Craftsman 320.2768 User manual

PART# IB-2768
Operator's Manual
II:RAFTSMAN°I
12.0 Amp Fixed Base Router
Model No. 320.2768
WARNING: To reduce the risk of
injury, the user must read and
understand the Operator's manual
before using this product.
c_tus
• 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 14-29
Maintenance page 30-31
Troubleshooting page 32
Exploded View and Part List page 35-39
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
AWARNING: 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
2768 ManuaLRevised_11-0307 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.
_1, 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
SAFETY ALERT SYMBOL: Indicates DANGER, WARNING, OR CAUTION.
May be used in conjunction with other symbols or pictographs
DANGER: Indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury.
_, WARNING: Indicates a potentially hazardous situation, which, if not avoided,
could result in death or serious injury.
_1, CAUTION: Indicates an imminently hazardous situation, which, if not
avoided, may result in death or serious injury.
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.
A_, 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
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.
2768 ManuaLRevised_lI-0307 Page 3

SYMBOL NAME DESIGNATION/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
.../rain Per Minute Revolutions, strokes, surface speed,
orbits, etc., per minute
Wet Conditions Alert Do not expose to rain or use in damp
locations.
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.
,_ 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 theNo Hands Symbol blade will result in serious personal injury.
Failure to keep your hands away from theNo 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.
To reduce the risk of injury or damage,
Hot Surface avoid contact with any hot surface.
2768 ManuaLRevised_11-0307 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.
READ AND SAVE THESE INSTRUCTIONS
WORK AREA SAFETY
• Keep the work area clean and well lit. Cluttered or dark areas invite
accidents.
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.
2768 Manuai_Revised_11-0307 Page 5

When operating a power tool outdoors, use an extension cord suitable
for outdoor use. Use of a cord suitable for outdoor use reduces the risk of
electric shock.
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.
2768 Manuai_Revised_11-0307 Page 6

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.
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.
A_, 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.
2768 ManuaLRevised_lI-0307 Page 7

SERVICE SAFETY
•Have your power tool serviced by a qualified repair person using only
identical replacement parts. This will ensure that the safety of the power
tool is maintained.
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 on 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 the 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.
2768 ManuaLRevised_11-0307 Page 8

•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.
• Inspect and remove ai[ nails from [umber before routing.
• Check to see that the cord will 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 asingle pass. Excessive depth of
cut can result in loss of control that could result in personal injury.
• After completing acut, 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.
2768 Manuai_Revised_11-0307 Page 9

•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.
• 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 "Direction of Feed in" section in this manual.
"Climb cutting" increases the chance for loss of control resulting in possible
serious injury.
_, WARNING: Bits, sockets, and tools get hot during operation. Wear gloves
when touching them.
_, WARNING: Wear ear protection. Exposure to noise can cause hearing loss.
WARNING: To avoid injury, hold the tool by the insulated gripping surfaces
only. if the tool contacts hidden wiring or its own cord, exposed metal parts
of the tool could shock the operator and cause serious injury. Make sure that
hidden electrical wiring, water pipes, or other hazards are not in the cutting path.
_1, 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. Carefully lift the router out of the carton and place on a stable, flat surface.
2. Open the carton to locate the following:
• Vacuum port
• Chip shield (already installed on router)
• 1/4 inch collet/nut
• 1/2 inch collet/Nut (already installed on router)
• Collet/nut wrench
• Depth-Adjustment Wrench
• Edge Guide
• Manual
2768 Manuai_Revised_11@307 Page 10

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.
CARTON CONTENTS/LOOSE PARTS (Fig. 1)
©©
Fixed Base Router
Chip shield (already installed on router)
Vacuum port
1/4 inch Collet/Nut
1/2 inch Collet/Nut (already installed on router)
Depth-Adjustment Wrench
Edge Guide
Collet/Nut Wrench
2768 ManuaLRevised_11-0307 Page 11

KNOW YOUR ROUTER (Fig.l)
Fig. 2 Motor housing Top Cap
"Live Tool Indicator" Light Speed Dial
Variable Speed
Selection Chart
Quick Clamp
Motor Changing Motor Housing
System Fixed Base
Handles
Spindle lock
Self-Releasing Collets/Nuts System Non-Marring Sub-Base
ON/Off
Toggle Switch
Replaceable Carbon Brushes
(Sold separately)
uick Clamp
Motor Changing
System
Quick
Edge Guide Mounting Slot Vacuum port
2768 ManuaLRevised_11-0307 Page 12
ge Guide Mounting Slot

NOTE:Beforeattemptingtouseyourrouter,familiarizeyourselfwithallofthe
operatingfeaturesandsafetyrequirements.
Yourfixedbaserouterhasaprecision-builtelectricmotoranditshouldonly
beconnectedtoa120-volt,60-HzAConlypowersupply(normalhousehold
current).Donotoperateondirectcurrent(DC).Thislargevoltagedropwillcause
alossofpowerandthemotorwilloverheat.Iftherouterdoesnotoperatewhen
pluggedintoacorrect120-volt,60-HzAConlyoutlet,checkthepowersupply.
Thisrouterhasan8-ft.,2-wirepowercord(noadapterneeded).
A_, 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 severe injury
PRODUCT SPECIFICATIONS
Rating 12.0 Amps
No Load Speed 10,000-25,000 RPM
Peak HP 2
Input 120-volt, 60Hz AC
Collets/Nuts and Cutter bit Shank Diameters 1/4 in. and 1/2 in.
Fixed Base Diameter 6 inches
Sub-Base Opening (Diameter for cutter bit use) 1-1/4 inches
Sub-Base Thickness 1/4 inch (6mm)
Fixed Base Depth of Cut 1-3/4 inches (45mm)
_h, 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 Fixed Base Router has the following features:
1.
2.
3.
4.
5.
6.
Powerful, 12.0 Amp Soft Start Motor develops 2 Peak HP to handle most
routing jobs.
Variable=Speed Motor runs at 10,000 to 25,000 RPM (no-load speed).
Speed Dial allows matching proper speed to material and bit size.
Electronic Feedback Circuitry provides soft starts for longer motor life,
maintains constant speed under load for a quality finish in all materials.
Fixed Base features Coarse and Fine Depth Adjustments for accurate
set-ups. Ideal for use with a router table, sold separately.
Spindle Lock for easy 1-wrench bit changes. Includes 1/4 inch 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.
2768 ManuaLRevised_lI-0307 Page 13

7. 100% Ball Bearings for smooth, efficient operation and long life.
8. Base features Ergonomically Designed Handles for comfort and maximum
control.
9. Base features large Base Opening and large Chip Shield, combined
with 3 LED Worklights on the motor to provide high visibility of bit and
workpiece.
10. Durable Non-Marring Sub-Base glides smoothly over the workpiece. The
sub-base has a cutter-bit opening of 1-1/4 inches. Do not use a bit with a
cutter diameter larger than 1-1/4 inches, as it will not pass through the sub-
base opening.
11. Base constructed of Die-Cast Aluminum to provide durability and stability.
12. Motor housing constructed of High Density Nylon and Precision Milled
Cast Aluminum for strength and exact fit into base.
13. High-impact resistant Motor Housing Top Cap and Handles on Base help
protect tool from damage.
14. Heavy-duty Edge Guide for most routing applications such as decorative
edging, grooving, dadoing, slotting and straight edge planing/trimming.
15. Conveniently located ON/OFF toggle switch, side mounted for added
visibility and easy access.
16. Vacuum Port allows the base to attach a to 1-1/4 inche vac hose
attachment, sold separately.
17. "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.
18. Replaceable carbon brushes (sold separately) for dependable service.
19. Includes soft bag for easy carrying and storage.
NOTE: This tool is shipped completely assembled. To install or remove 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 cutter bits with
1/4 inch and 1/2 inch shanks, respectively.
,_, WARNING: Do not use a router cutter bit that has a cutter bit diameter larger
than 1-1/4 inches with the sub-base that is installed on this router, as it will not
fit through the sub-base opening, will cause damage to the sub-base and the
motor, and could cause serious personal injury to the operator.
2768 ManuaLRevised_11-0307 Page 14

NOTE: The sub-base installed on this router has an opening of 1-1/4 inches. To
use cutter bits with larger diameters, 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 (available separately) (Fig. 3, 4 and 4a)
iNSTALLiNG THE CUTTER BiT
1.
2.
Turn the motor off and unplug the router
from the power source.
Remove the motor housing from the fixed
base.
NOTE: See the instructions for installing and
removing the motor housing from the fixed
base on pages 17 and 18.
3.
4.
5.
Set the motor upside down on its top cap,
with the collet/nut pointing up.
Press the spindle-lock button to engage and
lock the spindle shaft and collet/nut. (Fig.3)
Place the wrench on the collet/nut and
turn it counterclockwise to loosen the
collet/nut slightly so that it can accept the
cutter bit shank.
6. 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)
NOTE: To ensure 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.
Fig. 3 _ Collet Spindle
Nut
Fig. 4a
3utter:
7. With the cutter bit inserted and the spindle-lock button pressed in to engage
the shaft, place the wrench on collet/nut and turn it clockwise until the collet/
nut is firmly tightened on the cutter bit shank.
_1, 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.
2768 ManuaLRevised_lI-0307 Page 15

NOTE: To prevent damage to the tool, do not tighten the collet/nut without a
cutter bit installed.
REMOVING THE CUTTER BiT
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 fixed base on pages 17 and 18.
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 it counterclockwise to loosen the
collet/nut slightly; remove the cutter bit shank.
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, press the spindle lock and turn the collet/nut
counterclockwise until it is free from the motor 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.
_1, 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
collet/nut a little more until it releases.
CUTTER BiTS
For faster, more accurate cutting results, keep cutter bits clean and sharpen only
the inside of the cutting edges. 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 is same as originally ground.
2768 ManuaLRevised_11-0307 Page 16

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.
NOTE: Before installing the motor housing in the fixed base, have the collet/nut
and router cutter bit you are going to use already installed in motor housing. See
"INSTALLING AND REMOVING THE CUTTER BIT".
_, 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. Turn the motor off and unplug the router from the power source.
2. Place the fixed base on a fiat surface.
3. With the back of the fixed base facing you, open the motor clamp (A).
4. Press in Coarse Adjustment Knob (B) while you align the router motor key
strip slot (C) with the key strip (D) in the fixed base.
5. When the motor's slot is aligned and engaged into the base's slot, slide the
motor down into the fixed base.
6. The motor will now slide up or down to set coarse adjustments when the
coarse adjustment knob is pressed in.
7. After all adjustments are made, close the motor clamp 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. Turn the motor off and unplug the router
from the power source.
2. Place the router (fixed base and motor
housing) on a fiat surface.
3. With the back of the router facing you,
open the motor clamp (A).
4. Press in Coarse Adjustment Knob (B) while
you align the motor key strip slot (C) with
the key strip (D) in the fixed base.
Fig. 5
BA
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5. Set the motor upside down on its top cap with the collet pointing up and
remove the cutter bit.
_, WARNING: Always remove the cutter bit from collet/nut when the router is
not being used. Leaving bits installed could result in 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, cutter bits, cleaning the product or when it is not in use.
Disconnecting the router will prevent accidental starting, which could cause
serious personal injury.
NOTE: All depth adjustments on the fixed base must be made with the motor
clamp open.
NOTE: For all fixed base routers, the cutter bit depth equals the amount of the
cutter that is exposed below the surface of the sub-base.
The fixed base is designed with a fine adjustment worm-gear system. When the
bit is lowered to the approximate position desired (coarse setting), the system
then can be micro-adjusted to the precise depth.
Coarse Adjustment:
Depressing the coarse adjustment knob (B) allows you to quickly lower or raise
the cutter bit to an approximate depth setting.
Micro Adjustments:
NOTE: Be sure that the worm gear system is engaged before making fine
adjustments. Test it by turning the fine adjustment dial (C) clockwise and
counter-clockwise to see if the bit lowers and raises. If it does not, press in the
coarse adjustment knob and turn the fine adjustment dial until the gears engage,
then reset zero "0" on depth indicator ring (D).
The depth indicator ring (D) located on the fine adjustment dial is marked in
1/64-inch increments. Turning the fine adjustment dial clockwise 180°(1/2 turn),
lowers the cutter bit 1/16 inch. One full turn clockwise (360 °) lowers the bit 1/8 inch.
The system allows a maximum of 7 full 360 ° revolutions, clockwise, to lower the
cutter bit a total of 7/8 inch.
The depth indictor ring may be reset to zero "0" without moving the fine
adjustment dial. This allows the user to begin adjustments from any reference
point desired.
To Adjust Depth (Figs. 6 and 6a}
1. Turn the motor off and unplug the router from the power source.
2. Place the router on a flat, level surface with the back of the fixed base facing
you.
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3.
5.
6.
Open the motor clamp (A).
With the cutter bit already installed, press ir
the coarse adjustment knob (B), and lower
the motor into the base until the cutter bit is
very close to the flat surface on which the
base is sitting. Turn the fine adjustment dial
(C) until the cutter bit just touches the flat
surface on which the base is sitting. Lock
motor clamp (A).
While continuing to press the coarse
adjustment knob (B), turn the fine
adjustment dial (C) until zero "0" is aligned
with the "l" mark on the base.
7. Release the coarse adjustment knob,
making sure that the "0" remains aligned
with the mark.
8. Place the router on two level scrap
workpieces and position it so that the
cutter bit can be lowered below the sub-
base. (Fig. 6a).
10. Turn the fine adjustment dial (C) clockwise
to lower the bit to the desired depth of
cut. Turn the dial counter-clockwise to
raise the cutter bit.
11. Once your depth of cut is set, close the
motor clamp (A)securely.
Fig. 6
Fig. 6a
A
NOTE: Making a single deep cut is never
advisable. Smaller diameter cutter bits are
easily broken by too much side thrust and torque. Larger cutter 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.
Fig. 7
TOGGLE "ON/OFF" SWITCH (Fig. 7)
Use the toggle switch located on the top cap
of the motor housing to turn the router "ON"
and "OFF".
The left side of the toggle switch hood (as
you face it) is marked "l" 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 "l", or "On". To
turn the motor "OFF" push the toggle switch
to the right side marked "O", or "Off".
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Contact the workpiece with the router and
cutter bit only after the router has reached full
speed. Turn the router motor "OFF" and allow
the cutter bit to come to a complete stop
before removing the router and cutter bit from
the workpiece.
SOFT START FEATURE
The soft start feature minimizes torque twist,
customary in larger router motors, by limiting
the speed at which the motor starts. This
increases the motor's life.
Fig. 8
ELECTRONIC FEEDBACK CONTROL
The electronic feedback control maintains
a constant speed under load to provide a
smooth finish.
LED WORKLIGHTS (Fig. 8)
Your router motor has 3 built-in worklights
located around the collet/nut to provide high
visibility of workpiece when cutting. These
lights are always "On" when the toggle switch
is in the "On" position.
"LIVE TOOL iNDiCATOR" LIGHT (Fig. 9)
Fig. 9
Your router also has a "Live Tool Indicator" green light, located on the motor
housing top cap where the power cord enters the motor housing. This green
light is always on when router motor is plugged into power source.
HEAVY=DUTY EDGE GUIDE (Fig.lO)
The Fixed-Base Router comes with a heavy-
duty edge guide. This edge guide can be
used as an aid in routing applications such as
decorative edging, straight edge planning and
trimming, grooving, dadoing and slotting.
To attach the edge guide to the fixed base,
simply insert the edge guide rods into edge-guide
mounting slots either from the left or the right.
Fig. 10
Tighten the lever on the left by turning it
clockwise to secure the edge guide rod
(Fig.lO). Tighten the lever on right by turning
counterclockwise to secure the rod (Fig.lO).
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