Operation; Maintenance - DeWalt DW660 Instruction Manual

WARNING: Always wear proper personal hearing protection that conforms to ANSI
S12.6 (S3.19) during use. Under some conditions and duration of use, noise from this product
may contribute to hearing loss.
• The label on your tool may include the following symbols. The symbols and their definitions are
as follows:
V .....................volts
Hz ...................hertz
min .................minutes
or DC .....direct current
...................Class I Construction
.......................(grounded)
...................Class II Construction
(double insulated)
.../min ............per minute
IPM .................impacts per minute
SPM ...............strokes per minute
SAVE THESE INSTRUCTIONS FOR FUTURE USE
Motor
Be sure your power supply agrees with the nameplate marking. Voltage decrease of more than
10% will cause loss of power and overheating. D
not operate, check power supply.
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 tool.
• Do not start the tool with bit engaged in the material. The bit may grab the material.
Switch
To start the motor, slide the switch (A) to "I" position. To stop the motor, slide the switch to "O"
position (Fig. 1).
Installing and Removing the Bit (Fig. 2)
This tool is designed for spiral cutting bits with either a 1/8" (3 mm) or 1/4" (6 mm) shank and has
a tool-free bit change system. To change bits, FIRST turn off the tool and disconnect from power
supply. Remove the guide.
1. To replace bit, depress both spindle lock (C) and collet lock (B) and turn collet grip counter-
clockwise.
2. Insert bit.
WARNING: The bits are sharp and should be handled with great care.
CAUTION: When replacing bits, do not insert cutting flutes into the collet. This may result in
broken bits.
3. While depressing both spindle and collet locks, turn the collet grip clockwise to firmly tighten the
collet. For some heavy duty applications, it may be necessary to use a wrench to further tighten
the nut (D) while depressing the spindle lock (C).
4. Attach guide.
CAUTION: Never tighten the collet without a bit installed.
This tool comes with both 1/8" (3 mm) and 1/4" (6 mm) collets. To change collets, remove the collet
nut and insert the desired collet.
Depth Guide (Fig. 3)
To attach depth guide to the motor unit, TURN OFF TOOL AND DISCONNECT FROM POWER
SUPPLY.
Depth guide snaps onto locators as shown. Keep depth guide in place at all times during operation
of the tool. For best results, adjust the guide using knob (E) to allow the bit to protrude about 1/8"
(3 mm) past the material to be cut.
Side Handle DW6619 (Fig. 4)
When operating the tool, use the side handle for optimum control. To attach the side handle to the
motor unit, TURN OFF TOOL AND DISCONNECT FROM POWER SUPPLY.
1. Remove depth guide.
2. Loosen knob (F) until the collar of the tool is able to fit into the strap (G) of the side handle.
3. Align the locator on the tool with the locator on the side handle. (Detail) Tighten knob (F).
4. Snap the depth guide over the side handle strap (G) from the opposite side. Keep the depth
guide in place at all times during operation of the tool.
5. For best results, adjust the guide using knob (E) to allow the bit to protrude about 1/8" (3 mm)
through the material to be cut.
6. To remove the side handle, remove the depth guide, loosen the knob (F) until the tool can come
off the locator and slip out of the strap (G).
7. Reattach the depth guide.
Circle Cutter DW6621 (Fig. 5)
To attach the circle cutter to the motor unit, TURN OFF THE TOOL AND DISCONNECT FROM
POWER SUPPLY.
1. Remove the depth guide.
2. Loosen knob (H) until the collar of the tool is able to fit into the strap (J) of the circle cutter.
3. Align the locator on the tool with the locator on the circle cutter. (Detail) Tighten knob (H).
4. Disassemble the depth guide collar. Snap the upper half (M) onto the strap (J).
5. Loosen knob (L) and extend circle cutter frame to the limit of travel.
6. Insert knob (E) through the frame (N).
7. Set depth of cut for your material and tighten knobs (E) and (L).
8. Measure to the center of the circle you wish to cut and adjust the length of the guide to that
radius.
9. Tighten the knob (O) holding the centerpoint in position.
10. Drill a 5/32" (4 mm) hole in the material to be cut at the center of the radius.
11. Plug in the tool, start the motor and allow the tool to spin up to speed.
12. Position the center point into the hole and plunge the cutter into the material.
13. With firm pressure, hold the center point in place and move the cutter counterclockwise around
to the finish.
CAUTION: At the finish of the circle, the material may drop out. Hold the tool with both hands
to maintain control.
14. To remove the circle cutter, loosen knob (H) until the tool can come off the locator and slip out
of the strap (J).
15. Reassemble the depth guide and reattach.

OPERATION

CUTTING A HOLE FOR AN ELECTRICAL OUTLET (FIG. 6)
WARNING: Shut off all live electric circuits to any areas where cut outs will be made.
1. Push any wiring deeply into the outlet box to avoid damage from the cutting bit.
2. Before hanging the sheet covering the outlet, mark the approximate location of the center of the
outlet on the wall board. Check the cutting bit depth against the side of the board to be sure it
will cut entirely through the material.
3. Tack the sheet in place with a few fasteners avoiding the stud holding the outlet. This allows the
wall board to flex slightly around the protruding fixture box.
4. Turn the cut-out tool on. Holding the tool firmly with both hands, (Fig. 6) plunge the bit straight
into the center of the outlet.
5. Cut to the right until the edge of the box is touched. Pull out just enough for the bit to clear the
edge of the box. Plunge in again holding the bit gently against the outside of the box.
6. Follow the outside of the box as shown keeping slight pressure against the box. This will
minimize wandering and give you a clean precise cut.
7. Remove the waste and dust from the outlet. Finish fastening the sheet of wall board.
A .........................amperes
W ........................watts
or AC .............alternating current
or AC/DC......alternating or direct current
n o .......................no load speed
n .........................rated speed
.......................earthing terminal
........................safety alert symbol
BPM ...................beats per minute
RPM ...................revolutions per minute
sfpm ...................surface feet per minute
WALT tools are factory tested; if this tool does
E
FIG. 1 A
"O"
"I"
LOCATOR
POSITIONNEUR
FIG. 3 LOCALIZADOR
E
FIG. 5
FIG. 6

MAINTENANCE

WARNING: To reduce the risk of injury, turn unit off and disconnect it from power
source before installing and removing accessories, before adjusting or when making
repairs. An accidental start-up can cause injury.
Lubrication
All bearings are factory lubricated for the life of the tool.
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 when performing
this.
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 D
this product, use of such accessories with this tool could be hazardous. To reduce the risk of injury,
only D WALT recommended accessories should be used with this product.
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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 D
Industrial Tool Co., 701 East Joppa Road, Towson, MD 21286, call 1-800-4-D
9258) or visit our website: www.dewalt.com.
Repairs
To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including brush
inspection and replacement) should be performed by a D
authorized service center or other qualified service personnel. 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/register.
Three Year Limited Warranty
D WALT will repair, without charge, any defects due to faulty materials or workmanship for three
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years from the date of purchase. This warranty does not cover part failure due to normal wear or tool
abuse. For further detail of warranty coverage and warranty repair information, visit www.dewalt.
com or call 1-800-4-D WALT (1-800-433-9258). This warranty does not apply to accessories or
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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, D WALT tools are covered by our:
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1 YEAR FREE SERVICE
D WALT will maintain the tool and replace worn parts caused by normal use, for free, any time
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during the first year after purchase.
90 DAY MONEY BACK GUARANTEE
If you are not completely satisfied with the performance of your D
for any reason, you can return it within 90 days from the date of purchase with a receipt for a full
refund – no questions asked.
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-D WALT (1-800-433-9258) for a free replacement.
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FIG. 2
COLLET GRIP
DOUILLE DE
SERRAGE
ABRAZADERA
DEL COLLAR
D
FIG. 4
LOCATOR
POSITIONNEUR
LOCALIZADOR
G
LOCATOR
POSITIONNEUR
LOCALIZADOR
J
H
M
E
N
WALT, have not been tested with
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WALT (1-800-433-
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WALT factory service center, a D
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WALT Power Tool, Laser, or Nailer
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C
B
GUIDE
GUIDE
GUÍA
F
L
O
WALT
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WALT
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