DeWalt DWP610 Instruction Manual

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DEWALT Industrial Tool Co., 701 Joppa Road, Baltimore, MD 21286
(AUG10) Part No. A27313 DWP610, DWP611 Copyright © 2010 DEWALT
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 configu-
ration; and the array of lozenge-shaped humps on the surface of the tool.
If- Definitions: Safety Guidelines
The definitions below describe the level of severity for each signal word. Please read the
manual and pay attention to these symbols.
,&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.
A CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE: Indicates a practice not related to personal injury which, if not avoided, may
result in property damage.
IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL, CALL
US TOLL FREE AT: 1-800-4-DEWALT (1-800-433-9258).
O WARNING: To reduce the risk of injury, read the instruction manual.
General Power Tool Safety Warnings
_ ARNING! Read all safety warnings and all instructions Failure to follow the warnings
and instructions 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) ff operating a power tool in a damp location is unavoidable, use a ground fault
circuit interrupter (GFCl) 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 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 energising 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 orjewellery. Keep your hair, clothing and
gloves away from moving parts. Loose clothes, jewellery or long hair can be caught in
moving parts.
g) ff 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.
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 the battery pack 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. 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.
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.
Additional Specific Safety Rules
• Hold power tools by insulated gripping surfaces when performing an operation where
the cutting tool may contact hidden wiring or its own cord. Contact with a "live" wire will
make exposed metal parts of the tool "live" and shock the operator.
• Use clamps or another practical way to secure and support the workpiece to a stable
platform. Holding the work by hand or against your body leaves it unstable and may lead to
loss of control.
• DO NOT cut metal
• Keep handles and gripping surfaces dry, clean, and free from oil and grease. This will
enable better control of the tool.
• Maintain firm grip with both hands on router to resist starting torque.
• Keep hands away from cutting area. Never reach under the workpiece for any reason.
Keep the router base firmly in contact with the workpiece when cutting. These precautions
will reduce the risk of personal injury.
• Never run the motor unit when it is not inserted in one of the router bases. The motor
is not designed to be handheld.
• Keep cutting pressure constant. Do not overload motor.
• Check to see that the cord will not snag or impede the routing operation.
• Use sharp cutters. Dull cutters may cause the router to swerve or staff under pressure.
• Be sure that the motor has stopped completely before you lay the router down. If the
cutter head is still spinning when the tool is laid down, it could cause injury or damage.
• 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.
• ALWAYS disconnect tool from power source before making adjustments or changing
bits.
• Keep hands clear of bit when motor is running to prevent personal injury.
• NEVER touch the bit immediately after use. It may be extremely hot.
• Provide clearance under workpiece for router bit when through-cutting.
• Tighten collet nut securely to prevent the bit from slipping.
• Never tighten collet nut without a bit.
• Do not use router bits with a diameter in excess of 1-3/8" (34.9 mm) in this tool
• Always use cutters with a shank diameter of 1/4" (6.4 mm) which corresponds to the size of
the collet in your tool.
• Always use cutters suitable for a speed of min. 27,000 min -_ and marked accordingly.
• Not recommended for use in a router table.
• Avoid climb-cutting (cutting in direction opposite that shown in Figure 12).
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.
• 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 smaller the gauge
number, the heavier the cord.
Minimum Gauge for Cord Sets
Volts Total Length of Cord in Feet (meters)
Ampere Rating 120V 25 (7.6) 50 (15.2) 100 (30.5) 150 (45.7)
240V 50 (15.2) 100 (30.5) 200 (61.0) 300 (91.4)
More
Than
0
6
10
12
Not More
Than
6
10
12
16
18
18
16
14
AWG
16
16
16
12
16 14
14 12
14 12
Not Recommended
AWARNING: 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
EQUIPMEN_
• ANSI Z87.1 eye protection (CAN/CSA Z94.3),
• ANSI $12.6 ($3.19) 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.
• 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.
AWARNING: 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.
_WARNING: Always wear proper personal hearing protection that conforms to ANSI
$12.6 ($3.19) 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 fl Construction
(double insulated)
.../min ............. per minute
OPM ................ orbits per minute
A ................ amperes
W ............... watts
, ............. alternating current
............. alternating or direct current
no .............. no load speed
@............... earthing terminal
_ .............. safety alert symbol
BPM .......... beats per minute
RPM .......... revolutions per minute
SAVE THESE INSTRUCTIONS
Motor
Be sure your power supply agrees with nameplate marking. 120 Volts AC means your tool will
operate on alternating current. As little as 10% lower voltage can cause loss of power and can
result in overheating. All DEWALT tools are factory-tested; if this tool does not operate, check
the power supply.
_ WARNING: 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, 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.
Components (Fig. 1-11)
A. Quick release tabs
B. Depth adjustment ring
C. Variable speed dial
(DWP611 only)
D. On(I)/off (o) switch
E. Spindle lock button
E Led lights (DWP611 only)
G. Guide pin groove
H. Micro adjustment scale
I. Locking lever
J. Edge guide slot (fixed base)
K. Subbase
(DWP610 has a round subbase,
DWP611 has a D-subbase) both
are available as an accessory.
L. Vacuum attachment
(For use with plunge base)
M. Holes for premium edge guide
(sold separately)
N. Turret stop
O. Depth adjustment rod
OPERATION
R Plunge lock lever
Q. Edge guide
R. Guide pins
S. Locking lever adjustment screw
T. Centering tool
U. Collet nut
V. Vacuum attachment (fixed base)
W. Screws (vacuum attachment)
X. Edge guide slot (plunge base)
Z. Motor unit
AA. Motor stop
BB. Thumb screw
CC. Knurled knob
DD. Depth adjustment scale
EE. Zero adjuster tab
FF. Sub-base screws
GG. Edge guide screws
HH. Tab (vacuum attachment)
II. Snap tab (vacuum attachment)
JJ. Plastic washer (vacuum attachment)
KK. Thumb screw (vacuum attachment)
_ 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.
NOTICE: Do not use router bits with a diameter in excess of 1-3/8" (34.9 ram) in this tool.
Connecting To Power Source
•_CAUTION: 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: 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 power
unit to come to a COMPLETE STOP before putting the tool down.
To turn unit on, depress the side of the dust-protected switch (D) that reads "ON" and corresponds
to the symbol "1." To turn the unit off, depress the side of the switch that reads "OFF" and
corresponds with the symbol "O."
Motor Quick Release (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 locking lever (I) on the base.
2. Grasp the motor unit with one hand, depressing both quick release tabs (A).
3. With the other hand, grasp the base and pull motor from the base.
Bit Installation and Removal (Fig. 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.
TO INSTALL THE BIT
1. Remove the motor unit from the base unit, see Motor Quick Release (if needed).
2. Clean and 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 1/16" (1.6 mm).
3. Depress the spindle lock button (E) to hold the spindle shaft in place while turning the collet
nut (U) clockwise with the wrench provided.
NOTE: The unit is equipped with multiple spindle lock detents allowing an optional "manual
ratchet" method of tightening the bit.
To tighten with the "manual ratchet" method:
a. Without removing the wrench from the collet nut (U), release pressure on the spindle lock
button (E).
b. With the wrench still on the collet nut (U), reverse the tightening direction to reset the
wrench position.