Craftsman 320.27666 User Manual

Operator's Manual

II:RAFTSMAN°I

10.0 Amp 1-3/4 Peak HP
Plunge-Base Router

Model No. 320.27666

c_tus

• WARRANTY

• SAFETY

• UNPACKING

WARNING: To reduce the risk of

injury, the user must read and
understand the Operator's manual
before using this product.

Sears Brands Management Corporation, Hoffman Estates, IL 60179 U.S.A.
www.craftsman.com

• DESCRIPTION

• OPERATION

• MAINTENANCE

• TROUBLESHOOTING

• ESPANOL

iII_ =[e_[_e__]

Warranty page 2
Safety Symbols page 3

Safety Instructions page 5-10
Unpacking page 10-14
Description page 14-29
Operation page 14-29
Maintenance page 30-31

Troubleshooting page 32

Exploded View and Part List page 33-37
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

WARNING: Some dust created by using power tools contains chemicals

known to the state of California to cause cancer and birth defects or other re-
productive 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.

27666 ManuaLRevised_11-0114 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

SAFTY 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 these 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.

27666 ManuaLRevised_11-0114 Page 3

_, WARNING: Read all safety warnings and instructions. Failure to follow

the warnings and instructions may result in electric shock, fire and/or serious

injury.

SYMBOL

v

A

Hz

W

min

n o

[]

NAME DESIGNATION/EXPLANATION

Volts Voltage

Amperes Current

Hertz Frequency (cycles per second)

Watt Power

Minutes Time

Alternating Current Type of current

Direct Current Type or a characteristic of current

No Load Speed Rotational speed, at no load

Class II Construction Double-insulated construction

_./rain

Read The Operator's Manual read and understand operator's manual

O Always wear safety goggles or safety

,_ Alert Precautions that involve

Per Minute Revolutions, strokes, surface speed,

Wet Conditions Alert Do not expose to rain or use in damp

Eye Protection glasses with side shields and a full face

Safety

No Hands Symbol Failure to keep your hands away from theblade will result in serious personal injury.

No Hands Symbol blade will result in serious personal injury.

No Hands Symbol blade will result in serious personal injury.

No Hands Symbol Failure to keep your hands away from the

orbits, etc., per minute

locations.

To reduce the risk of injury, user must
before using this product.

shield when operating this product.

safety.

your

Failure to keep your hands away from the

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.

27666 ManuaLRevised_11-0114 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

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.

• 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 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.

27666 Manual_Revised_11-0114 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.

27666 Manual_Revised_11-0114 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.

_1, 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.

A_, 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

• 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.

27666 ManuaLRevised_11-0114 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 on the router with both hands to resist starting torque.
Never attempt to use the router motor without first installing it in an

approved base. Failure to heed this warning could result in personal injury
and damage to the motor.

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.

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 all nails from lumber before routing.

27666 ManuaLRevised_11-0114 Page 8

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 34/2 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 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 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.

Disconnect the tool from the power source before making any
adjustments or changing cutter bits.

27666 ManuaLRevised_11-0114 Page 9

• 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: Bits, sockets, and tools get hot during operation.

Wear gloves when touching them.

_1, 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.

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 it on a stable, flat surface.

2.

Open the carton to locate the following:

• Vac adapter and 2 screws used to attach it to the base

• Chip shield (already installed on router)

• 1/4-inch .collet/nut (already installed on router)

• 1/2-inch collet/nut

• Collet/nut wrench

• Depth-Adjustment Wrench

• 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.

_1, 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.

27666 ManuaLRevised_11-0114 Page 10

CARTON CONTENTS (Fig. 1)

®ii

Plunge Base Router

Vac adapter

Chip shield (already installed on router)

2 screws (for attaching vac adapter)

1/4-inch Collet/Nut (already installed on router)
1/2-inch Collet/Nut

Depth-Adjustment Wrench

Collet/Nut Wrench

27666 ManuaLRevised_11-0114 Page 11

KNOW YOUR PLUNGE 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. 1

Motor housing

Super-fine

e base

adjustment knob

Depth indicators

Spindle lock

Depth-rod locking __ Self-releasing
knob Collet/Nut System

Depth rod p shield

Super-fine adj

screw Non-mar sub-base

Depth-stop turret

Air vents

"Live Tool Indicator"

Key-strip slot

On / Off Toggle Switch

Light

8-ft. power Cord

Ergonomic Handles

Plunge-depth
locking lever

Quick-release lever Plunge sub-base

Vacuum port

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.

27666 ManuaLRevised_11-0114 Page 12

PRODUCT SPECIFICATIONS

Rating 10.0 Amps
No Load Speed 10000-25000 RPM

Peak HP 1-3/4
Input 120-volt, 60Hz AC

Collets/Nuts and Cutter-bit Shank Diameters 1/4 in. and 1/2 in.
Plunge Base Diameter 6-11/16 inches

Sub-Base Opening (Diameter for cutter bit use) 1-1/4 inches
Sub-Base Thickness 1/4 inch

Plunge Base Depth of Cut 2-1/8 inches

_, 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.

Powerful, 10.0 Amp Soft Start Motor develops 1-3/4 Peak HP to handle
most routing jobs.

.

Variable-Speed Motor runs at 10,000 to 25,000 RPM (no-load speed).

3.

Variable-Speed Dial allows matching proper speed to material and cutter
bit size.

4.

Plunge Base features Fine and Micro Depth Rod Adjustments with Turret
Stops for precise set-ups and repetitive cutting.

5.

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.

7.

Spindle Lock for easy one-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.

8.

100% Ball Bearings for smooth, efficient operation and long life.

9.

Base Features Large Base Openings and Large Chip Shield, combined
with 3 LED Worklights on Motor to provide high visibility of bit and

workpiece.

10. Durable Non=marring Sub-base glides smoothly over the workpiece. Sub-
base cutter bit opening is 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!

27666 ManuaLRevised_11-0114 Page 13

11. Motor Housing constructed of High Density Nylon and Precision Milled
Cast Aluminum for strength and exact fit into bases.

12. High-impact resistant Motor Housing Top Cap and Handles on Base help

protect tool from damage.

13. Conveniently located ON/OFF toggle switch, side mounted for added
visibility, easy access.

14. Vac adapter allows base to hook up to 1-1/4 inch vac hose attachment, sold
separately.

15. Quick=release edge guide lever for quick installation of and adjustments to
an edge guide (sold separately).

16. "MVE TOOL INDICATOR" light is green when the router is plugged into a

power source. Light is located on motor housing top cap next to power cord
inlet.

17. Replaceable Carbon Brushes (sold separately) for dependable service.

18. Includes carry bag for easy carrying and storage.

NOTE: This tool is shipped completely assembled. To install or remove cutter
bits or add accessories such as vac adapter 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, 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.
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.

A_, 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.

27666 ManuaLRevised_11-0114 Page 14