DeWalt DCW600 - Compact Cordless Router Manual

Definitions: Safety Alert Symbols and Words

This instruction manual uses the following safety alert symbols and words to alert you to hazardous situations and your risk of personal injury or property damage.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
(Used without word) Indicates a safety related message.
NOTICE: Indicates a practice not related to personal injury which, if not avoided, may result in property damage.

Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

To reduce the risk of injury, read the instruction manual.

If you have any questions or comments about this or any DeWALT tool, call us toll free at: 1-800-4-D e WALT (1-800-433-9258).

GENERAL POWER TOOL SAFETY WARNINGS

Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below 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 mainsoperated (corded) power tool or battery-operated (cordless) power tool.

1. Work Area Safety
   1. Keep work area clean and well lit. Cluttered or dark areas invite accidents.
   2. 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.
   3. Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.
2. Electrical Safety
   1. 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.
   2. 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.
   3. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
   4. 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.
   5. 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.
   6. If operating a power tool in a damp location is unavoidable, use a ground fault circuit interrupter (GFCI) protected supply. Use of a GFCI reduces the risk of electric shock.
3. Personal Safety
   1. 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.
   2. 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.
   3. 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 energizing power tools that have the switch on invites accidents.
   4. 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.
   5. Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
   6. Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
   7. If 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.
   8. Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.
4. Power Tool Use and Care
   1. 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.
   2. 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.
   3. Disconnect the plug from the power source and/ or remove the battery pack, if detachable, 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.
   4. 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.
   5. Maintain power tools and accesories. 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.
   6. Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
   7. 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.
   8. Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.
5. Battery Tool Use and Care
   1. Recharge only with the charger specified by the manufacturer. A charger that is suitable for one type of battery pack may create a risk of fire when used with another battery pack.
   2. Use power tools only with specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire.
   3. When battery pack is not in use, keep it away from other metal objects, like paper clips, coins, keys, nails, screws or other small metal objects, that can make a connection from one terminal to another. Shorting the battery terminals together may cause burns or a fire.
   4. Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help.
      Liquid ejected from the battery may cause irritation or burns.
   5. Do not use a battery pack or tool that is damaged or modified. Damaged or modified batteries may exhibit unpredictable behavior resulting in fire, explosion or risk of injury.
   6. Do not expose a battery pack or tool to fire or excessive temperature. Exposure to fire or temperature above 265°F (130°C) may cause explosion.
   7. Follow all charging instructions and do not charge the battery pack or tool outside the temperature range specified in the instructions. Charging improperly or at temperatures outside the specified range may damage the battery and increase the risk of fire.
6. Service
   1. 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.
   2. Never service damaged battery packs. Service of battery packs should only be performed by the manufacturer or authorized service providers.

Additional Safety Rules for Routers

• Hold power tool by insulated gripping surfaces, when performing an operation where the cutting accessory may contact hidden wiring. Cutting accessory contacting a "live" wire may make exposed metal parts of the power tool "live" and could give the operator an electric shock.
• 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 the tool to resist starting torque. Maintain a firm grip on the tool at all times while operating.
• Always follow the bit manufacturer's speed recommendations as some bit designs require specific speeds for safety or performance. If you are unsure of the proper speed or are experiencing any type of problem, contact the bit manufacturer.
• Keep hands away from cutting area above and below the base. Never reach under the workpiece for any reason. Keep the router base firmly in contact with the workpiece when cutting.
• 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.
• Use sharp bits. Dull bits may cause the router to swerve or stall 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 cutting 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 follow the bit manufacturer's speed recommendations as some bit designs require specific speeds for safety or performance. If you are unsure of the proper speed or are experiencing any type of problem, contact the bit manufacturer.
• Not recommended for use in a router table.
• Avoid climb-cutting (cutting in the opposite direction of that shown in Figure Q). 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.
• Do not hand-hold the router in an upside-down or horizontal position. The motor can separate from the base if not properly attached according to the instructions.
• Before starting the motor clear the work area of all foreign objects.
• Do not use in a router table.
• Always keep the chip shield (if included) clean and in place.
• Do not press spindle lock button while the motor is running. Doing so can damage the spindle lock.
• Always make sure the work surface is free from nails and other foreign objects. Cutting into a nail can cause the bit and the tool to jump.

Additional Safety Information

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 EQUIPMENT:

• ANSI Z87.1 eye protection (CAN/CSA Z94.3),
• ANSI S12.6 (S3.19) hearing protection,
• NIOSH/OSHA/MSHA respiratory protection.

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 chemicallytreated 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.

Use of this tool can generate and/ or disperse 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 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.

When not in use, place tool on its side on a stable surface where it will not cause a tripping or falling hazard. Some tools with large battery packs will stand upright on the battery pack but may be easily knocked over.

• Air vents often cover moving parts and should be avoided. Loose clothes, jewelry or long hair can be caught in moving parts.

The label on your tool may include the following symbols. The symbols and their definitions are as follows:

V	volts	or AC/DC	alternating or direct current
Hz	hertz		Class II Construction (double insulated)
min	minutes
or DC	direct current
	Class I Construction (grounded)
.../min	per minute	no	no load speed
		n	rated speed
BPM	beats per minute		earthing terminal
IPM	impacts per minute		safety alert symbol
RPM	revolutions per minute		visible radiation
sfpm	surface feet per minute		wear respiratory protection
			wear eye protection
SPM	strokes per minute		wear hearing protection
			read all documentation
A	amperes
W	watts
or AC	alternating current

BATTERIES AND CHARGERS
The battery pack is not fully charged out of the carton. Before using the battery pack and charger, read the safety instructions below and then follow charging procedures outlined. When ordering replacement battery packs, be sure to include the catalog number and voltage.
Your tool uses a DeWALT charger. Be sure to read all safety instructions before using your charger.
READ ALL INSTRUCTIONS

Important Safety Instructions for All Battery Packs

Read all safety warnings and all instructions for the battery pack, charger and power tool. Failure to follow the warnings and instructions may result in electric shock, fire and/ or serious injury.

• Charge the battery packs only in designated DeWALT chargers.
• DO NOTsplash or immerse in water or other liquids.
• Do not store or use the tool and battery pack in locations where the temperature may reach or exceed 104°F (40°C) (such as outside sheds or metal buildings in summer). For best life store battery packs in a cool, dry location.
  NOTE: Do not store the battery packs in a tool with the trigger switch locked on. Never tape the trigger switch in the ON position.
• Do not incinerate the battery pack even if it is severely damaged or is completely worn out. The battery pack can explode in a fire. Toxic fumes and materials are created when lithium ion battery packs are burned.
• If battery contents come into contact with the skin, immedicately wash area with mild soap and water.
  If battery liquid gets into the eye, rinse water over the open eye for 15 minutes or until irritation ceases. If medical attention is needed, the battery electrolyte is composed of a mixture of liquid organic carbonates and lithium salts.
• Contents of opened battery cells may cause respiratory irritation. Provide fresh air. If symptoms persist, seek medical attention.

Burn hazard. Battery liquid may be flammable if exposed to spark or flame.

Fire hazard. Never attempt to open the battery pack for any reason. If the battery pack case is cracked or damaged, do not insert into the charger. Do not crush, drop or damage the battery pack. Do not use a battery pack or charger that has received a sharp blow, been dropped, run over or damaged in any way (e.g., pierced with a nail, hit with a hammer, stepped on). Damaged battery packs should be returned to the service center for recycling.

Transportation

Fire hazard. Do not store or carry the battery pack so that metal objects can contact exposed battery terminals. For example, do not place the battery pack in aprons, pockets, tool boxes, product kit boxes, drawers, etc., with loose nails, screws, keys, etc. Transporting batteries can possibly cause fires if the battery terminals inadvertently come in contact with conductive materials such as keys, coins, hand tools and the like. The US Department of Transportation Hazardous Material Regulations (HMR) actually prohibit transporting batteries in commerce or on airplanes in carry-on baggage UNLESS they are properly protected from short circuits. So when transporting individual battery packs, make sure that the battery terminals are protected and well insulated from materials that could contact them and cause a short circuit.
NOTE: Lithium-ion batteries should not be put in checked baggage.

Fuel Gauge Battery Packs (Fig. B)
Some DeWALT battery packs include a fuel gauge which consists of three green LED lights that indicate the level of charge remaining in the battery pack.
The fuel gauge is an indication of approximate levels of charge remaining in the battery pack according to the following indicators:

	75–100% charged
	51–74% charged
	< 50% charged
	Pack needs to be charged

To actuate the fuel gauge, press and hold the fuel gauge button. A combination of the three green LED lights will illuminate designating the level of charge left. When the level of charge in the battery is below the usable limit, the fuel gauge will not illuminate and the battery will need to be recharged.

NOTE: The fuel gauge is only an indication of the charge left on the battery pack. It does not indicate tool functionality and is subject to variation based on product components, temperature and end-user application.
For more information regarding fuel gauge battery packs, please call 1-800-4-DeWALT (1-800-433-9258) or visit our website www.dewalt.com.

The RBRC® Seal

The RBRC® (Rechargeable Battery Recycling Corporation) Seal on the nickel cadmium, nickel metal hydride or lithiumion batteries (or battery packs) indicates that the costs to recycle these batteries (or battery packs) at the end of their useful life have already been paid by DeWALT. In some areas, it is illegal to place spent nickel cadmium, nickel metal hydride or lithium-ion batteries in the trash or municipal solid waste stream and the Call 2 Recycle® program provides an environmentally conscious alternative.
Call 2 Recycle, Inc., in cooperation with DeWALT and other battery users, has established the program in the United States and Canada to facilitate the collection of spent nickel cadmium, nickel metal hydride or lithium-ion batteries. Help protect our environment and conserve natural resources by returning the spent nickel cadmium, nickel metal hydride or lithium-ion batteries to an authorized DeWALT service center or to your local retailer for recycling. You may also contact your local recycling center for information on where to drop off the spent battery. RBRC® is a registered trademark of Call 2 Recycle, Inc.

Important Safety Instructions for All Battery Chargers

Read all safety warnings and all instructions for the battery pack, charger and power tool. Failure to follow the warnings and instructions may result in electric shock, fire and/ or serious injury.

• DO NOT attempt to charge the battery pack with any chargers other than the ones in this manual.
  The charger and battery pack are specifically designed to work together.
• These chargers are not intended for any uses other than charging DeWALT rechargeable batteries.
  Any other uses may result in risk of fire, electric shock or electrocution.
• Do not expose the charger to rain or snow.
• Pull by the plug rather than the cord when disconnecting the charger. This will reduce the risk of damage to the electric plug and cord.
• Make sure that the cord is located so that it will not be stepped on, tripped over or otherwise subjected to damage or stress.
• Do not use an extension cord unless it is absolutely necessary. Use of improper extension cord could result in risk of fire, electric shock or electrocution.
• When operating a charger outdoors, always provide a dry location and use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
• 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 lower the gauge number, the heavier the cord.

Minimum gauge for Cord sets

Volts		Total length of Cord in Feet (meters)
120 V		25 (7.6)	50 (15.2)	100 (30.5)	150 (45.7)
240 V		50 (15.2)	100 (30.5)	200 (61.0)	300 (91.4)
Ampere Rating		American Wire gauge
More Than	Not More Than
0	6	18	16	16	14
6	10	18	16	14	12
10	12	16	16	14	12
12	16	14	12	Not Recommended

• Do not place any object on top of the charger or place the charger on a soft surface that might block the ventilation slots and result in excessive internal heat. Place the charger in a position away from any heat source. The charger is ventilated through slots in the top and the bottom of the housing.
• Do not operate the charger with a damaged cord or plug.
• Do not operate the charger if it has received a sharp blow, been dropped or otherwise damaged in any way. Take it to an authorized service center.
• Do not disassemble the charger; take it to an authorized service center when service or repair is required. Incorrect reassembly may result in a risk of electric shock, electrocution or fire.
• Disconnect the charger from the outlet before attempting any cleaning. This will reduce the risk of electric shock. Removing the battery pack will not reduce this risk.
• NEVER attempt to connect 2 chargers together.
• The charger is designed to operate on standard 120V household electrical power. Do not attempt to use it on any other voltage. This does not apply to the vehicular charger.

Shock hazard. Do not allow any liquid to get inside the charger. Electric shock may result.

Burn hazard. Do not submerge the battery pack in any liquid or allow any liquid to enter the battery pack. Never attempt to open the battery pack for any reason. If the plastic housing of the battery pack breaks or cracks, return to a service center for recycling.

Burn hazard. To reduce the risk of injury, charge only DeWALT rechargeable battery packs. Other types of batteries may overheat and burst resulting in personal injury and property damage.

Under certain conditions, with the charger plugged into the power supply, the charger can be shorted by foreign material. Foreign materials of a conductive nature, such as, but not limited to, grinding dust, metal chips, steel wool, aluminum foil or any buildup of metallic particles should be kept away from the charger cavities. Always unplug the charger from the power supply when there is no battery pack in the cavity. Unplug the charger before attempting to clean.

Charging a Battery

NOTE: To ensure maximum performance and life of lithiumion battery packs, charge the battery pack fully before first use.

Charger Operation
Refer to the indicators below for the charge status of the battery pack.
DCB107, DCB112, DCB113, DCB115, DCB118, DCB132

	Charging
	Fully Charged
	Hot/Cold Pack Delay*

* DCB107, DCB112, DCB113, DCB115, DCB118, DCB132:
The red light will continue to blink, but a yellow indicator light will be illuminated during this operation. Once the battery pack has reached an appropriate temperature, the yellow light will turn off and the charger will resume the charging procedure.

The compatible charger(s) will not charge a faulty battery pack. The charger will indicate faulty battery pack by refusing to light.

NOTE: This could also mean a problem with a charger.
If the charger indicates a problem, take the charger and battery pack to be tested at an authorized service center.

Hot/Cold Pack Delay
When the charger detects a battery pack that is too hot or too cold, it automatically starts a Hot/Cold Pack Delay, suspending charging until the battery pack has reached an appropriate temperature. The charger then automatically switches to the pack charging mode. This feature ensures maximum battery pack life.
A cold battery pack will charge at a slower rate than a warm battery pack. The battery pack will charge at that slower rate throughout the entire charging cycle and will not return to maximum charge rate even if the battery pack warms. The DCB118 charger is equipped with an internal fan designed to cool the battery pack. The fan will turn on automatically when the battery pack needs to be cooled. Never operate the charger if the fan does not operate properly or if ventilation slots are blocked. Do not permit foreign objects to enter the interior of the charger.

Electronic Protection System
Li-Ion tools are designed with an Electronic Protection System that will protect the battery pack against overloading, overheating or deep discharge.
The tool will automatically turn off if the Electronic Protection System engages. If this occurs, place the lithiumion battery pack on the charger until it is fully charged.

Wall Mounting
DCB107, DCB112, DCB113, DCB115, DCB118, DCB132
These chargers are designed to be wall mountable or to sit upright on a table or work surface. If wall mounting, locate the charger within reach of an electrical outlet, and away from a corner or other obstructions which may impede air flow. Use the back of the charger as a template for the location of the mounting screws on the wall. Mount the charger securely using drywall screws (purchased separately) at least 1" (25.4 mm) long, with a screw head diameter of 0.28–0.35" (7–9 mm), screwed into wood to an optimal depth leaving approximately 7/32" (5.5 mm) of the screw exposed. Align the slots on the back of the charger with the exposed screws and fully engage them in the slots.

Charger Cleaning Instructions

Shock hazard. Disconnect the charger from the AC outlet before cleaning. Dirt and grease may be removed from the exterior of the charger using a cloth or soft non-metallic brush. Do not use water or any cleaning solutions.

Important Charging Notes

1. Longest life and best performance can be obtained if the battery pack is charged when the air temperature is between 65°F and 75°F (18 ° – 24°C). DO NOT charge the battery pack below +40°F (+4.5°C), or above +104°F (+40°C). This is important and will prevent serious damage to the battery pack.
2. The charger and battery pack may become warm to the touch while charging. This is a normal condition, and does not indicate a problem. To facilitate the cooling of the battery pack after use, avoid placing the charger or battery pack in a warm environment such as in a metal shed or an uninsulated trailer.
3. If the battery pack does not charge properly:
   1. Check operation of receptacle by plugging in a lamp or other appliance;
   2. Check to see if receptacle is connected to a light switch which turns power off when you turn out the lights;
   3. Move the charger and battery pack to a location where the surrounding air temperature is approximately 65°F – 75°F (18 ° – 24°C);
   4. If charging problems persist, take the tool, battery pack and charger to your local service center.
4. The battery pack should be recharged when it fails to produce sufficient power on jobs which were easily done previously. DO NOT CONTINUE to use under these conditions. Follow the charging procedure. You may also charge a partially used pack whenever you desire with no adverse effect on the battery pack.
5. Foreign materials of a conductive nature such as, but not limited to, grinding dust, metal chips, steel wool, aluminum foil, or any buildup of metallic particles should be kept away from charger cavities. Always unplug the charger from the power supply when there is no battery pack in the cavity. Unplug the charger before attempting to clean.
6. Do not freeze or immerse the charger in water or any other liquid.

Storage Recommendations

1. The best storage place is one that is cool and dry, away from direct sunlight and excess heat or cold.
2. For long storage, it is recommended to store a fully charged battery pack in a cool dry place out of the charger for optimal results.

NOTE: Battery packs should not be stored completely depleted of charge. The battery pack will need to be recharged before use.
SAVE THESE INSTRUCTIONS FOR FUTURE USE

COMPONENTS

1. Battery pack
2. Battery release button
3. On/Off switch
4. Variable speed dial
5. Depth adjustment ring
6. Motor
7. Spindle lock button
8. Spindle
9. Guide pin groove
10. Worklights
11. Micro-adjustment scale

Never modify the power tool or any part of it. Damage or personal injury could result.

Intended Use
This tool is designed for professional medium-duty routing applications.
DO nOT use under wet conditions or in presence of flammable liquids or gases.
DO nOT let children come into contact with the tool.
Supervision is required when inexperienced operators use this tool.

ASSEMBLY AND ADJUSTMENTS

To reduce the risk of serious personal injury, turn unit off and remove the battery pack before making any adjustments or removing/ installing attachments or accessories. An accidental start-up can cause injury.

Bit Installation and Removal (Fig. D)


Projectile hazard. Only use bits with shanks that match the installed collet. Smaller shank bits will not be secure and could become loose during operation.

Never tighten the collet without first installing a router bit in it. Tightening an empty collet, even by hand, can damage the collet.
NOTICE: Do not use router bits with a cutting diameter in excess of 1-3/8" (34.9 mm) in this tool.

To Install the Bit

1. Remove the motor unit from the base unit. Refer toRemoving the Motor from the Fixed Base/Removing the Motor from the Plunge Base (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 to hold the spindle shaft in place while turning the collet nut 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:

1. Without removing the wrench from the collet nut , release pressure on the spindle lock button .
2. With the wrench still on the collet nut, reverse the tightening direction to reset the wrench position.
3. Depress the spindle lock button again and turn the wrench clockwise.
4. Repeat the procedure until the collet nut reaches desired tightness.

NOTE: Tighten collet nut securely to prevent the bit from slipping.
NOTICE: Plunge Base Only—When tightening or changing collets, do not allow the wrenches to contact the plunge rods. If the rods are damaged, the plunge action will be restricted.

To Remove the Bit

1. Remove the motor unit from the base unit (refer to Removing the Motor from the Fixed Base/Removing the Motor from the Plunge Base).
2. Depress the spindle lock button to hold the spindle shaft in place while turning the collet nut counterclockwise with the wrench provided.

To loosen using the "manual ratchet" method:

1. Without removing the wrench from the collet nut , release pressure on the spindle lock button .
2. With the wrench still on the collet nut , reverse the loosening direction to reset the wrench position.
3. Depress the spindle lock button again and turn the wrench counterclockwise.
4. Repeat the procedure until the collet nut is loose and the bit can be removed.

Collets
NOTE: Never tighten the collet without first installing a router bit in it. Tightening an empty collet, even by hand, can damage the collet.
To change collet sizes, unscrew the collet assembly as described above. Install the desired collet by reversing the procedure. The collet and the collet nut are connected. Do not attempt to remove the collet from the collet nut.

Locking Lever Adjustment (Fig. E)
Excessive force should not be used to clamp the locking lever. Using excessive force may damage the base.
When the locking lever is clamped, the motor should not move in the base.
Adjustment is needed if the locking lever will not clamp without excessive force or if the motor moves in the base after clamping.

To adjust the locking lever's clamping force:

1. Open the locking lever (fixed base) or (plunge base).
2. Using a hex wrench turn locking lever adjustment screw in small increments.
   Turning the screw clockwise tightens the lever, while turning the screw counterclockwise loosens the lever.

Centering the Subbase (Fig. A, F1, F2)
If you need to adjust, change, or replace the subbase, a centering tool is recommended (refer to Accessories). The centering tool consists of a cone and a pin.

To adjust the subbase, follow the steps below.
Figure F1 shows adjusting the subbase on the fixed base and Figure F2 shows adjusting the subbase on the plunge base.

1. Loosen but do not remove the subbase screws so the subbase moves freely.
2. Insert the pin into the collet and tighten the collet nut.
3. Insert the motor into the base and clamp the locking lever on the base.
4. Place the cone on the pin and lightly press down on the cone until it stops. This will center the subbase.
5. While holding down on the cone, tighten the subbase screws.

Using Template Guides
The round subbase will accept universal template guides. Recommended accessories for use with your tool are available at extra cost from your local dealer or authorized service center.
NOTE: The D-shape subbase does not accommodate template guides and is designed to accommodate bits up to 1-3/8" (34.9 mm) in diameter.

To Use Template guides:

1. Center the subbase. SeeCentering The Subbase.
2. Install template guide (available as an accessory) on the subbase and tighten securely.

Installing a Fixed Base Edge Guide (Fig. G)
(Included with some models)
An edge guide (model DNP618) for your fixed base is available from your local retailer or service center at extra cost.

1. Remove the motor from the fixed base. Refer to Removing the Motor from the Fixed Base.
2. Remove flat head screws from storage holes on edge guide.
3. Slide edge guide into edge guide slot on side of fixed base (Fig. G). Insert the two flat head screws through the appropriate holes in the subbase to secure the edge guide. Tighten hardware.
4. Follow all instructions included with the edge guide.

NOTE: To remove the edge guide, reverse the above procedure. After removing edge guide, always replace the two flat head screws into the storage holes on the edge guide to prevent loss.

Using a Premium Edge Guide
(Plunge Base Only)
(Included with some models)
A Premium Edge Guide (model DW6913) is available from your local retailer or service center at extra cost. Follow the assembly instructions included with the edge guide.

Installing a Plunge Base Edge Guide with Guide Rods (Fig. H)
(Included with some models)
An edge guide (model DW6913) for your plunge base is available from your local retailer or service center at extra cost.

1. Attach the guide rods to the plunge router base.
2. Attach the thumb screws and springs to the base.
3. Tighten the thumb screws .
4. Slide the edge guide 38 over the rods.
5. Attach thumb screws 36 and springs 37 to the edge guide.
6. Tighten the thumb screws temporarily. Refer to Adjusting the Edge Guide.

Adjusting the Edge Guide (Fig. A, H)
Follow the assembly instructions included with the edge guide.

1. Draw a cutting line on the material.
2. Lower the router carriage until the cutter is in contact with the workpiece.
3. Lock the plunge mechanism by releasing the plunge lock lever
4. Position the router on the cutting line. The outer cutting edge of the cutter must coincide with the cutting line.
5. Slide the edge guide against the workpiece and tighten the thumb screws .

Attaching a Dust Extraction System to the Fixed Base (Fig. I)
(Included with some models)
To connect the router to a dust extraction system for dust collection, follow these steps:

1. Remove the motor unit from the base. Refer toRemoving the Motor from the Fixed Base.
2. Attach dust extraction system attachment accessory to the base as shown. Tighten thumb screws securely by hand.
3. Attach hose adapter to dust extraction system attachment accessory.
4. When using dust extraction system attachment, be aware of the placement of the dust extraction system. Be sure that the dust extraction system is stable and that its hose will not interfere with the work.

Attaching a Dust Extraction System to the Plunge Base (Fig. J)
(Included with some models)

1. Remove the motor unit from the base. Refer toRemoving the Motor from the Plunge Base.
2. Slide tab (inset) on dust extraction system attachment into slot in plunge base and snap tab (inset) into hole in plunge base.
3. Secure to base with supplied plastic washer and thumb screw . Tighten thumb screw securely by hand.
4. Attach hose adapter to dust extraction system attachment.

When using dust extraction system attachment, be aware of the placement of the dust extraction system. Be sure the dust extraction system is stable and its hose will not interfere with the work.

Set-Up: Fixed Base (Fig. A, K, L)
Inserting the Motor into the Fixed Base

1. Open the locking lever on the base.
2. If the depth adjustment ring is not on the motor , thread the depth adjustment ring onto the motor until the ring is about halfway between the top and bottom of the motor as shown. Insert the motor into the base by aligning the groove on the motor with the guide pins on the base. Slide the motor down until the depth adjustment ring snaps into place.
   NOTE: Guide pin grooves are located on either side of the motor so it can be positioned in two orientations.
3. Adjust the depth of cut by turning the depth adjustment ring. Refer to Adjusting the Depth of Cut.
4. Close the locking lever when the desired depth is achieved.

Adjusting the Depth of Cut (Fig. L)

1. Open the locking lever and turn the depth adjustment ring 5 until the bit just touches the work piece. Turning the ring clockwise raises the cutting head while turning it counterclockwise lowers the cutting head.
2. Turn the micro-adjustment scale clockwise until the 0 on the scale lines up with the pointer on the bottom of the depth adjustment ring.
3. Turn the depth adjustment ring until the pointer lines up with desired depth of cut marking on the microadjustment scale .
   NOTE: Each mark on the adjustment scale represents a depth change of 1/64" or.015" (0.4 mm) and one full (360º) turn of the ring changes the depth 0.5" (12.7 mm).
4. Close the locking lever to lock the base.

Removing the Motor from the Fixed Base (Fig. K)

1. Remove the battery pack from the motor. Refer toInstalling and Removing the Battery Pack.
2. Open the locking lever on the base.
3. Grasp the motor unit with one hand, depressing both quick release tabs .
4. With the other hand, grasp the base and pull motor from the base.

Set-up: Plunge Base (Fig. A, M)
Inserting the Motor into the Plunge Base

1. Remove the depth adjustment ring from the motor . It is not used with the plunge base. NOTE: Snap depth adjustment ring onto fixed base, when not in use, to prevent loss.
2. Open the plunge base locking lever.
3. Making sure the spindle lock button is facing front, insert the motor into the base by aligning the groove on the motor with the guide pins on the base. Slide the motor down until the motor stops on the motor stop .

4. Close the locking lever 39.

Adjusting the Plunge Routing Depth (Fig. M)

Laceration hazard. Do not change the turret stop while the router is running. This will place your hands too near the cutter head.

To prevent loss of control, ALWAYS tighten the travel-limiting nuts together. Inadvertent movement could prevent full bit retraction.

To prevent loss of control, set the travel-limiting nuts so that bit can be retracted into the base of the router, clear of the workpiece.

To reduce the risk of injury, NEVER adjust or remove the stop nut. Motor can disengage resulting in loss of control.

Turn the router on before plunging the cutter head into the workpiece.

1. Unlock the plunge mechanism by pulling down the plunge lock lever . Gently push down on the two handes to plunge the router down as far as it will go, allowing the bit to just touch the workpiece.
2. Lock the plunge mechanism by releasing the plunge lock lever .
3. Loosen the depth adjustment rod by turning the thumb screw counterclockwise.
4. Slide the depth adjustment rod down so that it meets the lowest turret stop .
5. Slide the zero adjuster tab on the depth adjustment rod down so that the top of it meets zero on the depth adjustment scale .
6. Grasping the top, knurled section of the depth adjustment rod , slide it up so that the tab aligns with the desired depth of cut on the depth adjustment scale .
7. Tighten the thumb screw to hold the depth adjustment rod in place.
8. Keeping both hands on the handles, unlock the plunge mechanism by pulling the plunge lock lever down. The plunge mechanism and the motor will move up. When the router is plunged, the depth adjustment rod will hit the turret stop, allowing the router to reach exactly the desired depth.

Using the Rotating Turret for Stepped Cuts (Fig. M)
If the depth of cut required is more than is acceptable in a single pass, rotate the turret so that depth rod lines up with taller turret stop initially. After each cut, rotate the turret so that the depth stop lines up with shorter post until the final depth of cut is reached.

Do not change the turret stop while the router is running. This will place your hands too near the cutter head.

Fine Adjustment of Routing Depth (Fig. M)
The knurled knob at the bottom end of the depth adjustment rod can be used to make minor adjustments.

1. To decrease the cutting depth, rotate the knob clockwise (looking down from the top of the router).
2. To increase the cutting depth, rotate the knob counterclockwise (looking down from the top of the router).

NOTE: One complete rotation of the knob results in a change of about 5/128" or.04" (1 mm) in depth.

Removing the Motor from the Plunge Base (Fig. M)

1. Remove the battery pack from the motor. Refer toInstalling and Removing the Battery Pack.
2. Open the locking lever on the base.
3. Grasp the motor unit with one hand and the base with the other hand, pull motor from the plunge base.

OPERATION

To reduce the risk of serious personal injury, turn unit off and remove the battery pack before making any adjustments or removing/ installing attachments or accessories. An accidental start-up can cause injury.

Installing and Removing the Battery Pack (Fig. N)

Before inserting the battery, check to see that the switch is in the OFF position. An accidental start-up can cause injury.

NOTE: For best results, make sure your battery pack is fully charged.
To install the battery pack into the tool handle, align the battery pack with the rails inside the tool's handle and slide it into the handle until the battery pack is firmly seated in the tool and ensure that it does not disengage. To remove the battery pack from the tool, press the release button and firmly pull the battery pack out of the tool handle. Insert it into the charger as described in the charger section of this manual.

Proper Hand Position (Fig. A, O, P)

To reduce the risk of serious personal injury, ALWAYS use proper hand position as shown.

To reduce the risk of serious personal injury, ALWAYS hold securely in anticipation of a sudden reaction.
When using the fixed base, one hand should be on top of the battery and the other hand around the fixed base (Fig. O). When using the plunge base, grasp the side handles (Fig. A) firmly as shown in Fig. P.

Starting and Stopping the Motor (Fig. A, N)

Before starting the tool, clear the work area of all foreign objects. Also keep firm grip on tool to resist starting torque.

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 the unit on, depress the side of the dust-protected switch that has the symbol "I." To turn the unit off, depress the side of the switch that has the symbol "O."

Cutting with the Fixed Base
Set up the router to use the fixed base by following the instructions in the Assembly and Adjustments section.
After the router is set-up, install the battery pack as shown in Fig. N, then set your router speed (refer to Choosing Router Speed).
NOTE: Always feed the router opposite to the direction in which the cutter is rotating.

Cutting with the Plunge Base (Fig. A, P)
NnOTE: The depth of cut is locked in the plunge base's default state. The plunge lock requires user actuation to enable the "release to lock" plunge mechanism.
NOTE: Grip both side handles while operating.

1. Depress the plunge lock lever and plunge the router down until the bit reaches the set depth.
2. Release the plunge lock lever when desired depth is reached.
   NOTE: Releasing the plunge lock lever automatically locks the motor in place.
   NOTE: If additional resistance is needed, use the hand to depress the plunge lock lever.
3. Perform the cut.
4. Depressing the plunge lock lever will disable the locking mechanism allowing the router bit to disengage from the workpiece.
5. Turn the router off.

Direction of Feed (Fig. Q)
The direction of feed is very important when routing and can make the difference between a successful job and a ruined project. The figures show the proper direction of feed for some typical cuts. A general rule to follow is to move the router in a counterclockwise direction on an outside cut and a clockwise direction on an inside cut.
Shape the outside edge of a piece of stock by following these steps:

1. Shape the end grain, left to right
2. Shape the straight grain side moving left to right
3. Cut the other end grain side
4. Finish the remaining straight grain edge

Choosing Router Speed (Fig. A)
Refer to the Speed Selection Chart to choose a router speed. Turn the variable speed dial to control router speed.

Soft Start Feature
The compact routers are equipped with electronics to provide a soft start feature that minimizes the start up torque of the motor.

Variable Speed Control (Fig. A)

If the speed control ceases to operate, or is intermittent, stop using the tool immediately. Take it to a DeWALT factory service center or a DeWALT authorized service center for repair.

Always follow the bit manufacturer's speed recommendations as some bit designs require specific speeds for safety or performance. If you are unsure of the proper speed or are experiencing any type of problem, contact the bit manufacturer.
This router is equipped with a variable speed dial with 7 speeds between 16000 and 25500 RPM. Adjust the speed by turning the variable speed dial .
NOTICE: The router is equipped with electronics to monitor and maintain the speed of the tool while cutting. In low and medium speed operation, the speed control prevents the motor speed from decreasing. If you expect to hear a speed change and continue to load the motor, you could damage the motor by overheating. Reduce the depth of cut and/or slow the feed rate to prevent tool damage.
The compact routers are equipped with electronics to monitor and maintain the speed of the tool while cutting.

SPEED SELECTION CHART*

DIAL SETTING	APPROX. RPM	APPLICATION
1	16000	Large diameter bits and cutters
2	17500
3	19100
4	20700	Small diameter bits and cutters. Softwoods, plastics, laminates.
5	22300
6	23900
7	25500

*The speeds in this chart are approximate and are for reference only. Your router may not exactly produce the speed listed for the dial setting.
NOTE: Make several light passes instead of one heavy pass for better quality work.

Worklights (Fig. A)
The worklights are located at the front of the motor . To turn on the worklight, switch on the on/off switch . Worklights will remain on 20 seconds after the on/off switch is moved to the off position.
NOTE: The worklights are for lighting the immediate work surface and are not intended to be used as a flashlight.
NOTE: If worklights flash, check the charge on the battery; it could be low. If they still flash with a charged battery, the unit should be taken to a service center for evaluation.

MAINTENANCE

To reduce the risk of serious personal injury, turn unit off and remove the battery pack before making any adjustments or removing/ installing attachments or accessories. An accidental start-up can cause injury.

Cleaning

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.

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 dry cloth. Never let any liquid get inside the tool; never immerse any part of the tool into a liquid.
NOTE FOR PLUNGE BASE ONLY: Use only a DRY cloth to wipe the plunge rods. These rods require no lubrication. Lubricants attract dust, reducing the performance of your tool.

Waxing Motor and Base
To maintain a smooth action when moving the motor unit in relation to the base, the outside of the motor unit and the inside of the base can be waxed using any standard paste or liquid wax. Per the manufacturers instructions, rub the wax onto the outside diameter of the motor unit and the inside diameter of the base. Allow wax to dry and buff off residue with a soft cloth.

Accessories

Since accessories, other than those offered by DeWALT, have not been tested with this product, use of such accessories with this tool could be hazardous. To reduce the risk of injury, only DeWALT recommended accessories should be used with this product.
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 DeWALT Industrial Tool Co., 701 East Joppa Road, Towson, MD 21286, call 1-800-4-DeWALT (1-800-433-9258) or visit our website: www.dewalt.com.

Repairs
The charger and battery pack are not serviceable.

To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including brush inspection and replacement, when applicable) should be performed by a DeWALT factory service center or a DeWALT authorized service center. Always use identical replacement parts.

Register Online
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.

If you have questions or comments, contact us.
1-800-4-DeWALT