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• Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling,
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.
WARNING: Use of this tool can generate and/or disburse dust, which may cause serious and
permanent respiratory or other injury. Always use NIOSH/OSHA approved respiratory protection
appropriate for the dust exposure. Direct particles away from face and body. Always operate tool
in well-ventilated area and provide for proper dust removal. Use dust collection system wherever
possible.
WARNING: Always use eye protection. All users and bystanders must wear eye protection
that conforms to ANSI Z87.1.
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
................. direct current
...................... Class I Construction
..........................
(grounded)
...................... Class II Construction
..........................
(double insulated)
.../min ............... per minute
Motor
Your D
WALT tool is powered by a D
E
with the nameplate markings. Voltage decrease of more than 10% will cause loss of power and
overheating. All D
WALT tools are factory tested.
E
COMPONENTS (Fig. 1)
WARNING: Never modify the power tool or any part of it. Damage or personal injury could
result.
A. Motor
B. Handles
C. Depth adjusting ring
G. OFF/ON switch
D. Fixed base
H. Clamp
INTENDED USE
This heavy-duty router has been designed for professional routing at various work sites (i.e.,
woodworking shops). DO NOT use under wet conditions or in presence of flammable liquids or
gases.
This heavy-duty router is a professional power tool. DO NOT let children come into contact with
the tool. Supervision is required when inexperienced operators use this tool.
ADJUSTMENTS
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.
WARNING: To reduce the risk of injury, accessories must be rated for at least the speed
recommended on the tool warning label. Accessories running over rated speed can fly apart and
cause injury. Accessory ratings must always be above tool speed as shown on tool nameplate.
WARNING: To reduce the risk of injury, do not use router bits with a diameter in excess
of 2-1/8" (54 mm) in this tool.
WARNING: To reduce the risk of injury, never modify the power tool or any part of it. Damage
or personal injury could result.
Installing the Bit (Fig. 2, 3)
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.
WARNING: To reduce the risk of injury, do not use router bits with a diameter in excess of
2-1/8" (54 mm) in this tool.
NOTICE: Avoid possible damage to the collet. Never tighten the collet without a bit.
NOTE: This router can accommodate bits with 1/4", 3/8" or 1/2" diameter shanks that are
installed directly into the motor collet. An accessory collet may be required for some shank sizes.
For this router use only these collets:
•
Part No. 42950 (1/2")
•
Part No. 42975 (3/8")
•
Part No. 42999 (1/4")
One or more of these may be included with your router. Other D
for this router.
1. To remove the motor unit from the base unit:
a. Open the clamp (H).
b. While holding the base, turn the motor counter-clockwise until the lower pin (I) in the motor
housing is disengaged from groove in base.
c. Lift the motor free from the base unit.
2. Clean and insert the shank of the bit into the collet until the shank bottoms, then back it out
approximately 1/16" (1.6 mm).
3. Lay the motor on its side on a bench with the collet pointing AWAY from you.
4. Place one wrench on the flats of the chuck with the opposite end of the wrench resting on
the bench to your left.
5. Place the other wrench on the collet and tighten counter-clockwise. Tighten firmly.
6. To remove the bit, reverse the procedure.
Installing the Motor (Fig. 2)
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.
1. Open the clamp (H) and set the motor in the base unit.
2. Align the lower pin of the motor (I) with the groove in the base.
3. Rotate the motor clockwise into the base until the upper guide pins are set in the groove of the
base.
4. Close the clamp.
Adjusting the Depth of Cut (Fig. 4)
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.
1. Open the clamp (H).
2. Hold the base (D) and turn the motor (A) counter-clockwise until the tip of the bit is above
the bottom of the base.
3. Set the tool on a flat surface.
4. Turn the motor (A) clockwise until the bit touches the work.
5. Close the clamp (H).
6. Rotate the depth adjusting ring (C) until the zero-line is opposite the index line (J) on the
housing.
7. Open the clamp (H).
8. Tip the router so that the bit is clear of the work surface. Turn the motor (A) clockwise until
the index line (J) on the motor housing reaches the desired depth indicated on the ring.
9. Close the clamp (H).
NOTE: Setting the index line to 1/4" on the ring means the cutting edge of the bit is exposed
1/4" below the base.
Adjusting the Sub-base Alignment (Fig. 5)
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.
Applications using a template guide require the bit to be centered in the guide. This, in turn,
requires the center hole in the sub-base to be in line with the collet of the motor unit. Your model
has an adjustable sub-base that has been aligned at the factory. The fixed-base router comes
with the large hole.
A ....................... amperes
W ...................... watts
.................... alternating current
.................... alternating or direct current
n o ..................... no load speed
..................... earthing terminal
..................... safety alert symbol
BPM ................. beats per minute
RPM ................. revolutions per minute
WALT-built motor. Be sure your power supply agrees
E
E. Collet
F. Subbase
WALT collets are not designed
E
FIG. 1
B
E
FIG. 2
FIG. 4
A
J
H
FIG. 6
1. Loosen the sub-base mounting screws (K) just enough to allow the sub-base (F) to move.
2. Open the clamp (H) and adjust the motor so that the collet nut (E) engages the center hole in
the sub-base (F). Allow the sub-base to center itself on the collet nut. Close the clamp (H).
3. Tighten the sub-base mounting screws (K) securely.
OPERATION
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.
WARNING: To reduce the risk of injury, avoid "Climb-Cutting" (cutting in direction opposite that
shown in Fig. 6). "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.
CAUTION: To reduce the risk of injury, always be sure the work is rigidly clamped or otherwise
secured before making a cut. Since the cutter rotates clockwise (when viewing router from top),
move the router from left to right as you stand facing the work. When working on the inside of a
template, move the router in a clockwise direction. When working on the outside of a template,
move the router in a counter- clockwise direction.
Connecting to Power Source
CAUTION: To reduce the risk of injury, before connecting tool to power source, check to see
that the switch is in the "OFF" position. Also, check the power circuit to see that it is the same as
that shown on specification plate of the tool.
Starting and Stopping the Motor (Fig. 1)
CAUTION: To reduce the risk of injury, before starting the tool, clear the work area of all
foreign objects. Also keep firm grip on tool to resist starting torque.
CAUTION: To avoid personal injury and/or damage to finished work, always allow the motor
to come to a COMPLETE STOP before putting the tool down.
To start the tool, move the OFF/ON switch (G) to the "ON" or "I" position. To stop the tool, move
the rocker switch to the "OFF" or "O" position.
Proper Hand Position (Fig. 1)
WARNING: To reduce the risk of serious personal injury, ALWAYS use proper hand position.
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 both handles (B), with the router's subbase flat
against the workpiece.
Router Tables
Your router can be used in a router table. Refer to the router table manual for complete, detailed
set-up instructions.
WARNING: To reduce the risk of injury, always read the router instruction manual and
accessory instructions before using any accessory. Failure to heed these warnings may result in
personal injury and serious damage to the router and the accessory. When servicing this tool,
use only identical replacement parts.
A
G
C
B
H
D
F
FIG. 3
I
H
FIG. 5
F
C
D
E
K
H
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