Owner's Manualmm_

CRFIFTSMFIN°DELUXE ROUTER

PANTOGRAPHModel No. 335.25187

Caution:

Before using this product,read this manual and follow

all its Safety Rules andOperating Instructions.

• Safety

• Assembly

° Operation

Sears, Roebuck and Co., Hoffman Estates, IL 60179P/N 15881

REV 4/00

Read and understand all instructions. Failure to follow all instructions listedbelow, may result in electric shock, fire and/or serious personal injury.

SAVE THESE INSTRUCTIONS

Work AreaKeep your work area clean and well lit.Cluttered benches and dark areas inviteaccidents.

Do not operate power tools in explosiveatmospheres, such as in the presence offlammable liquids, gases, or dust. Power toolscreate sparks which may ignite the dust orfumes.

Keep by-standers, children, and visitors awaywhile operating a power tool. Distractions cancause you to lose control.

Electrical SafetyDouble Insulated tools are equipped with apolarized plug (one blade is wider than theother.) This plug will fit in a polarized outletonly one way. If the plug does not fit fully inthe outlet, reverse the plug. If it still does notfit, contact a qualified electrician to install apolarized outlet. Do not change the plug inany way. Double Insulation [_eliminates theneed for the three wire grounded power cord andgrounded power supply system. Before pluggingin the tool, be certain the outlet voltage suppliedis within the voltage marked on the nameplate,Do not use "AC only" rated tools with a DCpower supply.

Avoid body contact with grounded surfacessuch as pipes, radiators, ranges andrefrigerators, There is an increased risk ofelectric shock if your body is grounded. Ifoperating the power tool in damp locations isunavoidable, a Ground Fault Circuit Interruptermust be used to supply the power to your tool.Electrician's rubber gloves and footwear willfurther enhance your personal safety.

Don't expose power tools to rain or wetconditions. Water entering a power tool willincrease the risk of electric shock.

Do not abuse the cord. Never use the cord tocarry the tools or pull the plug from an outlet.Keep cord away from heat, oil, sharp edges ormoving parts. Replace damaged cordsimmediately. Damaged cords increase the risk ofelectric shock.

When operating a power tool outside, use anoutdoor extension cord marked "W-A" or "W."These cords are rated for outdoor use andreduce the risk of electric shock.

Personal SafetyStay alert, watch what you are doing and usecommon sense when operating a power tool.Do not use tool while tired or under theinfluence of drugs, alcohol, or medication. Amoment of inattention while operating powertools may result in serious personal injury.

Dress properly. Do not wear loose clothing orjewelry. Contain long hair. Keep your hair,clothing, and gloves away from moving parts.Loose clothes, jewelry, or long hair can be caughtin moving parts. Keep handles dry, clean and freefrom oil and grease.

Avoid accidental starting. Be sure switch is"OFF" before plugging in. Carrying tools withyour finger on the switch or plugging in tools thathave the switch "ON" invites accidents.

Remove adjusting keys or wrenches beforeturning the tool "ON". A wrench or a key that isleft attached to a rotating part of the tool mayresult in personal injury.

Do not overreach. Keep proper footing andbalance at all times. Proper footing and balanceenables better control of the tool in unexpectedsituations,

Use safety equipment. Always wear eyeprotection. Dust mask, non-skid safety shoes,hard hat, or hearing protection must be used forappropriate conditions.

Tool Use and CareUse clamps or other practical way to secureand support the workpiece to a stableplatform. Holding the work by hand or againstyour body is unstable and may lead to loss ofcontrol.

Do not force tool. Use the correct tool for yourapplication. The correct tool will do the jobbetter and safer at the rate for which it isdesigned.

Do not use tool ff switch does not turn it "ON"or "OFF". Any tool that cannot be controlled withthe switch is dangerous and must be repaired.

Disconnect the plug from the power sourcebefore making any adjustments, changingaccessories, or storing the tool. Suchpreventive safety measures reduce the risk ofstarting the tool accidentally.

Store idle tools out of reach of children andother untrained persons. Tools are dangerous in

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in the hands of untrained users.

Maintain tools with care. Keep cutting toolssharp and clean. Properly maintained tools, withsharp cutting edges are less likely to bind andare easier to control. Any alteration ormodification is a misuse and may result in adangerous condition.

Check for misalignment or binding of movingparts, breakage of parts, and any othercondition that may affect the tools operation.If damaged, have the tool serviced beforeusing. Many accidents are caused by poorlymaintained tools. Develop a periodicmaintenance schedule for your tool.

Use only accessories that are recommendedby the manufacturer for your model.Accessories that may be suitable for one tool,may become hazardous when used on anothertool.

Service

Tool service must be performed only byqualified repair personnel. Service ormaintenance performed by unqualified personnelcould result in a risk of injury. For example:internal wires may be misplaced or pinched,safety guard return springs may be improperlymounted.

When servicing a tool, use only identicalreplacement parts. Follow instructions in theMaintenance section of this manual. Use ofunauthorized parts or failure to followMaintenance Instructions may create a risk ofelectdc shock or injury. Certain cleaning agentssuch as gasoline, carbon tetrachloride, ammonia,etc. may damage plastic parts.

Hold tool by insulated gripping surfaceswhen performing an operation where thecutting tool may contact hidden wiring or itsown cord, Contact with a "live" wire will makeexposed metal parts of the tool "live" andshock the operator. If cutting into existing wallsor other blind areas where electrical wiring mayexist is unavoidable, disconnect all fuses orcircuit breakers feeding this worksite.Always make sure the work surface is freefrom nails and other foreign objects. Cuttinginto a nail can cause the bit and the tool tojump and damage the bit. i

Never hold the workpiece in one hand andthe tool in the other hand when in use.Never place hands near or below cuttingsurface. Clamping the material and guiding thetool with both hands is safer.

Never lay workplece on top of hardsurfaces, like concrete, stone, etc...Protruding cutting bit may cause tool to jump.

Always wear safety goggles and dust mask.Use only in well ventilated area. Usingpersonal safety devices and working in safeenvironment reduces risk of injury.

After changing the bits or making anyadjustments, make sure the collet nut andany other adjustment devices are securelytightened. Loose adjustment device canunexpectedly shift, causing loss of control,loose rotating components will be violentlythrown.

Never start the tool when the bit is engagedin the material. The bit cutting edge may grabthe material causing loss of control of thecutter. Always hold the tool with two hands

during start-up. The reaction torque of themotor can cause the tool to twist.

The direction of feeding the bit into thematerial is very important and it relates tothe direction of bit rotation. When viewingthe tool from the top, the bit rotatesclockwise. Feed direction of cutting mustbe counter-clockwise. NOTE: inside andoutside cuts will require different feed direction,refer to section on feeding the router. Feedingthe tool in the wrong direction, causes thecutting edge of the bit to climb out of the workand pull the tool in the direction of this feed.

Always use the tool with the depth guidesecurely attached and positioned flatagainst material being cut. The guidesecurely positioned on the material improvesthe stability and control of your tool.

Never use dull or damaged bits. Sharp bitsmust be handled with care. Damaged bitscan snap during use. Dull bits require moreforce to push the tool, possibly causing the bitto break.

Never touch the bit during or immediatelyafter the use. After use the bit is too hot to be

touched by bare hands.

Never lay the tool down until the motor hascome to a complete standstill. The spinningbit can grab the surface and pull the tool out ofyour control.

Do not use the tool for drilling purposes.This tool is not intended to be used with drillbits.

Never use bits that have a cutting diametergreater than the opening in the base.

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ASSEMBLY

1, Locate the REAR TUBE ASSEMBLYand remove the two PIVOT CAPSwhich are not holding a tube. With setof (3) HOLES up, place the end of theGUIDE ARM on REAR PIVOT,making sure LOCATING HOLE intube is on PROJECTING PIN ofpivot. Secure tube by replacing pivotcap and SCREWS. With set of (3)holes up, place the end of LEFTSIDE TUBE on the other PIVOT andsecure as you did GUIDE ARM. (FIG. 1)

2. Turn the assembly over, RotateADAPTER PIVOTS so half circleseats are in position to accept tubes.ADAPTER PIVOTS are fastened toROUTER ADAPTER PLATE,

3.

NOTE: Both projecting pins must betoward rear tube assembly.

Place GUIDE ARM in right sideadapter pivot with projecting pin incenter hole. Secure in place withPIVOT CAP, SCREWS and NUTS.Slide nuts in slots of adapter pivot,see drawing Figure 2B. Place left sidetube in left side adapter pivot withprojecting pin in center hole. Secureas you did guide arm, (FIG. 2)

Press TUBE CAP in end of left sidetube. (FIG.2)

4. Assemble THUMB NUT threequarters of the way on STYLUS.Stylus has a nylon tip. Hold hex nut(3/8-16) up under STYLUSBRACKET and assemble stylusthrough stylus bracket and threadthrough hex nut. Secure with thumbnut. (FIG. 3)

5. Screw the two HANDLE KNOBS onHANDLES.

REAR PIVOT REAR TUBE ASSEMBLY

PROJECT,.GP'N/ iLOCATING HOLE _ _ ',

/OU,DEA.MSCREWS/\

X / LEFT SIDE TUBE

(3) HOLES

FIG. 1 / _,\

PROJECTING PiN :: _'

_ _SLIDE NUTS IN SLOTS

_' -t FIG. 2B

t' P,VOTCAPS

)TUBECAP '

ADAPTOR PIVOTS, / 'NUTS

ROUTER ADAPTER PLATE !_

FIG, 2 //STYLUS BRACKET

STYLUS HANDLE

ANDLE KNOB

3_ _ ___/.-_ HEX NUTFIG.NYLON TIP

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6. Screw a 3/8-16 HEX NUT on bothof the REAR SUPPORT SCREWS.Assemble both screws through theREAR PIVOT BOLTS until the ballend protrudes 1/2", Snap SLIDEBUTTON on ball of screw which is onguide arm side, (FIG. 4) Snap HOLDDOWN SOCKET on ball of screwwhich is on left side. (FIG. 5)

7. This ROUTER PANTOGRAPH canbe used for engraving designs,animals, signs and other flat work,also three dimensional wood

sculpturing. These can be done on aworkbench or table. We recommenda plywood fixture for using with workholding WEDGES supplied. Thisfixture will save time, especially whenmaking signs, and is a handy way tostore the unit on the workshop wall,set up and ready to use. See drawingto right.

OPERATINGINSTRUCTIONS8. Take one of the line drawing

template sheets supplied in thestencil set and engrave in redwoodas your first project. This is the bestway to learn about the unit and get afeel for its use. We recommend the V-

groove bit for line drawings. Installthe bit in the router collet leaving itabove the router base. Adjust depthwhen ready to cut.

9. Place router in the center of adapterplate, with cord to the rear. Securerouter in place using CARRIAGEBOLTS, ROUTER CLAMPS,WASHERS, and WING NUTS. (FIG.6) Place ROUTER CORD in CORDHOLDER allowing some slack. (FIG. 5)

10. Lay WORK PIECE on work surface.(Fixture described in step 7 orworkbench). Place adapter plate onwork piece, with router bit on centerof location to be engraved. Adjusthold down socket down to worksurface by turning support screw.When left side tube is parallel to worksurface, lock support screw with nut.

REAR SUPPORT SCREWS

OT BOLTS

FIG. 4SLIDE BUTTON

318-16 HEX NUT

HOLD DOWN SOCKETWITH CORD HOLDER

FIG, 5

1/2" PLYWOOD

WIDTH OF WORK PIECEPLUS 2 3/8" FOR WEDGES

FENCE3/4" X 3"

/

_ 3/4" X 3"BACK UFBLOCK

V-GROOVE ANDCHAMFERING Bl=r

48"

ROUTER CLAMP

CARRIAGE BOLT

WING NUT

FIG. 6

BACK UP BLOCK

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11. Adjust support screw on guide armcorner until guide arm is parallel. Nowleft side tube and guide arm areparallel to work bench. Secure inplace with nut.

12. Square pantograph frame so cornersare at 90 °. Fasten hold down socketto work surface through three holes.(Router bit is still on center of locationto be engraved.) Secure work pieceto work surface. Use wedgesprovided (FIG. 6) or C-clamps.

13. Place center of STENCIL COVER,(folded edge to left) under stylus(square stencil cover to work piece).Fasten to work surface with tacks intwo corners as shown. LocateTEMPLATE SHEET between leavesof stencil cover, all the way in againstfold and up against stem of tack.(FIG. 7) Adjust stylus down to within1/32" of stencil cover.Stylus shouldnot drag against stencil cover.

14. Adjust router bit to desired depth,check depth of cut on scrap lumber.Place stylus on line of drawing, turnrouter on and proceed to guide stylusover lines using handle knobs. Forinside lines not connected to border,lift handle bar until cutter is out ofwodd and move stylus to inside line,let cutter down gently, placing styluson line.

NOTE: Refer to Helpful Hints on last13age to finish the engraving.Additional features section explainshow to change ratio of reduction fromstencil to engraving.

SETTING UP TOMAKE SIGNS(Read steps 7 through 14 before starting.)

15. The plywood fixture described in step7 is helpful to make signs. If a fixtureis not used, mount a FENCE andwedge BACKUP BLOCK on workbench with proper distance forWORK PIECE and WEDGES. Thework piece can be clamped and slidin a straight line along fence whenmaking signs. (Be sure fence isalways thinner than work piece.)

SIGNS IN FIVE STYLES _ '

FENCE WORK PIECE

WORKWEDGE_

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MAKING SIGNS USINGCAPITAL LETTERS

"Modern Writing Style"

16. Locate stencil of first letter againstinside fold of stencil cover and upagainst tack. (Locating each stencilthe same results in straight work.) Besure cutter bit is on center of workboard when stylus is on center ofstencil sheet. Rout first letter. Switch

router off. Pick up handle bar andplace stylus on SPACING DOT atright of stencil sheet, allowing bitcutter to rest on wood. (This properlyspaces letters.)

17. Remove stencil of letter just routedand place stencil of next letter inplace. Loosen work piece and movework piece to left. Router andPantograph will ride on work pieceuntil stylus is on LOCATING DOT.Reclamp work piece.

18. Pick up handle bar and place stylusguide on line of stencil. Switch routeron and proceed. (Repeat until sign iscompleted.)

When going from capital to smallletter, space to desired distance.

MAKING SIGNS USINGSMALL LETTERS

"Modern Writing Style"

19. Pick out letters you are going to useand find those which come nearesttop and bottom of stencil. Use theseto locate word in CENTER OF WORKPIECE.

Place router bit cutter on center ofwork piece. Locate center of highestand lowest letter under stencil coverwith stylus on center distance.Relocate stencil cover if necessary.

Rout highest and lowest letters onscrap lumber to make sure your workwill be in center of work board.

20. Remove highest and lowest letter andlocate first stencil against inside foldof stencil cover and up against tack.Rout first letter. Switch router off.(Leave bit cutter in groove.)

f F,SPACING DOT

PUSH

LET ROUTER ANDPANTOGRAPHRIDE ON WORK PIECE

DO NOT TOUCH

PANTOGRAPH WHENMOVING WORK PIECE

LOCATING DOT

HIGHEST LETrER

WORK PIECE

LOWEST LETTER

PUSH WORK PIECE (WITH BIT CU'i-rER IN

GROOVE) CARRYING ROUTER

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21. Remove stencil just routed and locatenext stencil in place. (Leave bitcutter in groove.}

22. Loosen work piece and move workpiece to felt until stylus is onSTARTING POINT. Reclamp workpiece. Switch router on and proceed.(Repeat until sign is completed.)

OTHER FOUR STYLES

23.

24.

To rout a sign using "Old English","Script", or "Far East" follow samemethod as capital letters of "ModernWriting", (Step 16-17-18) for set upand spacing between letters. Use aflat bottom router bit (1/8" diameterworks good). No need to rout deep.

Turn router on and guide stylusaround letter keeping stylus on insideedge of letter. After bordering theletter, remove SHADED AREA ofletter with a series of short strokesbeing careful not to touch the edgesof the engraved border. (Guide theunit using handle knobs whilewatching the cutter, when routingcenter shaded area way.) Turn routeroff. Pick up handle bar and placestylus on SPACING DOT at right ofstencil sheet, allowing cutter to reston 'wood. (This properly spacesletters.)

Remove stencil of letter just routedand place next stencil in place.Loosen work piece and move to leftcarrying router until stylus is onLOCATING DOT. Rectamp workpiece.

ADDITIONALFEATURESThe pantograph has three settings whichgives different ratios of reduction fromstencil to engraving. Ratio is adjusted byremoving ADAPTER PIVOT CAPS onboth sides of adapter plate and adjustingGUIDE ARM TUBE and LEFT SUPPORTTUBE to the proper locating hole. Locaterouter on adapter plate so router cutter isIN LINE with stylus and PIVOT CORNER.

__SHADED AREA

SPACING DOT

LOCATING DOT

LEFT SUPPORT TUBE GUIDE ARM TUBE

ADAPTER PIVOTCAPS

RIGHT ,'_.

For 40% reduction,assemble adaptor pivotcaps in front holes intubes with router to right

of adapter plate,

For 50% reduction,assemble adapter pivotcaps in center holes intubes with router on

center of adapter plate.

For 60% reduction,

assemble adapter pivotcaps in rear holes intubes with router to left

side of adapter plate.

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THREEDIMENSIONALENGRAVING25. After selecting a pattern you will need

a work piece thick enough to acceptthe engraving plus 1/4" to 1/2".(Redwood is very easy to rout.)Maximum pattern size you can use is1 1/4" thick and 13" high by 24"long.

26. The 1/8" veining router bit is neededto get good detail in 3D routing.Install cutter leaving it above routerbase. (Veining bit has a sphericalend.) (We recommend removing therouter base plate so you can see thecutter as the image is sculptured.)

27. With tube frame at 90° (see step12)place work piece under adapter platewith cutter on center of location to beengraved. Locate PATTERN understylus with stylus on the center of thepattern. Secure work piece to worksurface with wedges or C-clamps.Secure pattern to work surface withscrews or other clamps.

28. Back off stylus and both rear supportscrews until adapter plate is flat onwork piece. Adjust both rear supportscrews down toward workbench untilrear edge of adapter plate is off workpiece by 1/8". Readjust only thesupport screw on the guide arm sideup until slide button leaves workbench by 1/4". Secure both rearsupport screws with hex nuts.

29. Place stylus on LOW POINT ofpattern. Adjust stylus against patternuntil front edge of adapter plate is1/8" off work piece (adapter plate iscompletely off work piece.) Securestylus with thumb nut.

Place stylus on high point of pattern.Adjust router cutter down toworkpiece (just touches).

PLASTER PATI'ERN FINISHED ENGRAVING

SUPPORT SCREW

\F \

WORK PIECE

PATTERN

WORK PIECE\ ,...._

I ,J*Rear of adapter plate is lifted byrear support screw (step 2B).

STYLUSPATTERN

\LOW POINT

Adapter plate is

completely off work

piece when stylus is _ _,on low point of _ ' " ' --pa.ern. 3--I 13

Front of adapter plate is lifted bystylus (step 29),

\HIGH POINT

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EASY DOES IT30. After reading helpful hints you are

ready to rout a 3D sculpture. A6" x 6" pattern will take a couple ofhours to complete. The stylus willhave to touch every place on thepattern. Move the stylus with an evenfeed and along grain lines of thepattern.

HELPFUL HINTS• Rest your forearm on bench for better

control,

3D ENGRAVINGS

Start routing at the highest point-andwork your way down to the lowerplaces, Avoid leaving tall thin sectionsbecause they will chip away easily.

Avoid letting the stylus fall off ledgesbut let the stylus down gently undercontrol over irregular surfaces.

Suggested way to finish a 3Dengraving is to lightly burn thesurface with a torch to bring outdetail and then stain or varrjish.

Easy way to finish a sign or line 'engraving. Paint entire board with

quick drying black enamel. (Aerosolcan is handy.) Plane off surface ofsign, using small plane or rasplane(not sandpaper). This leaves paint ineach letter.

° Children's color books have a wideselection of lille drawings of all typesfor imagination.

ALSO AVAILABLE AT SEARS

CAT. NO. -925172

ELECTRIC FOOT PEDAL SWITCH

USE WITH 115V A.C.POWER TOOLS WHICHDRAW 15 AMPS OR LESS

A CONVENIENT ON-OFFCONTROL FOR THESCROLL SAW

GIVES HANDS FREEOPERATION OF THEROUTER WHEN USEDWITH PANTOGRAPHS

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Forin-home major brandrepair service:

Call24 hours a day,7 days a week

1-800-4-1VIY-HOMEsM(1-800-469-4663)

Para pedir servicio de reparaci6n a domicilio - 1-800-676-5811

In Canada for all your service and parts needs call -1-800-665-4455Au Canada pour tout le service ou les pi_ces

Forthe repair or replacementparisyouneed:

Call 6 am - 11 pm, 7 days a week

PartsDirect sM

1-800-36B-PART (1-800-366-7278)

Para ordenar piezas con entrega a domicilio - 1-800-659-7084

Forthe locationof a Sears Parts and Repair Centerin yourarea:

Call 24 hours a day, 7 days a week

1-800-488-1222

For informationon purchasinga Sears MaintenanceAgreementor toinquire aboutan existingagreement:

Call 9 am - 5 pm, Monday - Saturday

1-800-827-6655

REV, 4/00 PRINTED IN U.S.A