DEWALT DW624 Plunge Cut Router/DW625 Electronic Plunge Cut Router Instruction Manual

**DEWALT DW624 Plunge Cut RouterDW625 Electronic Plunge Cut Router Instruction Manual

**

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS, OR ANY DEWALT TOOL, CALL US TOLL FREE AT 1- 8 0 0 – 4 – DEWALT (1-800-433-9258)

Important Safety Instructions

WARNING : When using Electric Tools, basic safety precautions should always be followed to reduce the risk of fire, electric shock, and personal injury, including the following:

WARNING : Use of this tool can generate dust containing chemicals known to cause cancer, birth defects or other reproductive harm. Use appropriate respiratory protection.

CAUTION : Some wood contains preservatives such as copper chromium arsenate (CCA) which can be toxic. When cutting these materials extra care should be taken to avoid inhalation and mini – mize skin contact.

• KEEP WORK AREA CLEAN. Cluttered areas and benches invite injuries

• CONSIDER WORK AREA ENVIRONMENT. Don,t expose power tools to rain. Don,t use power tools in damp or wet locations. Keep work area well lit.

• GUARD AGAINST ELECTRIC SHOCK. Prevent body contact with grounded surfaces. For example: pipes, radiators, ranges, refrigerator enclosures.

• KEEP CHILDREN AWAY. All visitors should be kept away from work area. Do not let visitors contact tool or extension cord .

• STORE IDLE TOOLS. When not in use, tools should be
  stored in dry, and high or locked-up place  out of reach of children .

• DON,T FORCE TOOL. It will do the job better and safer at the rate for which it was intended.

• USE RIGHT TOOL. Don,t force small tool or attachment to do the job of a heavy-duty tool. Don,t use tool for purpose not intended, for example, donít use circular saw for cutting tree limbs or logs.

• DRESS PROPERLY. Do not wear loose clothing or jewelry. They can be caught in moving parts. Non-skid footwear is recommended when working outdoors. Wear protective hair covering to contain long hair.

• USE SAFETY GLASSES. Also use face or dust mask if operation is dusty.

• DON,T ABUSE CORD. Never carry tool by cord or yank it to disconnect from receptacle. Keep cord from heat, oil, and sharp edges.

• SECURE WORK. Use clamps or a vise to hold work. Itís safer than using your hand and it frees both hands to operate tool.

• DON,T OVERREACH. Keep proper footing and balance at all t i m e s .

• MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for better and safe performance. Follow instructions for lubricating and changing accessories. Inspect tool cords periodically and if damaged have repaired by DeWalt certified service center. Inspect extension cords periodically and replace if damaged. Keep handles dry, clean, and free from oil and grease.*

• DISCONNECT TOOLS. When not in use, before servicing, and when changing accessories.

• REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see that keys and adjusting wrenches are removed from tool before turning it on.
  AVOID UNINTENTIONAL STARTING. Don,t carry plugged-in tool with finger on switch. Be sure switch is off when plugging in .

• EXTENSION CORDS. Make sure your extension cord is in good condition. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. The following table shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gage. The smaller the gage number, the heavier the cord

Recommended Minimum Wire Size for Extension Cords

Total Length of Cord:

• 25 ft. 50 ft. 75 ft. 100 ft. 125 ft. 150 ft. 175 ft
  

• 7.6 m 15.2 m 22.9 m 30.5 m 38.1 m 45.7 m 53.3 m

Wire Size:

• 18 AWG 18 AWG 16 AWG 16 AWG 14 AWG 14 AWG 2 AWG
• OUTDOOR USE EXTENSION CORDS. When tool is used outdoors, use only extension cords intended for use outdoors and so marked.
• STAY ALERT. Watch what you are doing. Use common sense. Do not operate tool when you are tired.
• CHECK DAMAGED PARTS. Before further use of the tool, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting, and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced by a DEWA L T certified service center unless otherwise indicate d elsewhere in this instruction manual. Have defective switches replaced by a DEWA L T certified service center. Do not use tool if switch does not turn it on and off.
• DO NOT OPERATE portable electric tools near flammable liquids or in gaseous or explosive atmospheres. Motors in these tools normally spark, and the sparks might ignite fumes.

SAVE THESE INSTRUCTION FOR FEATURE USE

Double Insulation

Double Insulation DOUBLE-INSULATED tools are constructed throughout with TWO separate ìlayersî of electrical insulation between you and the toolís electrical system. Tools built with this insulation system are not intended to be grounded. As a result, your tool is equipped with a two-prong plug which permits you to use extension cords without concern for maintaining a ground connection.
NOTE : DOUBLE INSULATION does not take the place of normal safety precautions when operating this tool. The insulation system is for added protection against injury resulting from a possible electrical insulation failure within the tool.
CAUTION: When servicing all tools, USE ONLY IDENTICAL

Polarized Plugs

Polarized plugs (one blade is wider than the other) are used on equipment to reduce the risk of electric shock. When provided, this plug will fit into a polarized outlet only one way. If the plug does not fit fully into the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install the proper outlet. Do not change the plug in any way. REPLACEMENT PARTS. Repair or replace damaged cords

Motor

Your DEWALT tool is powered by a DEWALT-built motor. Be sure your power supply agrees with the nameplate marking. Volts 50/60 Hz or AC onlye means your tool must be operated only with alternating current and n e v e r with direct current. Volts DC60Hz or AC/DC means your tool may be operated with either alternating or direct current. Voltage decrease of more than 10% will cause loss of power and overheating. All DeWalt tools are factory tested; if this tool does not operate, check the power supply

Additional Specific Instructions for Routers

The electronic motor control system has two basic features.

• A. Soft start – when you turn on the router, you will notice that it
  does not have the jerk from the rapid acceleration of the motor.
  This router has a starting circuit which accelerates the motor up to
  speed smoothly, without jerking, and allows you to maintain easier
  control of the router during the start up period.

• B. Constant speed cutting – as you load the router, the selected cutting speed does not slow down during normal use. The electronic control governs the motor and gives you a consistent finish to your work. Only under very heavy loading will the speed of the unit fall below the governed speed. To set the router speed (from 8,000 rpm to 20,000 rpm) rotate the speed control wheel shown in the large figure on page 2. The higher the number the higher the speed. Consult TABLE 1 (page 3) to help select the proper speed for your application.

Specifications

PREPARATION FOR USE

The motor in this router is high-powered (750 Watts, max.). Despite this, it is advisable to cut deep grooves or remove large amounts of material in two or more passes

Operating Instructions

TURN OFF AND UNPLUG ROUTER

NOTE : Before installing a router bit in your unit, position the tool so that the collet is easily accessible. To do this, rotate the height stop thumb wheel, shown in Figure 1, counterclockwise until it is about 1/2î from the top of the threaded height stop rod. Raise the plunge release lever, shown in Figure 2, and let the router rise to its full height. Depress the plunge release lever to lock the tool in place.

TECHNICAL DATA

SPEED SELECTION CHART

TABLE 1: RECOMMENDATION FOR THE CORRECT CHOICE OF SPEED
Material
Cutter Diam.
Electronic Control Settings

Model #DW624/DW625

Hardwood, e.g., oak

| Small (1/2″) Medium (1/2″-1 1/8″) Large (over-1 1/8″)| Stage 1 8,000 rpm – X| Stage 2 12,000 rpm –– XX| Stage 3
16,000 rpm
O O O| Stage 4
18,000 rpm
X XX

–

| Stage 5
20,000 rpm
XX X

–

Softwood, e.g., pine| Small (1/2″) Medium (1/2″-1 1/8″) Large (over-1 1/8″)| –– X| – O XX| O X O| X XX O| XX XX

–

Plastic-laminated chipboard| Small (1/2″) Medium (1/2″-1 1/8″) Large (over-1 1/8″)| – – O| – O XX| O X X| X XX O| XX XX –
Plastics                                                    Small (1/2″) –                           O                            X X                          XX

Medium (1/2″-1 1/8″)           –                           O XX                          XX                          X

Large (over-1 1/8″)            X                          XX O                             –                            –

This Table can serve only as a guide, since wood is a living material. Even with the same species of timber there will be large differences in hardness and density. When a high speed is employed, set the electronic control one step higher.

KEY: XX very good         X good         O Satisfactory         – not recommended

Switch

TO SWITCH ON THE MACHINE
NOTE: Always pull the plug on the cord set out of its receptacle when changing a cutter or fitting the accessories in order to avoid any chance of an accident.
CONVENIENT SWITCH ACTUATOR PUSH UP FOR ICON DOWN FOR OFF.

Bit Installation and Removal

(TURN OFF AND UNPLUG ROUTER)
IMPORTANT NOTE: Always snap the collet firmly into the colletnut, (past the retainer spring) before installing a bit. Use the supplied wrench and the spindle lock as necessary to loosen (counterclockwise) the collet nut, as shown in Figure 3.

Insert the round shank of the desired router bit into the loosened collet as far as it will go and then pull it out about 1/16î. Hold the spindle shaft by depressing the spindle lock button, shown in Figure 3, while firmly tightening the collet nut with the wrench provided.

Your router has a unique locking system for retaining the bit. When removing a bit, the collet nut must be loosened with the wrench. The collet nut will turn approximately 3/4 of a turn and then become tight again. At this point the bit canít be removed. Using the same procedure, loosen the nut a second time.This lifts the collect and makes it very easy to remove the bit.

Collets
NEVER TIGHTEN THE COLLET ON THIS TOOL WITHOUT FIRST INSTALLING A ROUTER BIT IN IT. TIGHTENING AN EMPTY COLLET CAN DAMAGE THE COLLET.
To change collets, unscrew the collet assembly, as described above, sharply pull the old collet out of the collet nut and insert the new collet. Push firmly so that it snaps past the retainer spring in the collet nut.

Controls
NOTE : Before operating any of the controls, read this whole section .

PLUNGE RELEASE LEVER
The plunge release lever allows the router bit to be plunged directly into the work piece. Simply raise the plunge release lever when you want to lower the router into the work, as shown in Figure 2. You can lower the unit until it reaches your preset stop. To lock the tool in place anywhere along its vertical travel, depress the lever.

HEIGHT STOP ROD AND HEIGHT STOP THUMB WHEEL
As its name implies, the height stop rod and thumb wheel 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 2-7/8î above the work piece (See Figure 4).

For convenience, the thumb wheel is equipped with a quick release button 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.

MULTI-POSITION TURRET STOP
The turret stop 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 **(see Figure 5).

Routing depth can be set by selecting the screw of the appropriate length on the turret. The turret is rotatable with detent stops to properly align the screws.
It is the interaction of the depth stop bar and the turret stop that determine the routing depth.
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. (See Figure 6)
**
See the section ìSetting the Routing Depthî for instructions on how to use the turret stop in an actual operation.

The depth stop bar is what contacts the selected screw in the turret stop to limit the routing depth. At the bottom of the depth stop bar is a threaded shaft, a spring and a knurled knob, as shown in Figure 7.

A precision vernier scale is provided for extremely accurate adjustment of the routing depth.
See the section below ìSetting the Routing Depthî for instructions on how to use the depth stop bar and vernier in an actual Operation .

Familiarization
Please take a little time now and, without plugging the tool in, practice with these adjustments and controls and become familiar with their operation. Only with a complete, ìhands onî understanding of these systems will you be able to get the most out of this quality router .

Setting the Routing Depth
(TURN OFF AND UNPLUG THE ROUTER)

To set the routing depth follow the steps below:

1. Install the desired router bit as described previously.

2. Position the height stop thumb wheel at the top of the height stop rod. (See Figure 4) You can either turn the thumb wheel or use the handy quick release button discussed above.

3. Adjust the depth stop bar to the top of its travel by rotating the Depth Stop Control Knob shown in Figure 9.

4. Rotate the turret stop to position the shortest screw under the depth stop bar.

5. Raise the plunge release lever and push the router down until the end of the bit just touches the work piece.

6. Lower the depth stop bar until the knurled knob on the bottom of it touches the selected screw in the turret stop.

7. Raise or lower the plastic vernier to align the hairline in the vernier with the 0 mark on the graduated scale, as shown in Figure 8.

8. Using the depth stop control knob, raise the depth stop bar and align the desired mark on the graduated scale with the hairline in the vernier, as shown in Figure 9.
   (Scale graduated in 1/16ths of an inch).

9. Tighten the depth stop bar clamp.

10. The router is now set to cut to the set depth when plunged into the work piece.

Fine Adjustment of Routing Depth
TURN OFF AND UNPLUG ROUTER.

If, after setting the desired depth of cut, a small adjustment is needed, it is not necessary to go through the entire procedure for setting the depth. Minor adjustment can be easily made by rotating the knurled knob on the bottom end of the depth stop bar, as shown in Figure 8.

Rotating the knob clockwise (looking down from the top of the router) will result in a more shallow cut. Rotating the knob counterclockwise will result in a deeper cut. One complete rotation of the knob represents about 1 mm in depth adjustment.

Using the Turret Stop for Sequential

Routing Depth Setting

It is recommended that particularly deep grooves be cut with several passes rather than one deep pass. In order to do this and still maintain accuracy of depth when the job is finished, perform the following procedure.

1. Set the final desired routing depth as instructed above. For the purpose of this discussion, assume that the desired depth is 1/2î.

2. With a depth of 1/2î set on the shortest screw in the turret stop, adjust the second shortest screw to a point about halfway between the bottom of the knurled knob and the top of the shortest screw, as shown in Figure 10.
   

3. Leave the vernier setting alone and turn the adjusted second shortest screw into position under the depth stop bar.

4. Make your first cut at this setting.

5. Rotate the turret stop so that the shortest screw is directly under the depth stop bar and make your final cut

NOTE: The third screw in the turret stop is provided if your cut is even deeper and you want to make three cuts to achieve the final depth, or set final depth for multiple cuts at one time.

Operation

After setting the cutting depth as described, locate the router such that the bit is directly over the place you will be cutting. With the router running, lower the unit smoothly down into the work piece.
(DO NOT JAM THE ROUTER DOWN). When the tool reaches the pre-set depth, depress the Plunge Lock Lever. When you have finished routing, raise the lever and let the spring lift the router directly out of the work piece.

All common routing tasks can be performed with ease with the Plunge Cut Router: Grooving, rabbeting, recessing, veining, and profiling on all types of wood and plastic.
Always feed the router opposite to the direction in which the cutter is rotating.

Only carbide-tipped cutters should be used on panels faced with plastic laminates. The hard laminates will quickly dull steel cutters.
Your DeWalt certified Service center has a Router Craft Handbook available at extra cost which covers the use of routers in great detail and shows the various types of bits available.

Direction Of Feed (Fig. 12)
The direction of feed is very important when routing and can make the difference between a successful job and a ruined project.

Figures 11 and 12 show proper direction of feed for some typical cuts .
Mold the outside edge of a piece of stock by a) mold the end grain, left to right, b) do the straight grain side moving left to right, c) finish the other end grain side, and d) do the remaining straight grain edge.

The direction of feed is important in router usage. Be sure the cutter is rotating into the stock by moving left to right on outside edges and clockwise on inside cuts.

Using the Parallel Guide (Fig. 15)
A parallel guide, available at extra cost, router will increase the versatility of your router. Assemble the guide as shown in Figure 18. When itís fully assembled, insert the two bars through the holes in the router base as shown in Figure 19. Adjust as needed for parallel routing.

The guide will adjust in all the way to the cutter. In some cases the plastic slides on the guide will interfere with the cutter if they are not loosened and pushed back to provide clearance. Simply loosen the two screws on each slide and adjust it accordingly.

A fine adjust feature is included on the parallel guide and is operated by rotating the fine adjust knob, shown in Figure 14.

Turn the knob clockwise to move the guide in (closer to the bit). Turn the knob counterclockwise to move the guide out (away from the bit)

Template Guide Adapter
Your router comes equipped with a template guide adapter and two mounting screws. Put these away in a safe place for future use.

Connecting a Dust Extractor (Fig 16)
The dust extractor adapter consists of the body (A), the cover (B), and the hose guide (C). Assemble as follows:

1. Side the cover onto the main body and let it click into place.
2. Connect a dust extractor hose to the outlet.
3. Loosen the screw on the top cover of the router and secure the hose guide in place.

Accessories

If you need assistance in locating any accessory, please contact DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286 or call 1-800-4-DEWALT (1-800-433-9258).
CAUTION: The use of any other accessory might be hazardous.

Important
To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including brush inspection and replacement) should be performed by authorized service centers or other qualified service organizations, always using identical replacement parts.

Full Warranty
DEWALT heavy duty industrial tools are warranted for one year from date of purchase. We will repair, without charge, any defects due to faulty materials or workmanship. For warranty repair information, call 1-800-4-DEWALT. This warranty does not apply to accessories or damage caused where repairs have been made or attempted by others. This warranty gives you specific legal rights and you may have other rights which vary in certain states or provinces

In addition to the warranty, DEWALT tools are covered by our:
30 DAY NO RISK SATISFACTION GUARANTEE
If you are not completely satisfied with the performance of your DEWALT heavy duty industrial tool, simply return it to the participating seller within 30 days for a full refund. Please return the complete unit, transportation prepaid. Proof of purchase may be required.

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