DeWalt DW660 Instruction Manual

D WALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286
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Printed in U.S.A. (JUL02-CD-1) Form No. 392453-01
The following are trademarks for one or more D
scheme; the "D" shaped air intake grill; the array of pyramids on the handgrip; the kit box con-
figuration; and the array of lozenge-shaped humps on the surface of the tool.
F YOU HAVE A N Y QUESTIONS OR COMMENTS A B O U T THIS OR A N Y D
C A L L US TO L L FREE AT:
1 - 8 0 0 - 4 - D E WA LT (1-800-433-9258)

General Safety Rules

WARNING! READ AND UNDERSTAND ALL INSTRUCTIONS. Failure to follow all
instructions listed below may result in electric shock, fire and/or serious personal injury.
SAVE THESE INSTRUCTIONS
WORK AREA
Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents.
Do not operate power tools in explosive atmospheres, such as in the presence of flam -
mable liquids, gases, or dust. Power tools create sparks which may ignite the dust or fumes.
Keep bystanders, children, and visitors away while operating a power tool. Distractions can
cause you to lose control.
ELECTRICAL SAFETY
Grounded tools must be plugged into an outlet properly installed and grounded in accor -
dance with all codes and ordinances. Never remove the grounding prong or modify the plug in
any way. Do not use any adapter plugs. Check with a qualified electrician if you are in doubt as
to whether the outlet is properly grounded. If the tools should electrically malfunction or break
down, grounding provides a low resistance path to carry electricity away from the user. A p p l i c a b l e
only to Class I (grounded) tools.
Double insulated tools are equipped with a polarized plug (one blade is wider than the
o t h e r. ) This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the out -
let, reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized out -
let. Do not change the plug in any way. Double insulation
wire grounded power cord and grounded power supply system. Applicable only to Class II (dou -
ble insulated) tools.
Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refriger -
ators. There is an increased risk of electric shock if your body is grounded.
D o n 't 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 to carry the tools or pull the plug from an outlet. Keep
cord away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately.
Damaged cords increase the risk of electric shock.
When operating a power tool outside, use an outdoor extension cord marked "W-A" or
" W." These cords are rated for outdoor use and reduce the risk of electric shock. When using an
extension cord, be sure to use one heavy enough to carry the current your product will draw. A n
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.
7.6 m 15.2 m 22.9 m 30.5 m
Wire Size
18 AWG 18 AWG 16 AWG 16 AWG 14 AWG 14 AWG 12 AWG
PERSONAL SAFETY
Stay alert, watch what you are doing and use common sense when operating a power tool.
Do not use 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.
Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair,
clothing, and gloves away from moving parts. Loose clothing, jewelry, or long hair can be
caught in moving parts. Air vents often cover moving parts and should also be avoided.
DW660 Copyright © 2000
WA LT power tools: the yellow and black color
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eliminates the need for the three
125 ft. 150 ft. 175 ft.
38.1 m 45.7 m 53.3 m
• Avoid accidental starting. Be sure switch is off before plugging in. Carrying tools with you
finger on the switch or plugging in tools that have the switch on invites accidents.
• Remove adjusting keys or switches before turning the tool on. A wrench or key that is lef
attached to a rotating part of the tool may result in personal injury.
• Do not overreach. Keep proper footing and balance at all times. Proper footing and balance
enables better control of the tool in unexpected situations.
• Use safety equipment. Always wear eye protection. Dust mask, non-skid safety shoes, hard
hat, or hearing protection must be used for appropriate conditions.
TOOL USE AND CARE
• Use clamps or other practical way to secure and support the workpiece to a stable plat
form. Holding the work by hand or against your body is unstable and may lead to a loss of con
t r o l .
• Do not force tool. Use the correct tool for your application. The correct tool will do the job bet
ter and safer at the rate for which it is designed.
• Do not use tool if switch does not turn it on or off. Any tool that cannot be controlled with the
switch is dangerous and must be repaired.
• Disconnect the plug from the power source before making any adjustments, changing
accessories, or storing the tool. Such preventative safety measures reduce the risk of starting
the tool accidentally.
• Store idle tools out of reach of children and other untrained persons. Tools are dangerous
in the hands of untrained users.
• Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools, with
sharp cutting edges are less likely to bind and are easier to control.
• Check for misalignment or binding of moving parts, breakage of parts, and any other con
dition that may affect the tools operation. If damaged, have the tool serviced before using
Many accidents are caused by poorly maintained tools.
• Use only accessories that are recommended by the manufacturer for your model
Accessories that may be suitable for one tool, may become hazardous when used on anothe
t o o l .
SERVICE
• Tool service must be performed only by qualified repair personnel. Service or maintenance
performed by unqualified personnel could result in a risk of injury.
• When servicing a tool, use only identical replacement parts. Follow 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.
Additional Specific Safety Instructions for Cut-Out
Tools
• Hold tool by insulated gripping surfaces when performing an operation where the too
may contact hidden wiring or its own cord. Contact with a "live" wire will make exposed meta
parts of the tool "live" and shock the operator.
C A U T I O N : Wear appropriate personal hearing protection during use. Under some conditions
and duration of use, noise from this product may contribute to hearing loss.
C A U T I O N : Do not touch the bit or collet nut during or immediately after cutting material. The
bit and collet nut may be hot enough to burn bare skin.
WA R N I N G : After changing bits or making any adjustments, make sure the collet nut is
securely tightened to avoid injury.
WA R N I N G : Do not press spindle lock or collet lock buttons while motor is running. The oper
ator may lose control and drop the tool. Personal injury or serious tool damage may result.
WA R N I N G : Shut off all live electric circuits to any areas where cut outs will be made, to avoid
fire or serious personal injury.
WA R N I N G : Some dust created by power sanding, sawing, grinding, drilling, and other con
struction activities contains chemicals known to cause cancer, birth defects or other reproduc
tive 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 (CCA).
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 ou
microscopic particles.
• Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling,
WA LT TO O L ,
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and other construction activities. 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.
• Always wear eye protection. Dust mask or hearing protection must be used for appropriate con
ditions. Using personal safety devices is recommended. WORK S A F E .
• Always operate the tool with the depth guide in place. The guide keeps the bit from plunging
too deeply through the material. A minimum of penetration should be maintained to eliminate the
danger of cutting into electric wiring.
• Do not use this tool with drill or screwdriver bits. This tool is not intended to be used as a
drill or screwdriver.
• Be sure your cutting bits are sharp and in good condition. Damaged bits can cause the too
to jump, injuring the operator.
• Never touch the bit immediately after use. It may be extremely hot.
• Be sure that the motor has stopped completely before you lay the router down. If the cut
ter head is still spinning when the tool is layed down, it could cause injury or damage.
• Be sure that the router bit is clear of the workpiece before starting motor. If the bit is in con
tact with the workpiece when the motor starts it could make the router jump, causing damage o
i n j u r y.
• If your tool fails to function properly, take it to an authorized service center. There are no
user serviceable parts inside this tool and it should only be opened by trained service personnel
• The label on your tool may include the following symbols.
V . . . . . . . . . . . . . .v o l t s
H z. . . . . . . . . . . .h e r t z
m i n . . . . . . . . . .m i n u t e s
. . . . . . . . . .direct current
. . . . . . . . . . . . . .Class II C o n s t r u c t i o n
. . . . . . . . . . . .safety alert symbol
To Maintain Safe Tool Control
• Make sure the work surface is free of nails or screws. Cutting into a nail or screw may cause
the tool to jump, damaging the bit.
• Never operate the tool with one hand while holding the workpiece with the other hand
Always clamp the material and guide the tool with both hands.
• Do not cut material lying on a hard surface. Clearance behind material to be cut must be
allowed for protruding bit.
• Disconnect plug from power supply before making adjustments, changing bits, or cleaning
t o o l .
• Do not start the tool with bit engaged in the material. The bit may grab the material.
Motor
Be sure your power supply agrees with nameplate marking. 120 volts AC means your tool
may be operated only with alternating current and never with direct current.
Switch
To start the motor, slide the switch (A) to "I" position. To stop the motor, slide the switch to "O"
position. (See FIG. 1)
Installing and Removing the Bit (Fig. 2)
This tool has a tool-free bit change system. To change bits, FIRST turn off the tool and dis
connect from power supply. Remove the guide.
1 . To replace bit, depress both spindle lock (C) and collet lock (B) and turn collet grip counter
c l o c k w i s e .
2 . Insert bit.
WA R N I N G : The bits are sharp and should be handled with great care.
A. . . . . . . . . . . . . . . .a m p e r e s
W . . . . . . . . . . . . . .w a t t s
. . . . . . . . . . . . . .alternating current
n o . . . . . . . . . . . . . .no load speed
. . . . . . . . . . . . . .earthing terminal
. . . / m i n. . . . . . . .revolutions per minute