DEWALT DWE625 15A Plunge Router Instruction Manual

DWE625
15A Plunge Router
Instruction Manual

Components

1 Speed control wheel
2 Main handles
3 On/off trigger switch
4 Thumb wheel
5 Height stop rod
6 Plunge lock lever
7 Quick release button
8 Spindle lock button
9 Collet assembly
10 Base plate| 11 Multiple position turret stop
12 Depth stop bar
13 22 mm wrench
14 Quick zero reset ring
15 Quick height adjust lock
16 Quick height adjuster
17 Pointer
18 Fine height adjuster
19 Fine zero reset ring
20 Lock on button switch
---|---

WARNING: Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
WARNING: To reduce the risk of injury, read the instruction manual.

Intended Use

The router has been designed for professional heavy duty routing of wood, wood based materials and plastics.
This router is intended for routing grooves, edges, profiles and slots as well as copy routing.
DO NOT use under wet conditions or in presence of flammable liquids or gases.
This is a professional power tool.
DO NOT let children come into contact with the tool.
Supervision is required when inexperienced operators use this tool.

Definitions: Safety Alert Symbols and Words
This instruction manual uses the following safety alert symbols and words to alert you to hazardous situations and your risk of personal injury or property damage.

DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
**(Used without word) Indicates a safety related message.
NOTICE:** Indicates a practice not related to personal injury which, if not avoided, may result in property damage.

GENERAL POWER TOOL SAFETY WARNINGS

WARNING: Read all safety warnings, instructionsillustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE.
The term “power tool” in the warnings refers to your mains‑operated (corded) power tool or battery‑operated (cordless) power tool.

1. Work Area Safety
   a ) Keep work area clean and well lit. Cluttered or dark areas invite accidents.
   b ) 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.
   c ) Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

2. Electrical Safety
   a ) 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.
   b ) 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.
   c ) Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
   d ) Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool.
   Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock.
   e ) 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.
   f ) 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.

3. Personal Safety
   a ) Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.
   b ) Use personal protective equipment. Always wear eye protection. Protective equipment such as a dust mask, non‑skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.
   c ) Prevent unintentional starting. Ensure the switch is in the off‑position before connecting to power source and/or battery pack, 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.
   d ) 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.
   e ) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
   f ) 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.
   g ) If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust‑related hazards.
   h ) Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.

4. Power Tool Use and Care
   a ) Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.
   b ) 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.
   c ) Disconnect the plug from the power source and/or remove the battery pack, if detachable, 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.
   d ) 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.
   e ) Maintain power tools and accessories. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
   f ) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
   g ) Use the power tool, accessories and 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.
   h ) Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

5. Service
   a ) 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.

Safety Instructions for Routers

a ) Hold the power tool by insulated gripping surfaces only, because the cutter may contact its own cord. Cutting a “live” wire may make exposed metal parts of the power tool “live” and could give the operator an electrical shock.
b ) Use clamps or another practical way to secure and support the workpiece to a stable platform.
Holding the work by your hand or against the body leaves it unstable and may lead to loss of control.
c ) Never run the motor unit when it is not inserted in one of the router bases. The motor is not designed to be handheld.
d ) Keep handles dry, clean and free from oil and grease. This will enable better control of the tool.
e ) Maintain a firm grip with both hands on the tool to resist starting torque. Maintain a firm grip on the tool at all times while operating.
f ) Keep hands away from cutting area above and below the base. Never reach under the workpiece for any reason. Keep the router base firmly in contact with the workpiece when cutting.
g ) Never touch the bit immediately after use. It may be extremely hot.
h ) Be sure that the motor has stopped completely before you lay the router down. If the bit is still spinning when the tool is laid down, it could cause injury or damage.
i ) Be sure that the router bit is clear of the workpiece before starting the motor. If the bit is in contact with the workpiece when the motor starts, it could make the router jump, causing damage or injury.
j ) The permitted speed of the cutting bit must be at least equal to the maximum speed marked on the power tool. If cutting bits run faster than their rated speed, they may break and fly off.
k ) Always follow the bit manufacturer’s speed recommendations as some bit designs require specific speeds for safety or performance. If you are unsure of the proper speed or are experiencing any type of problem, contact the bit manufacturer.
l ) Do not use router bits with a diameter in excess of 2″ (50 mm) in this tool.
m ) Do not use cutters larger than 1 7/8″ (45 mm) unless the router is fitted in a router table.Do not use cutters larger than 1.78″ (45 mm) unless the router is fitted in a router table.
n ) Do not hand‑hold the router in an upside‑down or horizontal position. The motor can separate from the base if not properly attached according to the instructions.
o ) Before starting the motor, check to see that the cord will not snag or impede the routing operation.
p ) Keep cutting pressure constant. Do not overload motor.
q ) Provide clearance under workpiece for bit when through‑cutting.
r ) Do not press spindle lock button while the motor is running. Doing so can damage the spindle lock.
s ) Always make sure the work surface is free from nails and other foreign objects. Cutting into a nail can cause the bit and the tool to jump.
t ) Before starting the motor, clear the work area of all foreign objects.

Additional Safety Information

WARNING: Never modify the power tool or any part of it. Damage or personal injury could result.
WARNING: ALWAYS use safety glasses. Everyday eyeglasses are NOT safety glasses. Also use face or dust mask if cutting operation is dusty. ALWAYS WEAR

CERTIFIED SAFETY EQUIPMENT:

• ANSI Z87.1 eye protection (CAN/CSA Z94.3),
• ANSI S12.6 (S3.19) hearing protection,
• NIOSH/OSHA/MSHA respiratory protection.
  WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

Some examples of these chemicals are:

• lead from lead‑based paints,
• crystalline silica from bricks and cement and other masonry products, and
• arsenic and chromium from chemically‑treated lumber.

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

• Wear protective clothing and wash exposed areas with soap and water. Allowing dust to get into your mouth, eyes, or lay on the skin may promote absorption of harmful chemicals. Direct particles away from face and body.
• Use the appropriate dust extractor vacuum to remove the vast majority of static and airborne dust. Failure to remove static and airborne dust could contaminate the working environment or pose an increased health risk to the operator and those in close proximity.
• Air vents often cover moving parts and should be avoided. Loose clothes, jewelry or long hair can be caught in moving parts.
• An extension cord must have adequate wire size (AWG or American Wire Gauge) for safety. The smaller the gauge number of the wire, the greater the capacity of the cable, that is, 16 gauge has more capacity than 18 gauge. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. When using more than one extension to make up the total length, be sure each individual extension contains at least the minimum wire size. The following table shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The lower the gauge number, the heavier the cord.

Minimum gauge for Cord sets

The label on your tool may include the following symbols. The symbols and their definitions are as follows:

Motor
Be sure your power supply agrees with the nameplate marking. Voltage decrease of more than 10% will cause loss of power and overheating. These tools are factory tested; if
this tool does not operate, check power supply.

WARNING: Do not operate tools rated “AC only” on a DC supply.

Technical Data
DWE625

CAUTION: Before operating any of the controls, read the following sections.

Plunge Lock Lever (Fig. B)
The plunge lock lever  6  allows you to stop the working bit at a specified height.

1. Press down the plunge lock lever  6  when you want to lower the router bit into the workpiece.
2. You can lower the unit until it reaches your preset stop.
3. To lock the tool in place along its vertical travel, press quick release button  7 .

Collets (Fig. C)

WARNING: Projectile hazard. Only use bits with shanks that match the installed collet. Smaller shank bits will not be secure and could become loose during operation.
CAUTION: Never tighten the collet without first installing a router bit in it. Tightening an empty collet, even by hand, can damage the collet.
Two collets are included with the router.
‑ 1/4” (6 mm)
‑ 1/2” (13 mm).

1. To change collets  35 , unscrew the collet assembly  9 .
2. Sharply pull the old collet out of the collet nut  45  and insert the new collet  35 .
3. Push firmly so that the new collet snaps past the retaine rspring in the collet nut.

Multiple Position Turret Stop (Fig. E)

WARNING: Do not change the turret stop while the router is running. This will place your hands too near the cutter head.
The turret stop  11  limits the downward distance that the tool can be plunged. It consists of three screws of different lengths that serve to define the depth of cut by limiting the travel of the depth stop bar  12 .

1. Routing depth can be set by selecting the screw of the appropriate length on the turret.
2. The turret is rotatable with detent stops to properly align the screws.
3. It is the interaction of the depth stop bar and the turret stop that determine the routing depth.
4. If none of the provided screws seems close to the desired height each can be adjusted by loosening the hex nut at the bottom and then turning the screw either in or out to make it the proper length. After adjusting this screw be sure to tighten the hex nut at the bottom with the an 8 mm wrench  41  .
5. Refer to section Setting the Routing Depth for instructions on how to use the turret stop in an actual operation.

Height Stop Rod and Height Stop Thumb Wheel (Fig. G)
The height stop rod  5  and thumb wheel  4  limit how high the unit can travel up the rails. The system is adjustable from full down where the unit cannot rise regardless of the position of the plunge release lever to full up where the bottom of the collet is 3‑5/32” (80 mm) above the workpiece.
For convenience, the thumb wheel is equipped with a quick release button  23 that allows you to disengage the threads for fast positioning by simply depressing the button in the side of the wheel.
NOTE: It is easier to move the height stop thumb wheel UP if the plunge release lever is locked and easier to move the thumb wheel down if the unit is first moved down by
releasing the plunge release lever and then tightening it.

ASSEMBLY AND ADJUSTMENTS

WARNING: To reduce the risk of serious personal injury, turn unit off and disconnect it from power source before making any adjustments or removing/installing attachments or accessories.
An accidental start‑up can cause injury.

Installing and Removing a Cutter (Fig. C, F)

WARNING: Do not tighten the collet without a cutter fitted.
WARNING: Always use cutters with shanks which match the diameter of the collet.
WARNING: Do not use cutters larger than 1‑7/8″ (45 mm) unless the router is fitted in a router table.
CAUTION: Care should be taken when removing cutter to avoid cuts to fingers.

Installing a Cutter

1. Insert at least three fourths of the shank length of the cutter into the collet assembly  9 .

2. Press the spindle lock  8  forward until the router spindle is locked.
   NOTE: You may need to turn the spindle slightly to engage it.

3. Turn the collet nut  45  counterclockwise with the supplied 22 mm wrench  13  to tighten it.

Removing a Cutter

1. Press the spindle lock button  8  forward until the router spindle is lock.
2. Turn the collet nut  9  clockwise with the supplied 22 mm wrench  13  to loosen.
3. Keep turning the wrench until the collet nut tightens and then loosens again. This is the fail‑safe mechanism releasing the collet.
4. The cutter should now slide out.
   NOTE: Each time you finish using a cutter, remove it and store it in a safe place.

Adjusting the Depth of Cut (Fig. A, D, E)
Your router is equipped with a high‑precision depth adjustment system including a zero reset ring for both the quick height adjuster and the fine height adjuster.

Quick Adjustment Using the Graduation with Zero Reset Ring

1. Loosen the depth stop quick height adjuster lock 15 .
2. Unlock the plunge limiter by pushing the release lever 6 down.
3. Lower the router carriage until the cutter is in contact with the workpiece.
4. Press the quick release button 7 .
5. Adjust the depth stop bar 12 until it makes contact with the turret stop 11. Then set both the quick zero reset ring 14 and fine zero reset ring 19 to the zero position.
6. Adjust the depth of cut using the quick height adjuster 16 and the corresponding graduation. The adjusted depth of cut is indicated by the pointer 17.
7. Tighten depth stop quick height adjuster lock 15.

Fine Adjustment
When not using a depth template, or if the depth of cut needs readjustment, it is recommended to use the fine height adjuster 18.

1. Adjust the depth of cut as described in Adjusting the Depth of Cut.
2. Set the fine height adjuster to zero using the fine zero reset ring 19
3. Rotate the fine height adjuster  18  to the required position: one turn corresponds to approximately 1 mm and 1 mark to 0.1 mm.

Fitting a Guide Bush (Fig. H)
Together with a template, guide bushes play a valuable part in cutting and shaping to a pattern.

• Fit the guide bush  24  to the router base  10  using the screws  25  as shown.

Fitting the Parallel Fence (Fig. I, J)

1. Fit the guide rod  26  to the router base  10 .
2. Slide the parallel fence  27  over the rods.
3. Tighten the wing bolts  28  temporarily.

Adjusting the Parallel Fence (Fig. A, I, J)

1. Draw a cutting line on the material.
2. Lower the router carriage until the cutter is in contact with the workpiece.
3. Push quick release button  7  and limit the carriage return using the thumb wheel  4 .
4. Position the router on the cutting line.
5. Slide the parallel fence  27  against the workpiece and tighten the wing bolts  28 .
6. Adjust the parallel fence using the fine adjustment knob  29 . The outer cutting edge of the cutter must coincide with the cutting line.
7. If required, loosen the screws  30  and adjust the strips  31  to obtain the desired guiding length.

Connecting Dust Extraction Adaptor (Fig. K)

CAUTION: In normal plunge mode, ensure the base of the knurled nut is aligned correctly with the forks of the lower motor housing. This will enable the cutter to retract into the base safely.
WARNING: Whenever possible use the hose guide with a suitable extractor when routing.
The dust extraction adaptor consists of a main section  32 , a cover  33 , an extraction tube adaptor  34  , one extraction tube screw  37 , two base screws 42  and two nuts  36  .

1. Slide the cover  33  onto the main section  32  until it clicks into place.
2. Place the main section  32  on the base and secure with two screws  42  and nuts  36 .
3. Remove screw  37  from the top of the router and use this screw to assemble the extraction tube adaptor  34  to the router.

Connecting Dust Extractor Hose (Fig. P)

WARNING: Risk of dust inhalation. To reduce the risk of personal injury, ALWAYS wear an approved dust mask. A dust extraction tube adaptor  34  is supplied with your tool.
Vacuum hoses on most vacuum extractors will fit directly into the dust extraction spout.
WARNING: ALWAYS use a vacuum extractor designed in compliance with the applicable directives regarding dust emission when sawing wood. Vacuum hoses of most common vacuum cleaners will fit directly into the dust extraction outlet.

1. Connect a dust extractor hose  43  to the extraction tube adaptor  34  using the DeWALT quick lock system.

NOTE: When using dust extraction, be sure that the vacuum cleaner is out of the way and secure so that it will not tip over or interfere with the router or workpiece. The vacuum hose and power cord must also be positioned so that they do not interfere with the router or workpiece. If the vacuum cleaner or vacuum hose cannot be positioned properly, it should be removed.

OPERATION

WARNING: To reduce the risk of serious personal injury, turn unit off and disconnect it from power source before making any adjustments or removing/installing attachments or accessories.
An accidental start‑up can cause injury.
CAUTION: Before connecting tool to power source, check to see that the switch is in the “OFF” position. An accidental start‑up can cause injury.

Proper Hand Position (Fig. O)

WARNING: To reduce the risk of serious personal injuryALWAYS use proper hand position as shown.
WARNING: To reduce the risk of serious personal injury, ALWAYS hold securely in anticipation of a sudden reaction.
Proper hand position requires both hands on the main handles  2 .

Using the Router (Fig. A, L)
CAUTION: Turn the router on before plunging the cutter head into the workpiece.

CAUTION:

• Excessive cutting may cause overload of the motor or difficulty in controlling the tool, the depth of cut should not be more than 19/32″ (15 mm) at a pass when cutting grooves with a 5/16″ (8 mm) diameter bit.

• When cutting grooves with a 25/32″ (20 mm) diamter bit, the depth of cut should not be more than 3/16″ (5 mm) at a pass.

• For extra deep grooving, make two or three passes with progressively deeper bit settings.
  CAUTION:

• After long periods of working at low speeds, allow the machine to cool down by running it for three minutes at maximum speed, with no load.
  All common routing tasks can be performed with the plunge cut router on all types of wood and plastic:
  ‑ Grooving
  ‑ Rabbeting
  ‑ Recessing
  ‑ Veining
  ‑ Profiling
  To prevent overload of the tool by using the wrong speed selection, follow the reccommended settings below:

| CUTTER DIAMETER
---|---
| 13/32″ ‑ 1‑3/16″ (10 ‑ 30 mm)| 1‑3/16″ ‑ 2″ (30 ‑ 50 mm)
  MATERIAL| SPEED SELECTION
 Hardwood| 7 ‑ 5| 6 ‑ 2
 Softwood| 7 ‑ 6| 7 ‑ 5
 Chipboard Faced| 7 ‑ 6| 7 ‑ 4
 Plastic| 7 ‑ 5| 7 ‑ 4

NOTE: Only carbide‑tipped cutters should be used on panels faced with plastic laminates. The hard laminates will quickly dull steel cutters.
NOTE: For better plunge sliding movement, frequently clean the columns of dust or debris. If the plunging movement is not moving as smooth as desired, lubricate the columns with a dry teflon lubricant.

1. After setting the cutting depth as described, locate the router such that the bit is directly over the place you will be cutting.
2. With the router running, lower the unit smoothly down into the workpiece. DO nOT JAM ThE ROUTER DOWn.
3. When the tool reaches the pre‑set depth, push the quick release button  7  to lock.
4. When you have finished routing, push the plunge lock lever  6  to unlock and let the spring lift the router directly out of the workpiece.
5. Always feed the router opposite to the direction in which the cutter is rotating. Refer to Fig. L.

On/Off Trigger Switch (Fig. A)
WARNING: To reduce the risk of serious personal injury, turn unit off and disconnect it from power source before making any adjustments or removing/installing attachments or accessories.
An accidental start‑up can cause injury.

1. To turn the unit on, squeeze the on/off trigger switch  3 .
   Continue to squeeze the trigger switch or press the lock on button switch  20 for continuous running.

2. To turn the unit off:
   a. If lock on trigger is engage, release the lock on button by squeezing and releasing trigger.
   b. If the lock on switch is not engage, fully release the trigger.

Variable Speed Dial (Fig. A)

WARNING: If the speed control ceases to operate, or is intermittent, stop using the tool immediately. Take it to a DeWALT factory or authorized service facility for repair.
NOTICE: The router is equipped with electronics to monitor and maintain the speed of the tool while cutting. In low and medium speed operation, the speed control prevents the motor speed from decreasing.
If you expect to hear a speed change and continue to load the motor, you could damage the motor by overheating. Reduce the depth of cut and/or slow the feed rate to prevent tool damage.

Refer to the Speed Selection Chart to choose a router speed.
Turn the speed dial  1  to control router speed. The speed is variable from 9000 to 22000 rpm using the speed dial 1.

1. Turn the speed dial to the required position. The dial is numbered from 1 –7 and corresponds to router speeds of 9000 rpm to 22000 rpm.
2. Use the slower settings for large diameter cutters and the faster settings for small diameter cutters.
3. The correct setting will also depend on the density of the material, depth of cut and feed speed of the router.
   NOTE: A noticeable loss of motor rpm means motor overload.

SPEED SELECTION CHART

The speeds in this chart are approximate and are for reference only. Your router may not produce the exact speed listed for the dial setting.

WARNING: Always follow the bit manufacturer’s speed recommendations as some bit designs require specific speeds for safety or performance.
If you are unsure of the proper speed or are experiencing any type of problem, contact the bit manufacturer.

LED Worklight (Fig. F)

CAUTION: Do not stare into worklight. Serious eye injury could result.
Two LED worklights  57  are located next to the collet assembly  9 .

1. The worklights  57  will constantly illuminate when the router is plugged in to a power supply.
2. To switch off the worklights the router must be unplugged from the power supply.
   NOTE: The worklight is for lighting the immediate work surface and is not intended to be used as a flashlight.

Setting Plunge Lock System (Fig. B)
The plunge is fully automatically locking for all cuts. For heavy cut operations, ensure to push the lever towards the tool body. The plunge lock lever  6  position is set at the factory so the lever does not touch the motor body, if the plunge lock lever begins to hit the body when the quick release lever is pushed, readjust the locking lever position as follows:

1. Push in quick release button  7 . The plunge lever lock will unlock automatically.
2. Using a Torx 20 star bit  39 , loosen the shoulder screw  44  on the plunge lock lever  6  with six counterclockwise turns. Do not fully remove.
3. Lift the plunge lock lever, rotate and reposition the plunge lock lever at position 2 (at eleven o’clock).
4. Tighten the shoulder screw.
5. If after setting to position 2 sliding is not correct, repeat steps 1 to 3 and reposition the lock lever at position 1.
   Tighten the shoulder screw.

Moulding Natural Timbers

WARNING: When routing always lock the plunge locking lever.
When edge moulding natural timbers, always mould the end grain first, followed by the long grain. This ensures that if thereis breakout, it will be removed when the long grain is routed.

Setting the Routing Depth (Fig. D, E)

1. Place the router with cutter fitted on to the workpiece.

2. Set the multiple position turret stop 11 as required.

3. Loosen the quick height adjust lock 15 securing the depth stop 12 .

4. Push down the plunging lock lever 6 to start plunging.

5. Lower the router slowly until the cutter touches the workpiece and secure it in place by pushing quick release button  7 .

6. Rotate the quick depth adjuster 16 until the depth stop bar 12 touches multiple turret stop 11. Secure in position by tightening the quick height adjuster lock 15.

7. If the depth of cut needs re‑adjustment, it is recommended to use quick height adjusterr 16 for gross settings, or the fine height adjuster for accurate settings.

8. Adjust the depth of cut using the fine height adjuster 18
   NOTE: One turn of the fine height adjuster 18 corresponds to 3/64″ (1 mm), one turn of the quick height adjuster zero reset ring 14 corresponds to 1‑1/2″ (40 mm)

9. Read the depth of cut using the quick zero reset ring 14  and fine zero reset ring 19 .

10. The distance between the top of the revolving depth stop and the bottom of the depth stop is the required depth of cut.

11. The rotating turret stop screws 11 can be used for setting up to three depths of cut. The height can be adjusted using a flat screwdriver and a 5/16″ (8 mm) wrench.
    NOTE: By rotating the turret stop, three depth settings can be quickly made.

Direction Of Feed (Fig. L)

WARNING: Avoid climb‑cutting (cutting in direction opposite than shown in Fig. L). Climb‑cutting increases the chance for loss of control resulting in possible injury.
When climb‑cutting is required (backing around a corner), exercise extreme caution to maintain control of router. Make smaller cuts and remove minimal material with each pass.

The direction of feed is very important when routing and can make the difference between a successful job and a ruined project. Fig. L show proper direction of feed for most cuts.

1. When routing along an edge, the direction of the router travel should be against that of the rotation of the cutter.
   This will create the correct cutting action and prevent the cutter from snatching. It will also pull the router towards the workpiece and the side fence or guide bearing will be less likely to wander from the edge of the workpiece.

Feed Speed
The speed at which the cutter is fed into the wood must not be too fast that the motor slows down, or too slow that the cutter leaves burn marks on the face of the wood.
NOTE: Practice judging the speed by listening to the sound of the motor when routing.

Sequence of Plunging

WARNING: When routing always lock the plunge locking lever.

1. Plunge down and lock the motor carriage, by pushing quick release button 7 .
2. Perform the desired routing operation.
3. Push down the plunge lock lever 6 and the motor carriage returns to the normal position.

Fine Height Adjuster (Fig. D)
This router has a built in fine height adjuster. This should be used when fine height adjustment of the cutter is required.
This is especially recommended when using dovetail jigs or router tables.

Using a Side Fence (Fig. M)

CAUTION: Ensure working position is comfortable and at a suitable working height.

1. Ensure the wing bolts  28  are fully released. Slide the guide rods  26  into the routing base  10  and tighten the wing bolts.

2. Adjust the fence fine adjustment knob  29  to the required distance and clamp in place with the wing bolts  28 .

3. Then lower the cutter height until the cutter is just above the workpiece.

4. Fine adjustments are possible by loosening the wing bolt  28  and adjusting the side fence fine adjustment knob  29 .

5. Tighten the wing bolt  28  to secure the position.
   NOTE: One revolution of the side fence fine adjustment knob  29  equals 3/64″ (1.0 mm) of side feed.

6. Lower the cutter onto the workpiece and set the cutter height by to the required distance. Refer to Setting the Router Depth.

7. Switch the router on and after the cutter reaches full speed, gently lower the cutter into the workpiece and lock the plunge.

8. Feed along the workpiece, keeping sideways pressure to ensure the side fence does not wander away from the workpiece edge and downward pressure on the inside hand to prevent the router from tipping.

9. When finished, raise the router, secure with the plunge locking lever  6  and switch the router off.
   NOTE: When starting the cut, keep the pressure on the front cheek until the back cheek contacts the workpiece edge.
   NOTE: At the end of the cut, keep pressure on the back cheek until the cut is finished. This will prevent the router cutter swinging in at the end of the workpiece and nipping the corner.

Side Fence Routing (Fig. I, J)
The side fence is used to guide the router when moulding,
edge profiling or rebating the edge of a workpiece or whenrouting grooves and slots in the center of the workpiece, parallel to the edge.
The edge of the workpiece must be straight and true.
The strips  31  are adjustable and should be set ideally with a 1/8″ (3 mm) gap each side of the cutter.

MAINTENANCE

WARNING: To reduce the risk of serious personal injury, turn unit off and disconnect it from power source before making any adjustments or removing/installing attachments or accessories.
An accidental start‑up can cause injury.
Your DEWALT power tool has been designed to operate over a long period of time with a minimum of maintenance.
Continuous satisfactory operation depends upon proper tool care and regular cleaning.

Cleaning

WARNING: Blow dirt and dust out of all air vents with clean, dry air at least once a week. To minimize the risk of eye injury, always wear ANSI Z87.1 approved eye protection and an approved dust mask when performing this procedure.
WARNING: Never use solvents or other harsh chemicals for cleaning the non‑metallic parts of the tool. These chemicals may weaken the plastic materials used in these parts. Use a cloth dampened only with water and mild soap. Never let any liquid get inside the tool; never immerse any part of the tool into a liquid.

Accessories

WARNING: Since accessories, other than those offered by DEWALT, have not been tested with this product, use of such accessories with this tool could be hazardous.
To reduce the risk of injury, only DEWALT recommended accessories should be used with this product. Recommended accessories for use with your tool are available at extra cost from your local dealer or authorized service center. If you need assistance in locating any accessory, please contact DEWALT call 1‑800‑4‑DEWALT (1‑800‑433‑9258) or visit our website: www.dewalt.com.

Base Mounting Points for Accessories (Fig. N)
This router has three threaded holes 38 built into the base that allows it to attach to other accessories.

Repairs
WARNING: To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including power cord repairs, and brush inspection and replacement, when applicable) should be performed by a DEWALT factory service center or a DEWALT authorized service center. Always use identical replacement parts.

Register Online
Thank you for your purchase. Register your product now for:

• WARRANTY SERVICE: Registering your product will help you obtain more efficient warranty service in case there is a problem with your product.
• CONFIRMATION OF OWnERshiP: In case of an insurance loss, such as fire, flood or theft, your registration of ownership will serve as your proof of purchase.
• FOR YOUR SAFETY: Registering your product will allow us to contact you in the unlikely event a safety notification is required under the Federal Consumer Safety Act.
• Register online at www.dewalt.com

Three Year Limited Warranty
For warranty terms, go to https://www.dewalt.com/Legal/Warranty/3‑Year‑Limited‑Warranty.
To request a written copy of the warranty terms, contact:
Customer Service at DEWALT Industrial Tool Co., 701 East Joppa Road, Towson, MD 21286 or call 1‑800‑4‑DEWALT (1‑800‑433‑9258).
LATIN AMERICA: This warranty does not apply to products sold in Latin America. For products sold in Latin America, see country specific warranty information contained in the packaging, call the local company or see website for warranty information.
FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are missing, call 1‑800‑4‑DEWALT (1‑800‑433‑9258) for a free replacement.

DEWALT Industrial Tool Co. 701 East Joppa Road, Towson, MD 21286
Copyright © 2021
The following are trademarks for one or more DEWALT power tools: the yellow and black color scheme, the “D” shaped air intake grill, the array of pyramids on the handgrip, the kit box configuration, and the array of lozenge‑shaped humps on the surface of the tool.
N896699
If you have questions or comments, contact us.
Pour toute question ou tout commentaire, nous contacter.
1‑800‑4‑DEWALT
www.DEWALT.com

References

• DEWALT® Power Tools Official Site | Guaranteed Tough®

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