cutters are
approximately 1/8 to 1/4 inch
away from the face of the collet/
nut. (Fig. 4, 4a)
Nut Collet
Spindle Lock
27669 ManuaLRevised_11 0215 Page 15

NOTE: To ensue proper gripping of the cutter
bit shank and minimize run-out, the shank of
the cutter bit must be inserted into the collet/
nut at least 5/8 inch.
7. With the cutter bit inserted and spindle-
lock button pressed in engaging shaft,
place the wrench on collet/nut and turn
clockwise until the collet/nut is firmly
tightened on the cutter bit shank.
_, WARNING: Tighten the collet/nut
securely to prevent the cutter bit from
slipping. If the collet/nut is not securely
tightened, the cutter bit may detach during
use, causing serious personal injury.
NOTE: To prevent damage to tool, do not tighten
the collet/nut without acutter bit installed.
REMOVING THE CUTTER BiT
Fig, 4 "_--f_ \ Cutters
"____ Bit Shank
"J _ Spindle
Fig. 4a .Cutters
_ Collet /
1. Turn the motor off and unplug the router
from the power source.
2. Remove the motor from the fixed base.
NOTE: See the instructions for installing and removing the motor housing from
the plunge base.
3. Set the motor upside down on its top cap, with collet/nut pointing up.
4. Press the spindle-lock button to engage and lock the spindle shaft and the
collet/nut. (Fig. 3)
5. Place the wrench on the collet/nut and turn counterclockwise to loosen the
collet/nut slightly.
6. Remove cutter bit shank.
NOTE: The collet/nut is self-releasing; it is necessary to strike the collet/nut
to free the router cutting bit. If the cutter bit seems stuck after use, loosen the
collet/nut a litter more until it releases.
COLLET/NUT CARE
Before each use, inspect the collet/nut to make sure that it is clean and that it is
gripping the cutter bit properly.
With the router cutter bit removed, turn the collet/nut counterclockwise (with
spindle-lock engaged) until it is free from the motor's spindle shaft.
Blow the collet out with compressed air, and clean the tapered inside of the
collet/nut with a tissue or a fine brush.
27669 ManuaLRevised_11 0215 Page 16

A
Jl_ WARNING: Always wear safety goggles or safety glasses with side shields
during power tool operations, or when blowing dust. If operation is dusty, also
wear a dust mask.
Always make sure that the cutter bit shank, collet/nut and motor spindle are
clean and free of woodchips, dust, residue, grease and rust before installing a
cutter bit or collet/nut.
Apply a slight amount of machine oil to the spindle shaft if it looks dry.
Replace a worn or damaged collet/nut immediately.
NOTE: The collet/nut is self-releasing; it is not necessary to strike the collet/nut
to free the router cutter bit. If the cutter bit seems to be stuck after use, loosen
the collet/nut a little more until it releases.
CUTTER BiTS
Keep cutter bits clean and sharp only the inside of the cutting edge for faster,
more accurate cutting results. Remove all accumulated pitch and gum from
cutter bits after each use.
When sharpening cutter bits, sharpen only the inside of the cutting edge. Never
grind the outside diameter. Be sure, when sharpening the end of a cutter bit, to
grind so that the clearance angle the same as originally ground.
iNSTALLiNG THE ROUTER MOTOR iN THE BASE (Fig. 5)
WARNING: Never use the router
motor without installing it into either an
approved fixed or plunge base. Failure
to do so could result in serious personal
injury and damage to motor.
WARNING: Always turn the motor
off and unplug the router from the power
source before making any adjustments
or installing accessories. Failure to turn
the motor off and unplug the router
could result in accidental starting, which
can cause serious personal injury.
1.
Fig. 5
B
Turn the motor off and unplug the J
router from the power source. _ _\
2. Place the plunge base on a flat surface.
3. With the back of the plunge base facing you, open the motor clamp (A) and
make sure the plunge action is in "UP" position, with the plunge lock lever
(B) be locked down.
4. With the motor housing pin (C) aligned with the plunge base slot (D), lower
the motor housing into the plunge base engaging the pin into the slot.
27669 ManuaLRevised_11 0215 Page 17

5. Slide the motor into the base as far as it will go.
6. Close the motor clamp securely.
NOTE: When making depth adjustments on the plunge base, the motor clamp
should always be closed securely.
REMOVING THE MOTOR FROM THE BASE (Fig. 5}
,_ WARNING: Always turn the motor off and unplug the router from the power
source before making any adjustments or installing accessories. Failure to turn
the motor off and unplug the router could result in accidental starting, which can
cause serious personal injury.
1.
2.
3.
Turn the motor off and unplug the router from the power source.
Place the router (plunge base and motor housing) on a flat surface.
With the back of the plunge base facing you, open the motor clamp (A) and
make sure plunge action is in "UP" position, with the plunge lock lever (B)
locked down.
4. Lift the motor straight up out of the base, sliding the motor housing pin (C)
free from the slot (D) in the plunge base.
5. Set the motor upside down on its top cap with the collet pointing up and
remove the bit.
WARNING: Always remove the cutter bits from the collet/nut when the
router is not being used. Leaving bits installed could result in an accidents
causing serious personal injury.
ADJUSTING THE DEPTH OF CUT
WARNING: Your router should never be turned on or be connected to the
power source when you are assembling parts, making adjustments, installing
or removing collets/nuts and cutter bits, cleaning or when it is not in use.
Disconnecting the router will prevent accidental starting, which could cause
serious personal injury. Fig. 6 /
PLUNGING ACTION (Fig. 6}
The plunge base features simplify
depth adjustment and allow the cutter
bit to be accurately lowered into the
workpiece for more precise set-ups.
To lower the cutter bit, release the
plunge-lock lever by moving it "up" to
the unlocked position.
Apply an even, downward pressure on
the plunge action until the cutter bit Edge
reaches the desired depth, then move Guide
the plunge-lock lever "down" to the
locked position.
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Slot Cutting
Page 18

To raise the bit and the plunge action, unlock the plunge-lock lever. The plunge
action will automatically retract from the workpiece and return to the raised position.
Always have the plunge action in the raised position and locked when the bit is
not cutting in the workpiece.
DEPTH-STOP ROD AND DEPTH-STOP TURRET (Fig. 7}
The depth-stop rod and the depth-
stop turret are used to control the
plunge action cutting depth as follows:
1. Turn the motor off and unplug the
router from the power source.
2. Place the router on a flat, levelsurface.
3. With the cutter bit already been
installed, lower the plunge action
until the cutter bit makes contact
with the flat, level surface the router
is sitting on. Lock the plunge depth
locking lever (F).This position is
zero - "0" from which further depth
adjustments can be made.
Fig. 7
4. To set a desired depth-of-cut, rotate depth-stop turret until the lowest step
of the turret (A) is aligned directly under the depth-stop rod (B). Loosen the
depth rod locking knob (C) and lower the depth-stop rod (B) until it contacts
the lowest step on the turret (A).
5. Slide the clear plastic depth-indicator (D) until the red line on the indicator is lined
up with zero- "0", marked in black on the bottom of the depth scale. (This is now
the indicating point at which the bit makes contact with the workpiece).
6. To set a desired cutting depth, slide the depth-stop rod (B) up until the red
line on the clear plastic depth-indicator points to your desired cutting depth
on the depth scale (E). Secure the depth-stop rod (B) at this position by
tightening the depth rod locking knob (C).
7. Unlock the plunge-depth-locking lever (F) to allow the bit to automatically
retract to the up position.
8. The desired depth-of-cut may now be achieved by plunging the router down until
the depth-stop rod (B) contacts the selected step on the depth-stop turret (A).
NOTE: When making depth adjustments on the plunge base, the motor clamp
should always be closed securely.
Using the Depth=Stop Turret to Set Up Deep Cuts (Fig. 8)
NOTE: Making a single deep cut is never advisable. Smaller diameter cutting
bits are easily broken by too much side thrust and torque. Larger cutting bits will
cause a rough cut and be difficult to guide and control. For these reasons, do
not exceed 1/8 in. depth of cut in a single pass.
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To produce deep cuts, always make several progressively deeper cuts by
starting with the highest step on the depth-stop turret, and, after each cut, rotate
the turret to the next lower step until the lowest step is reached.
Each of the steps progresses by 1/4 inch increments. The 4 steps represent a total of
"0" inch to 3/4-inch with afull 360° rotation of the turret. Repeat this process if necessary.
Micro-adjustments with the Depth=Stop Rod and Depth=Stop Turret (Fig. 8)
The depth-stop rod has a micro adjustment
knob (A) that turns a screw (B) (inside the
rod) either clockwise or counterclockwise to
lower or raise the depth-stop rod on the turret
(C) for micro-fine adjustments of the plunge
depth.
Each complete revolution of the Micro-
adjustment knob adjusts the plunging depth
by approximately 1/32 inch.
A reference indicator line is embossed into
the depth-stop rod under the fine-adjustment
knob to set a reference point of "0".
When micro-adjust the plunge depth, always
make sure that the micro-adjustment knob
has been turned down (clockwise) several
revolutions from the top before setting the
depth-stop rod and depth-stop turret.
Fig. 8
Always set your micro-adjustments with the plunge action locked in the raised,
(or up) position.
To use the micro-adjustment knob after the depth rod and turret have been set,
check the final depth setting and micro-adjust as follows:
• To micro-increase the plunge depth, raise the micro-adjustment screw by
turning the knob counterclockwise the desired amount.
To micro-reduce the plunge depth, lower the micro-adjustment screw by
turning the knob clockwise the desired amount.
TOGGLE "ON/OFF" SWITCH (Fig. 9}
Your router motor is turned "ON" and "OFF"
by the toggle switch located on the top cap
of the motor housing.
The left side of the toggle switch hood (as you
face it) is marked 'T' for "On" and the right side
(as you face it) is marked "O" for "Off".
To turn the motor "ON", Push the toggle
switch to the left side marked 'T', or "On"
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