Craftsman 320.27680 User Manual

Operator's Manual

I CRAFTSMAN°I

_ PROFESSI ONAL_

14.0 Amp, Variable Speed
2-1/2 Peak HP Router Combo

With Fixed Base and Plunge Base

Model No. 320.27680

c us

• WARRANTY

• SAFETY

• UNPACKING

• DESCRIPTION

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

• OPERATION

• MAINTENANCE

• TROUBLESHOOTING

• ESPANOL

Warranty page 2
Safety Symbols page 3

Safety Instructions page 5-9
Unpacking page 10-11
Description page 12-14
Operation page 15-36
Maintenance page 37

Troubleshooting page 39

Exploded View and Part List page 42-48
Sears Repair Parts Phone Number Back Cover

CRAFTSMAN PROFESSIONAL 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 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.

27683 ManuaLRevised_11-0120 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.

_h, 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
_1, SAFETY ALERT SYMBOL: Indicates DANGER, WARNING, OR CAUTION.

May be used in conjunction with other symbols or pictographs

_I, DANGER: Indicates a hazardous situation, which, if not avoided, will result

in death or serious injury.

_1, WARNING: Indicates a hazardous situation, which, if not avoided, could
result in death or serious injury.

CAUTION: Indicates an hazardous situation, which, if not avoided, may

result in minor or moderate 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 "NOTICE," as in the example below:

NOTICE: Equipment and/or property damage may result if these instructions are
not followed.

WARNING: To ensure safety and reliability, all repairs should be performed

at a Sears Parts & Repair Service Center.

_, WARNING: The operation of any power tools can

result in foreign objects being thrown into your eyes,
which can result in severe eye damage. Before beginning

power tool operation, always wear safety goggles or safety
glasses with side shield and a full face shield when needed.

We recommend a Wide Vision Safety Mask for use over
eyeglasses or standard safety glasses with side shields.

Always use eye protection which is marked to comply with
ANSI Z87.1

27683 ManuaLRevised_11-0120 Page 3

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.

SYMBOL NAME DESIGNATION/EXPLANATION

V Volts Voltage

A Amperes Current

Hz Hertz Frequency (cycles per second)

W Watt Power

rain 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,

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

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

O Always wear safety goggles or safety

Eye Protection glasses with side shields and a full face

Safety

Alert Precautions that involve

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.

27683 ManuaLRevised_11-0120 Page 4

GENERAL POWER TOOL SAFETY WARNINGS

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

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

• Know your power tool. Read the operator's manual carefully. Learn the

applications, as well as the specific potential hazards related to this tool.
Following this rule will reduce the risk of electric shock, fire or serious injury.

• Save these instructions. Refer to them frequently and use them to instruct

others who may use this tool. If someone borrows this tool, make sure they
have these instructions also.

The term "power tool" in the warnings refers to your mains-operated (corded)

power tool or battery-operated (cordless) power tool.

WORK AREA SAFETY

• Keep the work area clean and well lit. Cluttered or dark areas 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.

• 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.

• Inspect the tool cords periodically and, if damaged, have them repaired

at your nearest Sears Service Center. Be aware of the cord location.

• 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 (GFCI) protected supply. Use of a GFCI

reduces the risk of electric shock.

27683 ManuaLRevised_11-0120 Page 5

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 must wear.

• Use personal protective equipment. Always wear eye protection. Protective

equipment such as dust mask, non-skid safety shoes, hard hat, or hearing
protection used for appropriate conditions will reduce personal injuries.

• 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.

• 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.

27683 ManuaLRevised_11-0120 Page 6

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. 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.

A_, WARNING: When using power tools, basic safety precautions should always
be followed to reduce the risk of fire, electric shock, and personal injury.

WARNING: The operation of any tool can result in foreign objects being

propelled into your eyes, resulting in severe eye damage. When operating power

tool, always wear safety goggles or safety glasses with side shields and a full
face shield when needed.

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.

• 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 should be performed only at a Sears Parts & Repair Service

Center. Service or maintenance performed by unqualified personnel could
result in a risk of injury.

27683 ManuaLRevised_11-0120 Page 7

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.

• 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, 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 it is not properly attached according
to the instructions.

• Tighten the collet/nut securely to prevent the cutter bit from slipping.

If the collets/nut is not securely tightened, the cutter bit may detach during
use, causing serious personal injury.

• Never tighten collets/nuts without a cutter bit installed in the collets/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, and 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.

• Check to see that the cord will not "hang up" during the 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 the full

selected speed before contacting the workpiece.

• Keep hands clear of the cutter bit when the motor is running to prevent

personal injury.

27683 ManuaLRevised_11-0120 Page 8

• 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 router have openings 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 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.

• 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 the "OPERATION"

section in this manual. "Climb cutting" increases the chance for loss of
control resulting in possible serious injury.

27683 Manual_Revised_11-0120 Page 9

_h, 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 carton and place it on a stable, flat surface.

2. Open the carton to locate the following:

• Detachable power cord

• Fixed Base,plunge base and Router motor

• 2 Vacuum ports: one each for plunge base

• 1/4 in. collet/nut (the 1/2 in. collet/nut is already installed on the router)

• 2 screws for attaching the vacuum ports to plunge and fixed base

• Collet/Nut wrench

• 2 Chip shields: one each for the plunge and fixed bases

• Edge guide

• Depth-adjustment wrench

• Carry case

• 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
"Carton Contents" 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

Detachable power cord

Fixed Base and Router motor with 1/2-in.
Collet/Nut installed

27683 Manual_Revised_11-0120 Page 10

Plunge Base

Vacuum Port for Plunge Base

Vacuum Port for Fixed Base

2 Chip Shields

2 Thumb Screws (for attaching port to

plunge base)

©

1/4-in. Collet/Nut

Edge Guide

Depth-Adjustment Wrench

Collet/Nut Wrench

27683 ManuaLRevised_11-0120 Page 11

I,]_]_II]_III[,]_]

KNOW YOUR ROUTER (Fig. 1)
NOTICE: Before attempting to use your router, familiarize yourself with all of the

operating features and safety requirements.
Your 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 10-ft., 2-wire power cord (no adapter needed).

Fig. 1 Router Motor Top

Cap

Switch

Spindle Lock Collet/Nut

Depth-Rod

ust Knob

Depth-Rod
Indicator

Depth-Rod
Locking Edge Guide

knob

Depth-Stop

Turret

Mounting Slot

Variable Speed Micro Adjust- Live Tool Indicator Light

Dial ment Dial

. Power Outlet

Edge Guide p
Locking Knob i

;lear Plastic

Chip Shield

Edge Guide
Mounting Slot

Motor Clamp

Vacuum Port

Handlewith
Soft-Grip

\

Quick release
lever \

Plastic

Chip
Shield

Quick release

Lever

Sub-Base

Vacuum Port

Plunge-
Depth
Locking

Lever

27683 ManuaLRevised_11-0120 Page 12

_, WARNING: Do not allow familiarity with the router to cause a lack of alertness.
A fraction of a second of carelessness is enough to cause severer injury

PRODUCT SPECIFICATIONS

Rating 14.0 Amps
No Load Speed 10000-25000 RPM

Peak HP 2-1/2
Input 120V, 60Hz AC

Collets/Nuts and Cutter bit Shank

1/4 in. and 1/2 in.

Diameters
Fixed Base Diameter 6 inches

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 (6mm)

Fixed Base Depth of Cut 1-3/4 inches (45mm)
Plunge Base Depth of Cut 2-1/8 inches (55mm)

_1_ 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.

The Router Combo has the following features:

1. 14.0 Amp, 2 1/2 Peak HP, Variable Speed Motor runs at 10,000 to 25,000

RPM (no-load speed).

2. Variable Speed Dial for matching the speed to the material and cutter bit size.

3. Electronic Feedback Circuitry provides soft starts for longer motor life and

maintains constant speed under load to help produce a high-quality finish in
all materials.

4.

Quick-clamp System allows motor to be changed from the fixed to plunge
base and back without the use of tools.

5. Fixed Base features Coarse and Micro-Depth Adjustments for accurate

set-ups.

6. Plunge Base features Fine and Micro Depth Rod Adjustments with Turret

Stops for precise set-ups and repetitive cutting.

7. Smooth Plunge Action lowers the bit into the workpiece at 90 ° for more

accurate cutting.

27683 Manual_Revised_11-0120 Page 13

8. Protective Plunge Post Bellows protect guideposts from woodchips, dust,

and moisture.

9. Spindle Lock for easy 1-wrench bit changes. Includes 1/4 and 1/2 inch

Self-Releasing Collets/Nuts for use with a wide variety of 1/4 in. and 1/2 in.
router bits, sold separately.

10. 100% Ball Bearings for smooth, efficient operation and long life.

11. Both bases feature Ergonomically Designed Handles with soft grip for

comfort, maximum control with less vibration.

12. Both bases feature Large Base Openings and Large Chip Shields,

which,combined with 3 LED Worklights on the motor housing enhance the
visibility of bit and workpiece.

13. Durable Non-marring Sub-bases glide smoothly over the workpiece. Sub-

bases have cutter bit openings of 1 1/4-inches. Do Not Use a bit with a

cutter diameter larger than 1-1/4 inch with the included sub-bases, as it will

not pass through the sub-base opening!

14. Motor Housing constructed of Precision Milled Cast Aluminum for strength

and exact fit into bases.

15. High-impact Resistant Motor Housing Top Cap and Handles on bases

help protect tool from damage.

16. Heavy-duty Edge Guide for most routing applications, such as decorative

edging, grooving, dadoing, slotting and straight edge planing/trimming.

17. Conveniently located On/Off Toggle Switch, side mounted for added

visibility and easy access.

18. Vacuum Ports allow both bases to attach to a 1/4-inch vac hose

attachment, sold separately.

19. "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.

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

21. Includes carry bag for easy carrying and storage.

27683 ManuaLRevised_11-0120 Page 14

NOTICE: This tool is shipped completely assembled. To change the router
motor from one base to another, install or remove cutter bits or add accessories

such as vacuum ports for hook-up to vacs or install the heavy-duty edge guide,
see the following instructions.

DETACHABLE POWER CORD (Figs. 2, 2a)

The router has a detachable power cord for
easy carrying and storage.

Fig. 2

NOTICE: Always attach the detachable power

cord to the router before connecting the power
cord to the power source. Before turning the

router on, connect the long power cord to the

power outlet located on the router motor top

cap (see indicator label on the router).
SELECTING THE CUTTER BIT

This router comes with 1/4 inch-, and 1/2

inch-, collets/nuts that accept cutter bits with
1/4 inch and 1/2 inch shanks, respectively. Fig. 2a

_lk WARNING: Do not use a router cutter bit
that has a cutter bit diameter larger than 1-1/4

inches with the sub-bases that are supplied with

this router. A larger cutter bit 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.

NOTICE: The sub-bases included with this

router have openings 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
Installing the Cutter Bit for Fixed Base

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

2. Remove the motor housing from fixed base.
NOTICE: See the instructions for removing the motor housing from the fixed

base in this manual.

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

27683 ManuaLRevised_11-0120 Page 15

4. Press the spindle-lock button to engage

and lock the spindle shaft and collet/nut

Collet

Nut

Spindle Lock

(Fig. 3)

5. Place the wrench on the collet/nut and

turn it counterclockwise to loosen the
collet/nut slightly so it can accept cutter

bit shank.

6. 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).

NOTICE: To insure proper gripping of the

Fig. 4 /_<'w_ \ Cutters

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.

"_X_j Bit Shank

"J _ Spindle

7. With the cutter bit inserted and the spindle

lock button pressed in to engage the

shaft, place the wrench on the collet/nut
and turn it clockwise until the collet/nut is

firmly tightened on the cutter bit.

_, WARNING: Tighten the collet/nut
securely to prevent the cutter bit from

slipping. If the collet/nut is not securely

Fig. 4a . Cutters

_/ Collet /

tightened, the cutter bit may detach during

use, causing serious personal injury.
NOTICE: To prevent damage to the tool, do not

tighten the collet/nut without a cutter bit installed.

Removing the Cutter Bit from Fixed Base

1. Turn the motor off and unplug the router

from the power source.

NOTICE: See the instructions for removing the motor housing from the fixed base.

2. Remove the motor from the fixed base.

3. Set the motor upside down on its top cap, with the 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 counter-clockwise to loosen

the collet/nut slightly.

6. Remove the cutter bit shank.
Installing the Cutter Bit for Plunge Base

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

2. Remove the motor housing from the plunge base.

27683 ManuaLRevised_11-O120 Page 16

NOTICE: See the instructions for removing the motor housing from the plunge base.

3. Place the router motor upside down on its top cap with the collet/nut

pointing up.

4. Press the spindle-lock button to engage and lock the spindle shaft and

collet/nut (Fig. 3).

5. Place the wrench on the collet/nut, and turn it counterclockwise to loosen

collet/nut slightly to 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).

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

7. With the cutter bit inserted and the spindle-lock button pressed in to engage

the shaft, place the wrench on the collet/nut and turn it clockwise until the

router cutter bit and the collet/nut are firmly tightened.
_, 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.

NOTICE: To prevent damage to the tool, do not tighten the collet/nut without a

cutter bit installed.

Removing the Cutter Bit from Plunge Base

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

2. Remove the router motor from the base.

3. Place the router motor upside down on its top cap, with the 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 slightly

loosen collet/nut.

6. Remove the cutter bit shank.

NOTICE: The collet/nut is self-releasing; it is not necessary to strike the collet/
nut to free the router cutting bit. If the cutter bit seems stuck after use, loosen

the collet/nut a litter more until it releases.

COLLET/NUT CARE

Before each use, inspect the collet/nut to make sure that it is clean and that it _s

gripping the cutter bit properly.
With the router cutter bit removed, turn the collet/nut counter-clockwise (with the

spindle-lock engaged) until it is free from the motor's spindle shaft.

Blow the collet out with compressed air, and clean the tapered inside of the

collet/nut with a tissue or a fine brush.

27683 Manual_Revised_11-0120 Page 17

_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 small amount of machine oil to the spindle shaft if it looks dry.

Replace a worn or damaged collet/nut immediately.
NOTICE: The collet/nut is self-releasing; it is not necessary to strike the collet/

nut to free the router cutter bit. If the cutter bit seems to be stuck after use,
loosen the collet/nut a little more until it release.

CUTTER BITS

Keep cutter bits clean and sharp for faster, more accurate cutting results.
Remove all accumulated pitch and gum from cutter bits after each use.

When sharpening cutter bits, sharpen only the inside of the cutting edge for fast,

more accurate cutting results.
Never grind the outside diameter. Be sure, when sharpening the end of a cutter

bit, to grind the clearance angle is the same as originally ground.
INSTALLING THE ROUTER MOTOR IN THE BASES

_, WARNING: Never use the router motor without installing it into either an
approved fixed or plunge base. Failure to do so could result in serious personal

injury and damage to motor.

_, WARNING: Always turn the motor off and unplug the router from the power
source before making any adjustments or installing accessories. Failure to turn
the motor off and unplug the router could result in accidental starting which can

cause serious personal injury.
To Install the Motor in Fixed Base (Fig. 5}

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

2. Place the fixed base on a flat surface.

3. With the back of the fixed base

facing you, open the router motor

clamp (A).

4. Press in the coarse adjustment knob

(B) while you align the motor slot (C)

with the pin (D) in the fixed base.

5. When the motor slot is aligned

and engaged into the pin, slide the

motor down into the fixed base.

6. The motor will now slide up

or down to set the coarse

adjustments when the coarse

adjustment knob is pressed in.

27683 Manual_Revised_11-0120 Page 18

7. After all adjustments are made, close the motor clamp securely.
To install the Motor in Plunge Base (Fig. 5a)

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

2.

Place the plunge base on a

Fig. 5a

fiat surface.

3.

With the back of router facing you,

B

open the motor clamp (A) and make
sure that the plunge action is in the

"UP" position with the plunge lock
lever (B) locked.

4.

With the motor housing slot (C)
aligned with the plunge base pin

(D), lower the motor housing into
the plunge base, engaging the pin

into the slot.

5. Slide the motor into the base as far as it will go.

6. Close the motor clamp securely.

REMOVING THE MOTOR FROM THE BASES

To remove the Motor from the Fixed Base (Fig. 5)

A_, 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. Push in the coarse adjustment knob (B) to release the router motor housing
"slot" (C) from the pin (D) in the base, while you lift motor free of base.

5. Set the motor upside down on its top cap with the collet/nut 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.

To Remove the Motor from the Plunge Base (Fig. 5a}

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

2. Place the router (plunge base and motor housing) on a flat surface.

3. With the back of the plunge base facing you, open the motor clamp (A) and
make sure that the plunge action is in the "UP" position, with the plunge lock

lever (B) locked down.

27683 ManuaLRevised_11-0120 Page 19

4. Lift the motor straight up and out of the base, sliding the motor housing
"slot" (C) free from the pin in the plunge base.

5. Set the motor upside down on its top cap with the collet/nut 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 and cutter bits, cleaning or when it is not in use.

Disconnecting the router will prevent accidental starting, which could cause

serious personal injury.

DEPTH ADJUSTMENT WITH FIXED BASE (Figs. 6 and 7)
NOTICE: All depth adjustments on

the fixed base must be made with the
motor clamp open.

NOTICE: 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

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 cutter bit to an approximate
depth setting.

Fine Adjustments:
NOTICE: Test the fine adjustment

dial (C) by turning it 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).

Fig. 7

\

27683 ManuaLRevised_11-0120 Page 20

The depth indicator ring (D), located on the fine adjustment dial is marked in 1/64th

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 indicator 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 7)

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. Open the motor clamp (E).

3. With the cutter bit already installed, press in the coarse adjustment knob (B),
and lower the motor into the base until the cutter bit 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. Then lock

the motor clamp (E).

4. While continuing to press the coarse adjustment knob (B), turn the fine
adjustment dial (C) until the zero "0" mark on the depth indicator ring (D) is

aligned with the 'T' mark on the base.

5. Release the coarse adjustment knob, making sure that the "0" remains
aligned with the mark.

6. Place the router on two level scrap workpieces, and position it so that the
cutter bit can be lowered below the sub-base (Fig. 7).

7. Turn the fine adjustment dial (C) clockwise to lower the bit to the desired
depth of cut. Turn the dial counterclockwise to raise the cutter bit.

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

NOTICE: 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.
DEPTH ADJUSTMENT WiTH THE PLUNGE BASE

a 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 or cutter bits, cleaning, or when it is not in use.

Disconnecting the router will prevent accidental that which could cause serious
personal injury.

Plunge Action (Fig. 8}

The plunge base simplifies depth adjustment and allows the cutter bit to be
accurately lowered into the workpiece for more precise set-ups.

To lower the cutter bit, release the plunge-lock lever by moving it "up" to the

unlocked position.

27683 ManuaLRevised_11-0120 Page 21

Apply an even, downward pressure on the

plunge action until the cutter bit reaches the

desired depth, then move the plunge-lock

lever "down" to the locked position.

To raise the bit and the plunge action, unlock
the plunge-lock lever. The plunge action will

automatically retract from the workpiece and
return to the raised position.

Always have the plunge action in the raised

position and locked when the bit is not

cutting in the workpiece.

Plunge Action with Depth-Stop Rod and
Depth-Stop Turret (Fig. 9)

The depth-stop rod and the depth-stop turret
are used to control the plunge action cutting depth as follows:

1.

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

2.

Place the router on a flat, level surface.

3.

With the cutter bit already installed, lower

Fig. 9

the plunge action until the cutter bit

makes contact with the flat, level surface

on which the router is sitting. Lock the

plunge-depth locking lever (F). This
position is zero "0": the point from which

D

further depth adjustments can be made.

4.

To set a desired depth-of-cut, rotate the

C

depth-stop turret until the lowest step of
the turret (A) is aligned directly under the

depth-stop rod (B) (Fig. 9). Loosen the

B

depth-rod locking knob (C) and lower the
depth-stop rod until it contacts the lowest

A

step on the turret.

5.

Slide the clear plastic depth indicator (D) until the red line on the indicator is lined

up with zero "0" marked in black on the bottom of the depth scale. (This is now
indicating the point at which the bit makes contact with the workpiece).

6.

To set a desired cutting depth, slide the depth-stop rod up until the red line
on the clear plastic depth indicator points to your desired cutting depth on

the depth scale (E). Secure the depth-stop rod at this position by tightening
the depth rod locking knob (C).

7.

Unlock the plunge-depth-locking lever (F) to allow the bit to automatically

retract to the up position.

8.

The desired depth-of-cut may now be achieved by plunging the router down

until the depth-stop rod contacts the selected step on the depth-stop turret.

27683 ManuaLRevised_11-0120

Page 22

NOTICE: When making depth adjustments on the plunge base, the motor clamp

should always be closed securely.

Using the Depth-Stop Turret to Set Up Deep Cuts (Fig. 10)
NOTICE: Making a single deep cut is never advisable. Smaller diameter cutting

bits are easily broken by too much side thrust and torque. Larger cutting bits

will cause a rough cut and be difficult to
guide and control. For these reasons, do not

exceed 1/8 in. depth of cut in a single pass.
To produce deep cuts, always make several

progressively deeper cuts by starting with the
highest step on the depth-stop turret, and,

after each cut, rotate the turret to the next

lower step until the lowest step is reached.
Each of the steps progresses by 1/8-inch

increments. The 5 steps represent a total of

3/8 inch to 7/8-inch-. with a full 360 ° rotation
of the turret. Repeat this process if necessary.

Micro-adjustments with the Depth-Stop
Rod and Depth-Stop Turret

The depth-stop rod has a micro adjustment

knob (A) that turns a screw (B) (inside the rod)

either clockwise or counterclockwise to lower
or raise the depth-stop rod on the turret (C)

for micro-fine adjustments of the plunge depth.

Each complete revolution of the Micro-adjustment knob adjusts the plunging

depth by approximately 1/32 inch.
A reference indicator line is embossed into the depth-stop rod under the fine-

adjustment knob to set a reference point of "0".
When micro-adjusting the plunge depth, always make sure that the micro-

adjustment knob has been turned down (clockwise) several revolutions from the
top before setting the depth-stop rod and depth-stop turret.

Always set your micro-adjustments with the plunge action locked in the raised,
(or up) position.

To use the micro-adjustment knob after the depth rod and turret have been set,
check the final depth setting and micro-adjust as follows:

• To micro-increase the plunge depth, raise the micro-adjustment screw by
turning the knob counterclockwise the desired amount.

To micro-reduce the plunge depth, lower the micro-adjustment screw by
turning the knob clockwise the desired amount.

27683 Manual_Revised_11-0120 Page 23

TOGGLE "ON/OFF" SWITCH (Fig. 11)
Your router motor is turned "ON" and "OFF"

Fig. 11

with the toggle switch located on the top cap
of the motor housing.

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

right side (as you face it) is marked "1" for
"ON."

To turn the motor "OFF," push the toggle
switch to the left side marked "O" or "OFF."

To turn the router motor "ON," push the
toggle switch to the right side marked "1"
or "ON."

Always hold the router and cutter bit away from the workpiece when turning the
toggle switch "On." Only contact the workpiece with the router and cutter bit

after the router has reached the full selected speed. Only remove the router and
cutter bit from the workpiece after turning the router motor "OFF" and after the

cutter bit comes to a complete stop.

SOFT START FEATURE

The soft start feature minimizes torque twist,
customary in larger router motors, by limiting

Fig. 12

the speed at which the motor starts. This

increases the motor's life.
LED WORKLIGHTS (Fig. 12)

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. 13)
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 a power source.

"Live tool
indicator"

light

HEAVY-DUTY EDGE GUIDE

The router combo kit 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.

27683 ManuaLRevised_11-0120 Page 24

To attach the edge guide to the fixed or

Fig. 14

plunge base, simply insert the edge guide

rods into the edge-guide mounting slots
either from the left or the right.

For fix base Tighten the lever on the left
by turning it clockwise to secure the edge

guide rod (Fig.14). Tighten the lever on right

by turning counterclockwise to secure the

rod (Fig.14).

For plunge base Tighten the lever on the left
by turning it counterclockwise to secure the

edge guide rod (Fig.14a). Tighten the lever on
right by turning clockwise to secure the rod

(Fig.14a)

NOTICE: If the edge guide lever inner screws

wear down or require calibration:

• Pull the lever up and turn it clockwise and
then push the lever down (Fig.15).

Turn the lever counterclockwise to secure
the edge guide.

Fig. 15

ELECTRONIC VARIABLE SPEED

CONTROL (Fig. 16)

The electronic speed control feature allows

motor speed to be matched to cutter size and
material for an improved finish and extended

bit life.

Speed changes are made starting at "1",
rotating the speed control dial to the "LEFT"

to increase the speed, from 1 through 9.

NOTICE: The speed may be changed while

the router is "ON", but not if the cutter bit is in
the workpiece.

Your router motor top cap has a "Variable
Speed Selection Chart," located above
the "ON/OFF" toggle switch, to help you

determine the correct speed for the cutter bit

being used.

WARNING: Before operating your router, follow all safety instructions in this

manual. Failure to do so could result in serious personal injury.
NOTICE: Choose the applicable cutting speed according the bit diameter and

the material being cut.

27683 ManuaLRevised_11-0120 Page 25

Variable Speed Selection Chart

Never exceed these bit speeds
Cutting-Bit Diameter Maximum Speed
UP to 1 in. (25mm) 9

1-1/4 in. to 1-3/4 in. (31-44mm) 7-8

2 in. to 2-1/2 in. (50-63.5mm) 5-6
2-3/4 in. to 3 in. (69-75mm) 3-4
3 in. to 3-1/2 in. (75-90mm) 1-2

Reduce the speed when using extra large bits (with a cutting diameter 1 inch

or greater) or heavy cutter bits. Changing the rate of feed can also improve the
quality of the cut.

RPM

1

2
3
4

5
6

7
8

9

10,000
12,000
14,000
16,000
18,000

20,000
22,000
24,000
25,000

APPLICATIONDIAL SETTING

Non-ferrous metal, hardwoods, larger diameter

cutter bits

Softwoods, plastics, countertops, smaller

diameter cutter bits

The speed charts above indicate the relationship between the speed setting
and the cutting application. Exact settings are determined through operator

experience and preference, and also by recommendations by manufacturers of
cutter bits.

ELECTRONIC FEEDBACK CIRCUITRY

The router electronic feedback circuitry monitors and adjusts power to maintain
the desired speed for consistent performance and control, providing constant

speed under load for a high-quality finish in all materials.

PLACING THE ROUTER ONTO THE WORKPIECE AND STARTING THE CUT
A_, WARNING: Before operating the router, follow all safety instructions in this

manual. Failure to do so could result in serious personal injury.
NOTICE Making test cuts is essential with most routing applications. A test cut

will give a feel for the set-up, the router's speed, the depth of cut, and how the
cutting bit reacts to the workpiece.

27683 ManuaLRevised_11-0120 Page 26

Much of routing is a trial-and-error process of making various adjustments,

followed by test cuts. To avoid ruining good material, make test cuts on scrap

materials.
How you place your router onto a workpiece (starting the cut) with a fixed base

or a plunge base depends on the type of routing you are going to produce: Edge

Routing or Internal Routing, as discussed on

the following pages.

Fig. 17

For ease of operation and to maintain proper

control, your router has two handles, one on
each side of the router base. When operating

the router, always hold it firmly with both

hands (Fig. 17 and 17a).

_lk WARNING: Always be alert and watch
what you are doing. Never operate the router

when you are fatigued.

Deep Cuts

The proper cutting depth (for each pass), is
always determined by the material, the cutter

Fig. 17a

bit size and type, and the power of the motor.

Always make several progressively deeper
cuts by starting at one depth and then

making several passes, each time increasing

the cutting depth until your desired depth is
reached.

Making a cut that is too deep will stress the
motor and the cutter bit, and it may burn the

Edge Guide

workpiece and dull the cutter bit. It could also

"grab" too much of the workpiece and cause

you to lose control of the router, causing a
serious accident.

To be certain that your depth settings are
correct, always make test cuts in scrap material similar to your workpiece before

beginning your final cutting.
Remember, knowing the right depth for each cut comes with routing experience.

EDGE ROUTING (Figs. 17 and 17a)

1. With the depth-of-cut set, place the router on the edge of workpiece, making
sure that the cutter does not contact the workpiece. (With the plunge base,

lock the plunge action in the DOWN position, ready to cut).

2. Have an edge guide (or a board or a metal straightedge) clamped in place to
help guide router's base when making the edge cut.

3. Turn the router "ON," and allow the router motor to reach the selected
speed.

27683 ManuaLRevised_11-0120 Page 27

4. To begin the cut, gradually feed the cutter bit into the edge of the workpiece.

5. When the cut is complete, turn router motor "OFF" and allow the cutter bit
come to a complete stop before removing it from the workpiece.

6. Unplug the router from the power source, and inspect the finished cut.

_, WARNING: Always securely clamp your workpiece and keep a firm grip on
the router base with both hands at all times. Failure to do so could result in loss

of control causing possible serious personal injury.

A_, WARNING: Removing the cutter bit from the workpiece while it is still

rotating could damage the workpiece and result in loss of control, causing
serious personal injury.

INTERNAL ROUTING WITH FIXED BASE

(Figs.18, 18a, 18b and 19} Fig. 18

1. With the depth-of-cut set, tilt the router
and place it on the workpiece with the

leading edge of the sub-base contacting
the workpiece first (Fig. 18).

2. Turn the router motor "ON" and allow the Fig. 18a
router motor to reach the selected speed,

being careful not to allow the cutter bit to
contact the workpiece.

3. To begin your cut, gradually lower the
cutter bit into the workpiece until the sub- Fig. 18b

base is flush with the workpiece (see Fig.

18a and 18b).

4. When the cut is complete, turn the router
motor "OFF" and allow the cutter bit

come to a complete stop before removing
it from the workpiece.

5. Unplug the router from the power Fig. 19 _Z_
source, place the router upside down on

worktable, and inspect the finished cut in
the workpiece.

A_, WARNING: Always securely clamp your

workpiece and keep a firm grip on the router

base with both hands at all times. Failure to

do so could result in loss of control causing

possible serious personal injury. If using a

router table, large cutter bits should be used
for edging only.

_, WARNING: Removing the cutter bit
from workpiece while it is still rotating could

damage the workpiece and result in loss of control, causing serious personal

injury.

27683 ManuaLRevised_11-0120 Page 28

INTERNAL ROUTING WITH PLUNGE BASE (Fig. 20)

1. With the depth-of-cut set, and the plunge Fig. 20
action locked in the raised (Up) position,

turn the router motor "ON" and allow the
router motor to reach the selected speed

(see Fig. 20).

2. To begin your cut, unlock the plunge-lock
lever and gently lower the plunge action

evenly into the workpiece.

3. When the desired depth-of-cut is

achieved, lock the plunge-lock lever
(Down) and proceed to make the cut.

4. When the cut is completed, turn the

router motor "OFF" and allow the cutting

bit come to a complete stop.

5. When the cutting bit has come to a complete stop, unlock the plunge lock
lever (Up) and the plunge action will automatically retract the cutting bit from

the workpiece.

_, WARNING: Removing the cutter bit from the workpiece while it is still
rotating could damage the workpiece and result in loss of control, causing

serious personal injury.

6. Unplug the router from power source, place the router on the worktable, and

inspect the finished cut in the workpiece.

_, WARNING: Always securely clamp the workpiece in place, and keep a firm
grip on the router base with both hands at all times. Failure to do so could result

in loss of control, causing serious personal injury.
NOTICE: Making test cuts is essential with most routing applications. A test cut

will give a feel for the set-up, the router's speed, the depth of cut, and how the
cutting bit reacts to the workpiece.

FREEHAND ROUTING WITH THE FIXED
BASE (Fig. 21)

Fig. 21

A_, WARNING: Do not use large cutter bits

for freehand routing. Using of large cutter bits
when freehand routing could cause loss of

control or create other hazardous conditions
that could result in personal injury. If using

a router table, large bits should be used for
edging only.

When used freehand, the router becomes
a flexible and versatile tool. This flexibility

makes it possible to easily rout signs, relief

sculptures, etc.

27683 ManuaLRevised_11-0120 Page 29

When freehand routing:

1. Draw or lay out the pattern on the workpiece.

2. Choose the appropriate bit.

3. Follow the instructions for INTERNAL ROUTING, and rout the pattern in two

or more passes. Do not exceed 1/8 in. depth of cut in a single pass. This will

help provide better control, as well as serve as a guide on the next passes.

NOTICE: A core-box bit or V-groove bit is often used for routing letters and

engraving objects. Straight bits and ball mills are often used to make relief
carvings. Veining bits are used to carve small, intricate details.

NOTICE: Making a single deep cut is never advisable. Smaller-diameter bits are

easily broken by too much side thrust and torque. Larger 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.
A_, WARNING: Always securely clamp your workpiece in place, and keep a firm

grip on the router base with both hands at all times. Failure to do so could result

in loss of control causing possible serious personal injury.

EDGING WITH A PILOT BIT (Figs. 22 and 22a)

The arbor-type bits with pilots are excellent for edge shaping of any workpiece
edge that is either straight or curved at a curvature as great or greater than

the radius of the bit to be used. The pilot prevents the bit from making an
excessively deep cut; and holding the pilot firmly in contact with the workpiece

edge throughout prevents the cut from becoming too shallow.

Top Edge Shaping

Whenever the workpiece thickness, together
with the desired depth of cut (as adjusted by Fig. 22 Motor Housing

router depth setting) are such that only the
top part of the edge is to be shaped (leaving

at least a 1/16-in. thick uncut portion at the

bottom), the pilot can ride against the uncut
portion, which serves to guide it (Fig. 22).

Whole Edge Shaping

If the workpiece is too thin or the bit is set so Pilot Fixed Base Work-
low that there will be no uncut edge against sub-base piece

which to ride the pilot, an extra board must be TOP EDGE SHAPING

placed under the workpiece to act as a guide

(see Fig. 22a). This "guide" board must have exactly the same contour - straight
or curved - as the workpiece edge. If it is positioned so that its edge is flush with

the workpiece edge, the bit will make a full cut (in as far as the bit radius). On the
other hand, if the guide is positioned so that it extends beyond the edge of the

workpiece), the bit will make less than a full cut - which will alter the shape of the
finished edge.

27683 ManuaLRevised_11-0120 Page 30

NOTICE: The size (diameter) of the pilot that
is used determines the maximum cut width

Fig. 22a

that can be made with the pilot against the
workpiece edge (the small pilot exposes the

entire bit; the large one reduces this amount

by 1/16 in.).

_lk WARNING: Always securely clamp your
workpiece and keep a firm grip on the router

base with both hands at all times. Failure to

do so could result in loss of control causing

possible serious personal injury.

WHOLE EDGE SHAPING

Guide Board

FEEDING THE ROUTER (Fig. 23)

The secrets to professional routing are a careful set-up for the cut, selecting the

proper depth of cut, knowing how the cutter bit reacts in your workpiece, and

the rate and direction of feed of
the router.

DIRECTION OF FEED--
EXTERNAL CUTS

The cutter bit rotates clockwise.

Feeding the bit from left to right

will cause the bit to pull the
router towards the workpiece

(see Fig. 23). If the router is fed

in the opposite direction (right

to left), the rotating force of the
cutter bit will tend to throw the

bit away from the workpiece.

This is called "Climb-Cutting."

"Climb-Cutting" may cause loss

of control, possibly resulting in personal injury. When "Climb-Cutting" is required
(e.g., backing around a corner), exercise extreme caution to maintain control of

the router.

Fig. 23 ROUTER FEED DIRECTION

<

h-
0O

rr

ii

oo
z

<

rr

(.9
C3

z

uJ

h-
O

rr

)

ROUTER FEED DIRECTION

The high speed of the cutter bit during a proper feeding operation (left to right),
results in very little kickback under normal conditions. However, if the cutter bit

strikes a knot, an area of hard grain, or a foreign object, "Kickback" may result.

Kickback may damage your workpiece and could cause you to lose control of

the router, possibly causing personal injury. Kickback is always in the opposite
direction of the clockwise cutter bit rotation, or counterclockwise.

To guard against and help prevent Kickback, plan your set-up and direction
of feed so that you're always keeping the sharp edges of the cutter bit biting

straight into uncut wood. Also, always inspect your workpiece for knots, hard
grain, and foreign objects.

27683 ManuaLRevised_11-0120 Page 31

a WARNING: Kickback causes the power tool to jerk back toward the user,
causing possible loss of control and serious injury. Always take precautions

against kickback as described in this operator's manual.

DIRECTION OF FEED - INTERNAL CUTS (Figs. 24 and 24a)

When making an internal cut, such as a
groove, dado, or slot, always have the guide

you are using with the router (edge guide,
straight edge, board guide), on the right-hand

side of the router as you make the cut.
(Fig. 24)

When the guide is positioned on the
right hand side of the router, the router

travel should be from left to right and

"counterclockwise" around curves (see Fig.

24). This counterclockwise action around the

curve could cause "Climb cutting". Always be
alert and exercise extreme caution to maintain

control of the router when making this type of
cut around curves.

When the guide is positioned as shown in Fig.
24a, the router travel should be from left to

right and clockwise around curves.

If there is a choice, the set-up in Fig. 24 is

easier to use, but there is the possibility of

"Climb Cutting" around curves. In either case,
Fig. 24 or Fig. 24a, the sideways thrust of the

router cutting is always against the guide, as

is proper.

a WARNING: Always securely clamp the workpiece in place, and keep a firm
grip on the router base with both hands at all times. Failure to do so could result

in loss of control causing possible serious personal injury.

RATE OF FEED (Figs. 25 and 25a)

The proper rate of feed depends on several
factors: the hardness and moisture content

of the workpiece, the depth of cut, and the
cutting diameter of the bit. When cutting

shallow grooves in soft woods such as pine,
you may use a faster rate of feed. When

making deep cuts in hardwoods such as oak,

you should use a slower rate of feed.

Fig. 24 GUIDEOUTSIDE

BIT ROTATION

THRUS }

BIT ROTATION/ X

ROUTER FEED GUIDE
DIRECTION

Fig. 24a GUIDEINSIDE

d"

BIT ROTATION

GUIDE

BIT ROTATION

ROUTER FEED DIRECTION

Fig. 25

\

Bit Shank

Cut

Cutter

TOO FAST

27683 ManuaLRevised_11-0120 Page 32

FEEDING TOO QUICKLY (Fig. 25}

Clean and smooth cuts can only be achieved
when the cutter bit is rotating at a relatively

high speed, taking very small bites, producing

Fig. 25a

Bit Shank

tiny, clean-cut chips.

Forcing the feed of the cutter bit forward

too quickly slows the rotational speed of the
cutter bit, and the bit takes bigger bites as it
rotates. Bigger bites cause bigger chips and

a rough finish. This forcing action can also
cause the router motor to overheat.

Under extreme force-feeding conditions, the

Cut Cutter

TOO SLOW

speed can become so slow and the bites

become so large that chips become partially cut off, causing splintering and

gouging of the workpiece.
The router will make clean, smooth cuts if allowed to run freely without the

overload of forced feeding. You can detect forced feeding by the sound of the

motor. Its usual high-pitched whine will sound lower and stronger as it loses

speed. Holding the router against the workpiece will also be strained and harder
to do.

FEEDING TOO SLOWLY (Fig. 25a}

When you feed the cutter bit too slowly, the rotating cutter bit does not cut into

new wood rapidly enough to take a bite. Instead, it scrapes away sawdust-like
particles. This scraping produces heat, which can glaze, burn, and mar the cut in

the workpiece and, in extreme cases, overheat the cutter bit.
When the cutter bit is scraping instead of cutting, the router is more difficult to

control as you feed it.
With almost no load on the motor, the cutter bit has a tendency to bounce

off the sides of the cut in the workpiece, producing a cut with a rippled finish

instead of clean straight sides.

CHIP SHIELDS (Figs. 26 and 26a)
_1, WARNING: Always wear eye protection.

The chip shields are not intended as safety
guards.

To remove the chip shield from the fixed

base, press inward on the tabs until the

chip shield releases from the base and then
remove the chip shield. To attach, place the

chip shield back in position and flex the sides
while pushing the shield in until it snaps back

into place (Fig. 26).

The chip shield on the plunge base is held

in position with a screw. To remove the chip

27683 ManuaLRevised_11-0120 Page 33

shield from the plunge base, simply loosen -Fig. 26a
the screw and take the chip shield off the

base (Fig. 26a).

_1, WARNING: The chip shield helps to keep
dust and chips away from the operator; they

will not stop objects larger than woodchips
that may be thrown from the bit.

WARNING: Always have the appropriate

chip shield in place on the base when
operating the router.

A_, WARNING: Always turn the router 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.

DUST COLLECTION WITH VACUUM PORT (Figs. 27 and 27a)

Two vacuum ports are included with the router bases. Each adapter is sized to
accept a 1-1/4 in. vac hose adapter, sold

separately.

Fig. 27

Attach the Vacuum Port onto the Plunge

Base (Fig. 27)

To attach the vacuum port onto the plunge

base, position and secure it to the back of the
base with the two thumb screws (included),

as shown in Fig. 27.

Attach the Vacuum Port onto the Fixed

Basev (Fig. 27a)

To attach the vacuum port onto the fixed base, align the two tabs on the port
with the two slots on the port at back of the

base, and secure it by turning it clockwise Fig. 27a

(Fig. 27a).

27683 ManuaLRevised_11-0120 Page 34

TO ADJUST DEPTH WITH DEPTH-ADJUSTMENT WRENCH
(Figs. 28, 28a and 28b)

NOTICE: The Depth-Adjustment wrench

supplied is used to adjust the depth when Fig. 28
the router is fixed to the router table (Model

No. 320. 28160), sold separately.

WARNING: Always read and follow all

directions for mounting the router to a router
table and for use of the router table.

A_, WARNING: Always turn the router motor

off and unplug the router from the power
source before making any adjustments or

installing accessories. Failure to turn the

router motor off and unplug the router could
result in accidental starting, which can cause

serious personal injury.
_, WARNING: Only use router tables with

proper guarding for the cutting bit and with
"on-board," switch-controlled receptacles.

Failure to use router tables with appropriate

safety features could result in serious

personal injury.
Fixed Base Router

When using the fixed base to attach the
router to the router table, the bit depth can

be adjusted by turning the Micro-adjustment
Dial clockwise or counterclockwise with the

wrench supplied (Figs. 28 and 28a). 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. Turn off the router.

2. Loosen the router motor clamp.

3. Insert the wrench into the adjusting hole on the tabletop. Turn the adjustment

bolt on the router clockwise with the wrench to move the collet/nut up, or
counterclockwise to move the collet/nut down.

4. When the desired depth of cut is set, tighten the router motor clamp. The

precise depth of cut can be measured with a ruler.

Plunge Base Router

When using the plunge base to attach the router to the router table, the bit depth
can be adjusted by turning the depth rod clockwise or counterclockwise with the

wrench supplied (Fig. 28b).

27683 Manual_Revised_11-0120 Page 35

1.

Turn off the router.

2.

Loosen the router motor clamp.

3.

Lock the plunge-depth locking lever.

4.

Insert the wrench into the adjusting hole on the tabletop. Turn the depth

rod on the router clockwise with the wrench to move the collet/nut up, or
counterclockwise to move the collet/nut down.

5.

When the desired depth of cut is set, tighten the router motor clamp. The

precise depth of cut can be measured with a ruler

27683 ManuaLRevised_11-0120 Page 36

A
Alt WARNING: To ensure safety and reliability, all repairs should be performed

by a qualified service technician at a Sears 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 Craftsman service technician.

_, WARNING: For your safety, always turn off the switch and unplug the
router motor from the power source before performing any maintenance or

cleaning. Electric tools are subject to accelerated wear and possible premature
failure when they are used to work on fiberglass boats and sports cars,

wallboard, spackling compounds or plaster. The chips and grindings from these

materials are highly abrasive to electrical tool parts, such as bearings, brushes,

commutators, etc. Consequently, it is not recommended that this tool be used
for extended work on any fiberglass material, wallboard, spackling compound,

or plaster. During any use on these materials, it is extremely important that the
tool is cleaned frequently by blowing with an air jet.

_, 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.

ROUTINE MAINTENANCE

_, WARNING: Do not at any time allow 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 serious personal

injury.

1. When work has been completed, clean the tool to allow smooth functioning
of the tool over time.

2. Use clean, damp cloths to wipe the tool.

3. Check the state of all electrical cables.

4. Keep the motor air openings free from oil, grease, and sawdust or
woodchips, and store the tool in a dry place.

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

_, WARNING: For your safety, always turn off the switch and unplug the router

motor from the power source before performing any maintenance or cleaning.
Refer to "Collet/Nut Care" and "Cutter Bits" for collet and bit cleaning care.

27683 ManuaLRevised_11-0120 Page 37

REPLACEMENT OF CARBON BRUSHES (Fig. 29)

Replacement brush sets are

available through Sears Parts
and Repair Centers.

1. Unplug the router motor
before inspecting or

replacing brushes.

2. Replace both carbon
brushes when either has

less than 1/4 in. length of

carbon remaining, or if the
spring or wire is damaged

or burned.

3. Using a slotted screwdriver, remove the black, plastic cap on each side of

the router motor (Fig. 29) and carefully withdraw the spring-loaded brush
assemblies. Keep brushes clean and sliding freely in their guide channels.

NOTICE: To reinstall the same brushes, make sure that the brushes go back in

the same way they came out. This will avoid the need for a break-in period.

4. Insert new brush assemblies into the guide channels with the carbon part

going in first, being certain to fit the two metal "ears" into their slots in the
channel (Fig. 29).

5. Remember to replace both end caps after inspecting or servicing brushes.

Tighten the caps snugly, but do not over-tighten. The router should be
allowed to "run in" (run at no load without a cutter bit) for 5 minutes before

use, to seat the new brushes properly.

_, WARNING: For your safety, always turn off the switch and unplug the router

motor from the power source before performing any maintenance or cleaning.
LUBRICATION

Fig. 29

@

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

27683 Manual_Revised_11-0120 Page 38

PROBLEM CAUSE SOLUTION

Plug is not plugged into the Plug the detachable cord
router socket, into the router.

The router does Switch is in "OFF" position.

not work position.

The carbon brushes have
worn out completely, caps, and replace the old

Pull the switch to "ON"

Remove the carbon brush

brushes with new ones.

The surface of The bit is dull. Change to a sharp bit.
the workpiece is

not smooth after Routing at an inappropriate Select an appropriate bit

cutting bit speed speed.

Use only 1/4 in. diameter

Bit can not be Bit size is inappropriate for bits with the 1/4 in. collet;
installed the collet/nut use only 1/2 in. diameter

bits with the 1/2 in. collet.

AI
_l WARNING: The use of attachments or accessories that are not

recommended for this tool might be dangerous and could result in serious injury.
Sears and other Craftsman outlets offer a large selection of Craftsman router

accessories designed for specific routing applications.
There is a large selection of Craftsman Router Cutting bits available in High-

Speed Steel or Carbide Tipped High-Speed Steel for all your routing needs.

In addition to a wide variety of router bits, Sears also offers accessories such

as: router tables, various template sets, universal router fence with lock knobs
(64181), 11 pc bushing sets (64180) and clear sub-base sets, 6 pc. fixed sub-

bases (64182), 6 pc plunge sub-bases (64183).

_l WARNING: Only use router tables with proper guarding for the cutting bit

and with "on-board" switch-controlled receptacles. Failure to use router tables
with appropriate safety features could result in serious personal injury.

27683 ManuaLRevised_11-0120 Page 39

1/8-in. _ 3/8- n [7 1/4-in.

straight l i straight i i straight

....

[. 5/16-in. i[i} 1/2-in.

straght iLii straight

ri

3/4-in.

straight

straight

3/8-in. dove tail 1/2-in. dove tail

I,

1/2-in. round nose

1/2-in. 90 d v groove

1/2 x 1-in. 3/8x1/2-in.

flush trim flush trim

1/2-in. 1/4-in.

flush trim flush trim

3/8-in_ keyhole

dovetail

round nose

v groove

flush trim

t ................ j

keyhole

1/2-in. cove 1/4-in. cove

3/8-in. 1/4-in.

round over round over

_' round over round over

27683 ManuaLRevised_11-0120 Page 40

1/8-in. 1/2-in.

cove

round over

1/2-in.

bead and cove

bead cove

1/16-in.

classic cove

with bead

1/4-in. roman ogee

3 ¸

3/8-in. rabbeting

1/4-in. veining

1/2-in. core box

&bead

Roman ogee

rabbeting

veining

core box

1/2-in. mortising

1/4-in. panel pilot

1-3/8-in. 45 ochamfer

27683 ManuaLRevised_11-0120 Page 41

mortising

panel pilot

chamfer

14.0 Amp Combo Pro Router Model No. 320.27680

The Model Number will be found on the Nameplate attached to the motor unit.
Always mention the Model Number when ordering parts for this tool.

27683 Manual_Revised_11-0120 Page 42

14.0 Amp Combo Pro Router Model No. 320.27680

The Model Number will be found on the Nameplate attached to the motor unit.
Always mention the Model Number when ordering parts for this tool.

27683 ManuaLRevised_11-0120 Page 43

14.0 Amp Combo Pro Router Model No. 320.27680

The Model Number will be found on the Nameplate attached to the motor unit.
Always mention the Model Number when ordering parts for this tool.

27683 ManuaLRevised_11-0120 Page 44

14.0 Amp Combo Pro Router Model No. 320.27680

The Model Number will be found on the Nameplate attached to the motor unit.
Always mention the Model Number when ordering parts for this tool.

1 3321134000 Rear Cover 1

2 3123313000 Transparent Cap 1
3 5610220000 Thread Forming Screw 2
4 5610017000 Thread Forming Screw 2

5 4900278000 Speed Adjustor 1
6 5620017000 Hexagon Socket Screw 2
7 5610059000 Thread Forming Screw 2

8 3551635000 Sping Lock 1
9 3660468000 Compression spring 1

10 3123329000 Lock Ring 2
11 2823115000 Switch Assembly 1

12 3122851000 Seal Ring 1
13 3120537000 Brush Cap 2

14 2800005000 Brush Holder 2
15 4960019000 Carbon Brush 2
16 2822257000 Power Cord Assembly 1
17 4930314000 Receptacle 1

18 3125694000 Middle Housing 1

19 3520130000 Bearing Holder 1
20 3121049000 Rubber Ring 1
21 3700249000 Washer 1
22 2740240000 Stator 1

23 5610065000 Tapping Screw 2
24 2823163000 Rotor Set 1
25 3125687000 Fan Baffle 1

26 2823021000 LED Holder Assembly 1
27 3421186000 Motor Housing 1

28 5610076000 Tapping Screw 2
29 5700056000 Ball Bearing 1

27683 ManuaLRevised_11-0120 Page 45

30 5630179000 Nut 1
31 5620069000 Screw 3
32 2823121000 Collet assembly 1

33 5620061000 Screw 1
34 3421190000 Spindle lock cover 1

35 5620041000 Screw 1
36 3320460000 Adjusting Knob 1

37 3123281000 Indicator 3
38 3550854000 Shaft 1
39 3320274000 Handle 4

40 5620024000 Hexagon Socket Screw 4
41 2823165000 Mounting 1
42 3121637000 Chip Shield 1

43 2823122000 Lever Assembly 1
44 3703872000 Plate 1

45 5630015000 Prevailing Torque Hexagon Nut 2
46 5660005000 E Ring 5

47 3660498000 Spring 4
48 3705047000 Lever 4

49 5620466000 Screw 2
50 5650407000 Wave Washer 4

51 5650166000 Washer 2
52 2822272000 Adjusting Assembly 1

53 3700352001 Washer 1
54 5650172001 Wave Washer 1
56 3123294000 Dust Bracket 1
57 5620067000 Screw 1

58 3125119000 Base Plate 1
59 5620074000 Screw 6

60 3123338000 Lock Cap 2
61 3123337000 Knighthead 2
62 3660312000 Spring 2

63 5620032000 Screw 1
64 3123435000 Adjusting Knob 1

27683 Manual_Revised_11-0120 Page 46

65 5650014000 Plain Washer 1
66 3660313000 Spring 1

67 3550913000 Depth Stop Bar 1
68 3703949000 Clip 1

69 3123453000 Sleeve 1
70 3123453000 Sleeve 1
71 3123434000 Depth Indicator 1
72 3550083000 Depth Adjusting Bolt 1

73 3402338000 Lock Bolt 1
74 3123498000 Cap 1
75 5630016000 Hexagon Nut 1

76 3123497000 Cover 1
77 2823166000 Plunge Frame 1

78 5620039000 Screw 1
79 5650007000 Spring Washer 1

80 3420398000 Plunge Lock Lever 1
81 3660254000 Torsion Spring 1

82 5640045000 Bolt 1
83 5690138000 O Ring 1
84 5660139000 "E" Ring 1

85 5620103000 Slotted Shoulder Screw 2
86 3700078000 Wave Washer 1
87 3420570000 TurnTable 1

88 5700046000 Steel Ball 1
89 3660030000 Spring 1

90 2823164000 Mounting Assembly 1
91 3125884000 Base Plate 1

92 5620467000 Screw 2
93 5650023000 Plain Washer 1

94 3550929000 Bolt 1
95 3402220000 Depth Adjusting Lever 1

96 2823125000 Collet Assembly 1
97 3123454000 Vaccum Adapter 1

98 5620353000 Screw 2

27683 Manual_Revised_11-0120 Page 47

99 3123500000 Suppo_ Plate 1

100 3550588000 Guiding Rod 2
101 3703925000 Fence 1

102 5620050000 Screw 2
103 5650015000 Spring Washer 2

104 5650013000 Washer 2
105 3123344000 Chip Shield 1
106 3123286000 Vaccum Adapter 1

107 3402471000 Wrench 1
108 3126054000 Handle Sleeve 4

27683 Manual_Revised_11-0120 Page 48

27683Manual_Revised_11-0120 Page49

27683Manual_Revised_11-0120 Page50

27683Manual_Revised_11-0120 Page51

Your Home

For troubleshooting, product manuals and expert advice:

managemylife

www.managemylife.com

For repair - in your home - of all major brand appliances,

lawn and garden equipment, or heating and cooling systems,

no matter who made it, no matter who sold it!

For the replacement parts, accessories and

owner's manuals that you need to do-it-yourself.

For Sears professional installation of home appliances

and items like garage door openers and water heaters.

1-800-4-MY-HOME ® Call anytirne, day or night

(1-800-469-4663) (U.S.A. and Canada)

www.sears.com www.sears.ca

Our Home

For repair of carry-in items like vacuums, lawn equipment,

and electronics, call anytime for the location of the nearest

Sears Parts & Repair Service Center

1-800-488-1222 (U.S.A.) 1-800-469-4663 (Canada)

www .sears .com www .sears .ca

To purchase a protection agreement on a product serviced bySears:

1-800-827-6655 (U.S.A.) 1-800-361-6665 (Canada)

Parapedir serviciodereparacidn Au Canadapour serviceenfrangais:

a domicilio,y paraordenarpiezas: 1-800-LE-FOYERMc

1-888-SU-HOGAR® (1-800-533-6937)

(1-888-784-6427) www.sea rs.ca

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..... SesIr

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Mc Marque de commerce / Marque d_pos_e de Sears Brands, LLC

T_

MD