Sears, Roebuck and Co., Hoffman Estates, IL 60179

www.craftsman.com

ONE YEAR FULL WARRANT'( ON CRAFTSMAN TOOL

If this Craftsman tool fails to give complete satisfaction within one year from the date of purchase, return it to any Sears store or parts & repair center or other craftsman outlet in the United States for free repair (or replacement, if repair proves impossible).

This warranty does not include expendable parts such as lamps, batteries, bits, or blades.

This warranty applies for only 90 days from the date of purchase if this product is ever used for commercial or rental purposes

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Sears, Roebuck and Co., Hoffman Estates IL 60179

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]

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 dan- ger. The instructions and warnings they give are no substitutes for proper accident- prevention measures..

WARNING: BE SURE to read and understand all safety alert symbols, such as "DANGER," "WARNING," and "CAUTION" BEFORE using this product.

Failure to follow all instructions may result in electric shock, fire, and/or seri- ous personal injury.

SYMBOL MEANINGS

SAFETY ALERT SYMBOL: Indicates DANGER, WARNING, OR CAUTION. May be used in conjunction with other symbols or pictographs.

DANGER: Failure to obey this safety warning WILL 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.

WARNING: Failure to obey this safety warning CAN 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,

CAUTION: Failure to obey this safety warning MAY result in personal injury to yourself or others or property damage. Always follow the safety pre- cautions to reduce the risk of fire, electric shock and personal injury.

DAMAGE PREVENTION AND INFORMATION MESSAGES

These inform the user of important information and/or instructions that could tead 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

_k WARNING: BE SURE to road and understand all instructions in this man- ual before using this router. Failure to follow all instructions may result electric shock, fire and/or serious personal injury.

WORK AREA SAFETY

=Keep your work area clean and well lit. Cluttered workbenches and 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 bystanders, children and visitors away while operating a power tool. Distractions can cause you to lose control.

Make your workshop childproof with padlocks and master switches. Lock tools away when not in use,

MAKE SURE the work area has ample lighting so you can see the work and that there are no obstructions that will interfere with safe operation BE-

FORE using your router_

PERSONAL SAFETY

oKNOW your power tool. Read this operator's manual carefully?? Learn the router's applications and limitations, as well as the specific potential hazards related to this tool

oSTAY ALERT, watch what you are doing and use common sense when oper- ating a power tool.

,,DO NOT use toot 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.

,,DRESS properly. DO NOT wear loose clothing or jewelry. Pull back long hair. Keep your hair, clothing, and gloves away from moving parts. Loose clothing, or long hair can be caught in moving parts. Air vents often cover moving parts and shouid also be avoided..

oAVOID accidental starting?? Be sure switch is in "OFF" position before plug- ging in. DO NOT carry tools with your finger on the switch, Carrying tools with your finger on the switch or plugging in tools that have the switch in the "ON" position invites accidents.

REMOVE adjusting keys or blade wrenches before bJming the tool "ON." A wrench that is left attached to a rotating part of the tool may result in personal injury.

Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the tool in unexpected situationso

ALWAYS SECURE YOUR WORK. Use clamps or a vise to hold work piece securety_ It is safer than using your hand and frees both hands to operate tool,

USE SAFETY EQUIPMENT. Always wear eye protection. Dust mask, non-

skid safety shoes, hard hat, or hearing protection must be used for appropri- ate conditions,

???DO NOT USE ON A LADDER or unstable support. Stable footing on a solid surface enables better control of the tool in unexpected situations.

TOOL USE AND CARE

WARNING: BE SURE to read and understand all instructions before op-

erating this router. Failure to follow all instructions listed below may result in electric shock, fire and/or serious personal injury.

ALWAYS use clamps or other practical ways to secure and support the work piece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control.

DO NOT force the tool. Use the correct tool and bit for your application.

The correct tool and bit will do the job better and safer at the rate for which it is

designed.

DO NOT use the tool if switch does not turn it "On" or "Off." Any tool that cannot be controtted with the switch is dangerous and must be repaired.

DISCONNECT the plug from the power source before making any adjust- ments, changing accessories or storing the tool. Such preventive safety measures reduce the risk of starting the tool accidentally.

=NEVER leave the tool running. ALWAYS turn it off. DO NOT leave the tool until it comes to a complete stop.

???STORE idle tools out of the reach of children and other untrained per- sons. Tools are dangerous in the hands of untrained users.

???MAINTAIN tools with care. Keep cutting tools sharp and clean. Prop-

erly maintained tools with sharp cutting edges are less likely to bind and are easier to control.

CHECK for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tool's operation. If damaged, have the tool serviced before using. Many accidents are caused by poorly maintained tools,

USE ONLY accessories that are recommended for this tool. Accessories

that may be suitable for one tool may become hazardous when used on another tool.

ELECTRICAL SAFETY

_k WARNING: Do not permit fingers to touch the terminals of plug when installing or removing the plug from the outlet.

Double insulated tools are equipped with a polarized plug (one blade is

wider than the other). This plug will fit in a polarized outlet only one way.

If the plug does not fit fully in the outlet, reverse the plugo If it still does not fit,

contact a qualified electrician to install a polarized outleL Do not change the plug in any way??

oDouble insulation [] eliminates the need for the three-wire grounded power cord and grounded power supply system. Applicable only to Class !1 (double- insulated) tools. This router motor is double insulated.

_k WARNING: Double insulation DOES NOT take the place of normal safety precautions when operating this tool.

BEFORE plugging in the tool, BE SURE that the outlet voltage supplied is within the voltage marked on the tool's data plate. DO NOT use "AC only" rated tools with a DC power supply.

??AVOID body contact with grounded surfaces, such as pipes, radiators,

ranges and refrigerators. There is an increased risk of electric shock if your

body is grounded.

=DO NOT expose power tools to rain or wet conditions or use power tools in wet or damp locations. Water entering a power tool will increase the risk of electric shock.

INSPECT toot cords for damage. Have damaged tool cords repaired at a Sear Service Center. BE SURE to stay constantly aware of the cord location and keep it well away from the moving router.

DO NOT abuse the cord. NEVER use the cord to carry the tool by or to pull the plug from the outlet. Keep cord away from heat, oil, sharp edges or moving parts?? Replace damaged cords immediately. Damaged cords increase the risk of electric shock.

EXTENSION CORDS

Use a proper extension cord. ONLY use cords listed by Underwriters Labora- tories (UL). Other extension cords can cause a drop in line voltage, resulting in a loss of power and overheating of tool. For this tool an AWG (American Wire Gauge) size of at least 14-gaugeis recommended for an extension cord of 25-ft or less in length. Use 12-gauge for an extension cord of 50-ft. Extension cords

100-ft or longer are not recommended. Remember, a smaller wire gauge

size has greater capacity than a larger number (14-gauge wire has more

capacity than 16-gauge wire; 12-gauge wire has more capacity than 14-gauge)o When in doubt use the smaller number?? When operating a power tool outdoors, use an outdoor extension cord marked "W-A" or "W." These cords are rated for outdoor use and reduce the risk of electric shock.

,_ CAUTION: Keep the extension cord clear of the working area. Position the cord so that it will not get caught on lumber, tools or other obstructions while you are working with a power tool.

WARNING: Check extension cords before each use. If damaged replace immediately. Never use tool with a damaged cord since touching the dam- aged area could cause electrical shock, resulting in serious injury.

SERVICE SAFETY

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 router 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 and Repair Center.

Service or maintenance performed by unqualified personnel could result in a

risk of injury.

When servicing a tool, use only identical replacement parts. Follow in-

structions 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.

SAFETY RULES FOR ROUTER

CAUTION: Cutting bits coast after router is switched off,

???MAKE SURE the cutting bit is not in contact with the work piece before the switch is turned on. The bit must ALWAYS be running at full speed before contacting the work piece.

=KEEP HANDS CLEAR OF CUTTING BIT when router motor is running to prevent personal injury.

= PROVIDE CLEARANCE under work piece for muter cutting bit when through-cutting.

=KEEP CUTTING PRESSURE CONSTANT. Do not overload the motor.

???USE ONLY sharp cutting bits that are not chipped or cracked. Blunt cut- ting bits will cause stalling and burn the work piece.

???NEVER use this router motor with a cutting bit larger than 3-1/2 inch in diameter.

ALWAYS USE cutting bits that are designed for this router. Never use cutting bits which are larger in diameter than the opening in the muter sub-base. Cutting 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 inch. To

use cutting 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 cutting bits for freehand muting. Use of large cutting bits when freehand routing could cause loss of control or create haz-

ardous conditions that could result in serious personal injury. If using a router

table, large bits should be used for edging onlyo

BE SURE CUTTING BIT is centered in 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 motor OFF and let it come to a complete stop

BEFORE REMOVING router from work piece.

Let the motor come to a COMPLETE STOP before putting the router down. Cutting bits coast after power is turned off.

ONLY use router tables that conform to safe woodworking practices and

offer proper guarding for the cutting bit. Use router tables that are UL clas-

sified and identified suitable for use with this specific router model, Failure to comply could result in serious personal injury??

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 POWER SOURCE before making any

adjustments or changing cutting bits.

If you are changing a bit immediately after use, BE CAREFUL NOT TO TOUCH the collet!nut or cutting bit with your hands or fingers. The heat buildup from cutting could cause severe bums. 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??

A_k WARNING: Use of this product can generate dust containing chemicals known to the state of California to cause cancer, birth defects or other re- productive harm. Some examples of these chemicals are:

o Lead from lead-based paints.

Your risk from these exposures varies, depending upon how often you do this type of work. To reduce your exposure to these chemicals:

o Work in a wel!-ventilated area??

???Work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling and other construction activities. Wear protective clothing and wash exposed areas with soap and water. Allowing dust to get into your mouth, eyes or lay on the skin may promote absorption of harmful chemicals.

WARNING: Use of this tool can generate and/or disburse dust, which may cause serious and permanent respiratory or other injury. Always use NIOSH/OSHA approved respiratory protection appropriate for the dust ex- posure. Direct particles away from face and body.

ADDITIONAL RULES FOR SAFE OPERATION

WARNING: BE SURE to read and understand all instructions. Failure to follow all instructions listed below may result in electric shock, fire and/or serious personal injury.

??Know your power tool. Read this operator's manual carefully. Leam the ap-

plications and limitations, 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. Every- day eyeglasses have only impact-resistant Tenses; 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 prots_ction during use. Under some conditions noise from this product may conlTibut_ to headng loss.

=ALL VISTORS AND BYSTANDERS MUST wear the same safety equipment that the operator of the router wears.

_k WARNING: Your router should NEVER be connected to the power

source when you are assembling parts, making adjustments, installing or removing collets / nuts, cutting bits, cleaning or when it is not in use. Dis- connecting the router will prevent accidental starting, which could cause serious personal injury.

1o Carefully lift the Router Motor and Fixed Base, with the 1/2 in. colleVnut already installed, out of the color box and place it on a stable, flat surface.

2.Open the parts bag to locate the following: o Edge Guide

=1/4-in. Collet/Nut

=Collet/Nut wrench

??Power cord

??? Sawdust extraction adapter

o Depth-adjustment wrench

3.inspect the items carefully to make sure that no breakage or damage has occurred during shipping. If any of the items mentioned are missing, (refer to "PARTS LIST' illustration on page 12), return the router to your nearest Sears store or Craftsman outlet to have the router replaced??

_1_ WARNING: if any parts are broken or missing, DO NOT attempt to plug in the power cord or operate router until the broken or missing parts are replaced. Failure to do so could result in possible serious injury.

PARTS LIST (Fig. I)

Fig. 1

1. Fixed Base and Router Motor with 1/2-in,, Collet/Nut 2o Power cord

3.Sawdust extraction adapter

4.Edge Guide

5.1/4-in. Collet/Nut

6.Collet/Nut Wrench

7.Depth-adjustment wrench

Your fixed base router has a precision-built electric router motor and it should

only be connected to a 120wolt, 60-Hz AC ONLY power supply (normal house-

hold current). DO NOT operate on direct current (DC). This large voltage drop will cause a loss of power and the router motor will overheat,, tf the router does not

operate when plugged into a correct 120-volt, 60-Hz AC ONLY outlet, check the

power supply. This router has al 0-ft, 2-wire power cord (no adapter needed).

This Fixed Base Router has the following features:

1.12.5 Amp, 2-1/4 Peak HP, Variable Speed Router Motor runs at 12,000 to

25,000 RPM (no-load speed).

2_ Speed Dial allows matching proper speed to material and bit size??

3.Electronic Feedback Circuitry provides soft starts for longer motor life, maintains constant speed under load for a quality finish in all materials.

4_ Fixed Base features Coarse and Fine Depth Adjustments for accurate set- ups?? Ideal for use with router table, sotd separately.

. 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 inn and 1/2 in, router bits, sold separately.

6, Detachable power cord: a replaceable cord to prolong tool life and for easy

carrying and storage??

7.Ball bearings throughout the motor for smooth, efficient operation and bng life.

&Base features Ergonomically Designed Handles with soft grip for comfort, maximum control with less vibration.

9.Base features Large Base Opening and Large Chip Shield, combined wit;']3 LED Work lights on Router Motor to provide high visibility of bit and work piece??

10.Durable Non-Marring Sub-Base glides smoothly over work piece_ Sub-base has cutter-bit opening of 1-1/4 inch. Do Not Use a bit with a cutter diameter larger than 1-1/4 in., as it will not pass through the sub-base openingE

11o Base constructed of magnesium to provide light weight, durability and stability.

12.Router Motor housing constructed of High Density Nylon and Precision Milled Cast Aluminum for strength and exact fit into base.

13.High-impact resistant Router Motor Top Cap and Handles on Base helps protect tool from damage.

I 4. Heavy-duty Edge Guide for most routing applications such as decorative edging, grooving, dadoing, slotting and straight edge planing/rimming.

15.Conveniently located On/Off Toggle Switch, side mounted for added vis- ibility, easy access.

16.Sawdust Extraction Hood allows base to hook up to 1-1/4 inch vacuum hose attachment, sold separately.

17o "LIVE TOOL INDICATOR" Light is green when saw is plugged into a power source. Light is located on router motor top cap next to power cord inlet.

18.Replaceable Brushes (sold separately) for dependable service.

19.Includes carry bag for easy carrying and storage.

20.Integrated Depth-adjustment Wrench hole of the base for adjusting the depth of cut from above the table with depth-adjustment wrench.

NOTE: This tool is shipped completely assembled. To install or remove bits or add accessories such as sawdust ejection hoods for hook-up to vacu- urns, see the following instructions.

SELECTING THE CUTTING BIT

This router comes with 1/4-in. and 1/2-in. co!lets/nuts that accept 1/4 and !/2 inch diameter shanked cutting bits.

WARNING: Do not use router cutting bits that have a cutting bit diame- ter larger than 1-1/4 inches as they will not fit through the sub-base opening, and will cause damage to the sub-base, the muter motor, and could cause serious personal injury to the operator.

NOTE: The sub-base installed on this router has an opening of 1-1/4 inches.

To use cutting bits with a larger diameter, use a sub-base with a larger opening, sold separately at Sears stores or other Craftsman outlets.

_k WARNING: ALWAYS turn router motor off and unplug muter before mak- ing any adjustments or installing accessories. Failure to unplug the router could result in accidental starting which can cause serious personal injury.

WARNING: TIGHTEN COLLET/NUT SECURELY to prevent the cutting bit

from slipping, if the collet/nut is not securely tightened, the cutting bit may detach during use, causing serious personal injury.

NOTE: To ensure proper gripping of cutting bit shank and minimize run-out, the shank of the cutting bit must be inserted into the collet/nut at least 5/8 inch.

CAUTION: To prevent damage to tool, do not tighten collet/nut without a cutting bit installed.

REMOVING THE CUTTING BIT (Figs 3 and 4 see page16)

1.Turn router motor off and unplug from power source.

2.Remove router motor from fixed base.

3.Set the router motor upside clown on its top cap, with collet/nut pointing up.

4.Press spindle lock button to engage and lock the spindle sl-_qft and collet/nut, (Fig. 3).

5.Place the wrench on the colleVnut and turn counterclockwise and loosen cot- let/nut slightly and remove cutting bit shank.

COLLET/NUT CARE

From time to time, inspect the collet/nut to make sure it is clean and is gripping the cutting bit properly.. With the router cutting bit removed, turn the colleVnut counterclockwise (with spindle lock engaged) until it is free from router motor's spindle shaft.

Blow the collet out with compressed air, and clean the tapered inside of the cot- let/nut with a tissue or fine brush.

Always make sure the cutting bit shank, collet/nut and router motor spindle are clean and free of woodchips, dust, residue, grease and rust before installing.

Apply a slight amount of machine oil to spindle shaft if it looks dry.

Replace worn or damaged collets/nuts immediately,,

NOTE: The cotlet/nut is self-releasing; it is NOT necessary to strike the cotlet/nut to free the router cutting bit. If cutting bit seems stuck after use, loosen collet/nut a little more until it releases.

CUTTING BITS

Get faster, more accurate cutting results by keeping cutting bits clean and sharp. Remove all accumulated pitch and gum from cutting bits after each use,

When sharpening cutting bits, sharpen only the inside of the cutting edge. Never grind the outside diameter. Be sure, when sharpening the end of a cutting bit, to grind the clearance angle the same as originally ground??

INSTALLING ROUTER MOTOR IN BASE

WARNING: NEVER use the router motor without installing it into either

a fixed or plunge approved base. Failure to do so could result in serious personal injury and damage to router motor.

NOTE: Before installing router motor in fixed base, have the collet/nut and router cutting bit you are going to use already installed in router motor. See page 16 "INSTALLING AND REMOVING THE CUTTING BIT."

WARNING: ALWAYS turn router motor off and unplug router from power source before making any adjustments or installing accessories. Failure to

turn router motor off and unplug router could result in accidental starting which can cause serious personal injury.

INSTALLING ROUTER MOTOR IN BASE (Fig_ 5)

1. Turn router motor off and

Fig. 5

unplug from power source.

2.Place fixed base on

6.The router motor wilt 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 router motor clamp securely.

REMOVING ROUTER MOTOR FROM BASE (Fig. 5)

1. Turn router motor off and unplug from power source.

2_ Place router (fixed base/router motor) on flat surface_

3.With back of router facing you, open the router motor clamp (A).

4.Push in coarse adjustment knob (B) to release router motor "Position groove"

(C)from lock hook (D) in base, while you lift router motor free of base.

5.Set motor upside down on its top cap with collet pointing up and remove cut- ting bit. Store motor and base in carry bag when not being used.

WARNING: ALWAYS remove cutting bits from collet/nut when the router is not being used. Leaving bits installed could result in an accident causing serious personal injury.

ADJUSTING 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, cutting bits, cleaning 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 mo- tor clamp open.

NOTE: For all Fixed Base Routers, the cutting 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 micrometer fine adjustment 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 cutting bit to three depth settings.

Micro Adjustments:

NOTE: Before making fine adjustments, reset zero "0" on Depth Indicator

Ring (E, Fig.5).

The Depth Indicator Ring (E, Fig.5) located on the Fine Adjustment Dial (F, Fig?? 5) is marked incrementally in 64ths. Turning the fine adjustment dial clockwise 180 ?? (1/2 turn), lowers the cutting bit 1/16 inch. One full turn clockwise (360 ??) zero "0" to zero "0" lowers the bit 1/8 in.

The Depth Indicator Ring may be reset to zero "0" without moving the Fine Adjust- ment Dial. This allows the user to begin adjustments from any reference point desired

To Adjust Depth (Figs?? 6 and 6a)

. Turn router motor off and unplug from power source_

2_ Place router on a flat, level surface with back of fixed base facing you, Open Router Motor Clamp (A),

4_ While continuing to press the Coarse Adjustment Knob (B), turn the Fine Adjustment Dia! (F) until ZERO "0" mark on Depth Indicator Ring (E) is lined up with the "1" mark on base.

5.Release the Coarse Ad-

justment Knob, making sure the "0" stays lined up with the mark,

6_ Place the router on two level scrap work pieces, positioned so the cutting bit can be lowered below the sub-baseo

7.Turn the Fine Adjustment Dial (F) counterclockwiseito lower the bit to the desired depth of cut?? Turn the dial clockwise to raise the cutting bit,

8.Once your depth of cut is set, close the router motor clamp (A) securely.

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 OFICUT in a single pass.

Deep Cuts

The proper cutting depth for each pass is always determined by the material, the cutting bit size and type, and the power of the router motor.

Always make several progressively deeper cuts by starting at one depth and then make several passes, each time increasing the cutting; depth until your desired depth is reached.

Making a cut that is too deep will stress the router motor and the cutting bit, and it may burn the work piece and dull the cutting bit. It could also "grab" too much

of the work piece and cause you to lose control of the router, causing a serious accident.

To be certain that your depth settings are as desired, always make test cuts in scrap material similar to your work piece before beginning your final cutting.

Remember, knowing the right depth for each cut comes with routing experience.

TOGGLE "ON/OFF" SWITCH (Fig. 7)

"four router motor is turned "ON" and "OFF" by the toggle switch located on the top cap of the router motor.

The left side of the toggle switch hood (as you face it) is marked "1" for "On" and the

right side (as you face it) is marked "O" for "Off??"

TO TURN THE ROUTER MOTOR "ON," Push the toggle switch to the left side marked "1," or "On."

TO TURN THE ROUTER MOTOR

"OFF" Push the toggle switch to the right side marked "O," or "Off."

When turning the toggle switch "On," always support ohe edge of the router base on the work piece while holding the cutting bit away frdm the work piece. Only contact the work piece with the cutting bit after the rou_ter has reached full speed,. ONLY remove the router and cutting bit from the work piece AFTER turning the router motor "OFF," and the cutting bit has come to a cbmplete stop.

Operating in this manner will increase toggle switch and motor life, and will in- crease the quality of your work.

Using edge-guide with fixed base for intema] cuts

!

I

DETACHABLE POWER CORD (Fig., 11)

The router has a detachableFig,, 11 power cord for easy carrying

and storage.

Note: Always attach the Detach- able Power Cord to the Router before connecting the Power Cord to the power source

Before turning the router on, connect the end of the power cord with two sockets to the power outlet located on the router motor's top cap (See indicator label on the Router)??

Electronic Variable Speed Control

The electronic speed control feature allows router motor speed to be matched to cutter size and material hardness for an improved finisl_ and extended bit life.

Reduce the speed when using extra large 1 in. plus, or heavy cutting bits?? Chang- ing the router s rate of feed can also improve the quality, of the cut.

The speed charts above indicate the relationship between speed settings and the

cutting application. Exact settings are determined by operator experience and preference, and also by recommendations by manufacturers of cutting bits.

ELECTRONIC FEEDBACK CIRCUITRY

The router's electronic feedback circuitry monitors and adjusts power to main-

tain the desired RPM for consistent performance andlcontrol, providing constant speed under load for a quality finish in all materials

PLACING THE ROUTER ONTO THE WORKPIECE AND STARTING THE CUT

_k WARNING: Before operating your router follow all safety instructions in this manual. Failure to do so could result in serious personal injury.

NOTE: Making test cuts is essential with most routing applications. Even

with careful set-ups you won't know exactly how the cut will go until you

try it out. A test cut will give you a feel for the set-_p, the router's speed,

the depth of cut and how the cutting bit reacts to!he work piece. Much of muting is a trial-and-error process of making var=0us adjustments, fol-

lowed by test cuts as you become familiar with all iof your router's op- erational abilities. To avoid ruining good material, make your test cuts on

scrap materials.

How you place your router onto a work piece to start the cut depends on the type of routing you are going to perform: Edge Routing or In_rnal Routing.

EDGE ROUTING OR INTERNAL ROUTING

For ease of operation and to maintain proper control, your router has two handles, one on each side of the router base. When ofSerating the router, always hold it firmly with both hands (Fig, 12)o

Turn the router "On," let the router motor build to its full speed, then gradually feed the cutting bit into the work piece. ALWAYS be alert and watch what you are doing. NEVER operate the router when you are fatigued.

Edge Guide

EDGE ROUTING (Fig. 12)

,With depth-of-cut set, place router on edge of

work piece, making sure

the cutter does not con-Edging with Fixed Base tact the work piece..

,,

5_ When cut is completed, turn router motor "Off" arid let cutting bit come to a

complete stop before removing it from the work p!ece.

6.Unplug router from power source, place router upside down on worktable,

and inspect finished cut in work piece,i

A_ WARNING: Removing cutting bit from work pie_ce while it is still rotat-

ing could damage work piece and result in loss of icontrol, causing serious

OTE: Making test cuts m scrap materml that =s si_ndar to your work piece is

essential. Learning how the router's speed, depth._of-cut and cutting bit will react in the work piece will help you produce quali_ cuts.

INTERNAL ROUTING (Figs. 13, 13a, 13b)

1.With depth-of-cut set, tilt

,Turn router motor "On" and Fig. 13a let motor build up to its full

speed, being careful not to let cutting bit contact work piece,,

Fig. 13b

3_ To begin your cut, gradually feed the cutting bit into the work piece until the sub-

base is level with the workFeed Direction piece (see Fig 13a, 13b).

4.When cut is completed, turn motor "Off" and let c[Jtting bit come to a com- plete stop before removing it from the work piece.

5_ Unplug router from power source, place router upside down on worktable, and inspect finished cut in work piece.

FREEHAND ROUTING WITH THE FIXED BASE (Fig. i 14)

large cutting bits for free- hand routing. Use of large cutting bits when freehand routing could cause loss of control or create other haz- ardous conditions that could result in personal injury, if us- ing a router table, large bits should be used for edging only.

When used freehand, the router becomes a flexible and

versatile tool. This flexibilityl

makes it possible to easily rout signs, relief sculptures, letc. When freehand rout- ing:

1 Draw or layout the pattern on the work piece.

2_ Choose the appropriate bit.

NOTE: A core box or V-groove bit is often used for _outing letters and engraving objects. Straight bits and ball mills are o_ten used to make relief carvings. Veining bits are used to carve small, intricate details.

NOTE: Making a single deep cut is never advisable.fSmaller diameter bits are easily broken by too much side thrust and torqt_e. Larger bits will cause a rough cut and be difficult to guide and control. F_r these reasons, DO NOT EXCEED 1/8 in. DEPTH OF CUT in a single pass.

WARNING: Always securely clamp your work piece and keep a firm grip

on the router base with BOTH HANDS at all times. ITailure to do so could result in loss of control causing possible serious personal injury.

"Top Edge of Workpiece

cut-either because the work piece is too thin or the bit is

set too low (see Fig. 15a)o This guide board must have exactly the same contour r

- straight or curved - as the work-piece edge. If the guide board is positioned so

I

that it extends from the work piece, the bit will make less than a full cut, which will alter the shape of the finished edge

NOTE: The size (diameter) of the pilot determines ti_e maximum cut width

that can be made (the small pilot exposes all of the bit; the large one re -L duces this amount by 1/16 in.). Any of the piloted cutting bits can be used

without a pilot, but with a guide, for edge shaping.,

_t_ WARNING: Always securely clamp your work piece and keep a firm grip

on the router base with BOTH HANDS at all times. _ailure to do so could result in loss of control causing possible serious personal injury.

FEEDING THE ROUTER (Fig. 16)

TERNAL CUTS (Fig. 16)

If you feed the router in the opposite direction (right to le |), the rotating force of the cutting bit will tend to throw the bit away from the work i: iece, making it hard to control; this is called Climb-Cutting, which is cutting in tl- e opposite direction of the proper feed direction. Climb Cutting increases the chanc e for loss of control, pos- sibly resulting in personal injury. When Climb Cutting is r_quired (backing around a

corner for example), exercise extreme caution to maintai? control of the router. Because of the high speed of the cutting bit during a p_'oper feeding operation

(left to right), there is very little kickback under normal_onditionso However, if the cutting bit strikes a knot, an area of hard grain in the wood work piece, or a

foreign object, the normal cutting action could be affe_ed and cause "Kickback.."

This Kickback may cause damage to your work piece,h_nd could cause you to lose control of the router, causing possible personal injury. Kickback is always in the opposite direction of the clockwise cutting bit rotation, or counterclockwise.

To guard against and help prevent Kickback, plan y_ur set-up and direction of feed so you're always moving the router, keeping the sl_arp edges of the cutting

bit continuously biting straight into new (uncut) wood (v_ork piece). Also, always inspect your work piece for knots, hard grain, and foreign objects that could cause a kickback problem.

is the possibility of Climb Cutting around curves. In eithe case, Fig. 17 or Fig?? 15a, the sideways thrust of the router cutting is always against meguide, as is proper??

_k WARNING: Always securely clamp your work pi .=ce and keep a firm grip on the router base with BOTH HANDS at all times. I :allure to do so could result in loss of control causing possible serious pe rsonal injury.

Forcing the feed of the cutting bit forward too fast slows the

RPM of the cutting bit, and the bit takes bigger bites as it ro- tates,. Bigger bites mean bigger

chips and a rough finish. ThisTOO forcing action can also cause

the router motor to overheat.

!

Under extreme force-feeding conditions, the RPMs cari become so slow and the bites become so large that chips become partially cut _ff, causing splintering and gouging of the work piece.

The router will make clean, smooth cuts if allowed to ruln freely without the over- load of forced feeding. You can detect forced feeding !_ the sound of the motor.. Its usual high-pitched whine will sound lower and stronger as it loses speed.

Holding the router against the work piece will also be s!rained and harder to do

FEEDING TOO SLOW (Fig. 18a)

When you feed the cutting bit too slowly, the rotating c_ itting bit does not cut into new wood fast enough to take a bite. Instead, it scrape ; away sawdust-like par- ticles. This scraping produces heat, which can glaze, b Jrn and mar the cut in the work piece and, in extreme cases, overheat the cutting bit_

When the cutting bit is scraping instead of cutting, the outer is more difficult to control as you feed it.

L

shield deflector helps keep dust and chips away frc_m the operator; it will

not stop objects larger than woodchips thrown fror_ the bit.

/

CAUTION: ALWAYS have the chip shield deflector in place on the base when operating the router.

WARNING: ALWAYS turn router motor off and u_)plug router from power

source before making any adjustments or installin_ accessories. Failure to turn router motor off and unplug router could result in accidental starting which can cause serious personal injury.

To adjust Depth with the Depth-Adjustment Wrenc_ (Fig?? 21)

NOTE: The Depth-Adjustment Fig?? 2i

Wrench supplied is used to

adjust the depth of cut when the router fixed to the router

table (Model No. 320. 28180).

The bit depth can be adjusted

by turning the Micro Adjust- ment Dial clockwise or coun-

terclockwise with the wrench

supplied. The depth of the cut can be read on the scale

dial. Each mark on the scale

indicates a 1/64 in. change in

depth setting??

1.Switch off the router??

2.Loosen the router motor clamp??

3o Insert the wrench into the adjusting hole on the tabl_e top, turn the adjustment knob clockwise with the wrench to move the collet ]down, or counterclock-

wise to move the collet up,,

4.When the desired depth of cut is set, tighten the cl_mpincl lever.

_k WARNING: To ensure safety and reliability, all r_pairs should be per-, formed by a qualified service technician at a Seard Service Center=

GENERAL

Only the parts shown on the parts list are intended for repair or replacement by the customer. All other parts represent an important part of the double insulation system and should be serviced only by a qualified Sea_rs service technician.

_k WARNING: For your safety, ALWAYS turn off swiich and unplug muter mo- tor from the power source before performing any maintenance or cleaning.

It has been found that electric tools are subject to acce_lerated wear and possible

premature failure when they are used to work on fiber _lass boats and sports cars, wallboard, spackling compounds or plaster, The _hips and grindings from

these materials are highly abrasive to electrical tool pairs, such as bearings, brushes, commutators, etc. Consequently, it is not recommended that this tool

be used for extended work on any fiberglass material, _allboard, spackling com- pound or plaster?? During any use on these materials, it is extremely important that the tool is cleaned frequently by blowing with an air jetJ

A_k WARNING: Always wear safety goggles or safe_y glasses with side

shields during power tool operations, or when blov_ing dust. if operation is dusty, also wear a dust mask.

ROUTINE MAINTENANCE

A_k WARNING: DO NOT at any time let brake fluids, gasoline, petroleum- based products, penetrating oils, etc. come in contact with plastic parts.

Chemicals can damage, weaken or destroy plastic, which may result in seri- ous personal injury.

= Use clean damp cloths to wipe the tool

???Check the state of all electrical cables.

=Keep the router motor air openings free from oil, gr4ase and sawdust or

woodchips, and store tool in a dry place.

=Be certain that all moving parts are well lubricated, _aarticularly after lengthy exposure to damp and/or dirty conditions.

WARNING: For your safety, ALWAYS turn off switch and unplug muter mo-

tor from the power source before performing any m_jntenance or cleaning.

!

Refer to ColletiNut Care and Cutting Bits on page t 7 f_r cleaning and care

!

REPLACEMENT OF CARBON BRUSHES (Fig. 22)

Replacement brush sets are available through Sears Fiarts and Repair Centers_ 1o Unplug the router motor before inspecting or repla_ing brushes??

2.Replace both carbon brushes when either has les_ than 1/4 in. length of car- bon remaining, or if the spring or wire is damaged }or burned??

3o Using a slotted screwdriver, remove the black plastic cap on each side of the router motor (Fig?? 22) and carefully withdraw the s_ringqoaded brush assem- blies, Keep brushes clean and sliding freely in thei_ guide channels.

NOTE: To reinstall the same brushes, make sure th! brushes go back in the

same way they came out This will avoid a break4qperiod.

4.Insert new brush assemblies

Figo22

into guide channels, with the carbon part going in first, being certain to fit the tx???o metal "ears" into their slots in the channel (Fig. 22)_

_k WARNING: For your safety, ALWAYS turn off swiich and unplug router mo- tor from the power source before performing any maintenance or cleaning.

LUBRICATION

All of the bearings in this tool are lubricated with a suffi_cient amount of high- grade lubricant for the life of the tool under normal ope_ting conditions. There- fore, no further lubrication is required,,

WARNING: The use of attachments or accessories that are not recom-

mended for this tool might be dangerous and coul d result in serious injury.

,k

WARNING:Only use router tables with proper guarding for the cutting bit and with "on-board" switch controlled receptac,les." Failure to use router

tables with appropriate safety features could resul ! in serious personal

R _

inJUry.

I

12.5 Amp / Variable Speed / 2-1/4 Peak HP Fixed B_se Router MODEL NUM- BER 320.28190

The Model Number will be found on the Nameplate.

Always mention the too!'s model number when orderiqg parts,

Fixed Base

57

59

GO

12.5 Amp / Variable Speed / 2-1/4 Peak HP Fixed =se Router MODEL NUM-

BER 320.281g0

The Model Number will be found on the Nameplate.

Always mention the the tool's model number when or( ering parts??

Router Motor Unit

2_

24

25

15

28

f2

f 29

BER 320.28190

The Model Number will be found on the Nameplate.

Always mention tool's model number when ordering p rts,