DeWalt DW621 User Manual

DEWALT Industrial Tool Company, P.O. Box 158, 626 Hanover Pike, Hampstead, MD 21074 Printed in Italy (MAY96-1) Form No. 154716

Copyright © 1996

INSTRUCTION MANUAL
GUIDE D'UTILISATION
MANUAL DE INSTRUCCIONES

DW621
Plunge 2 HP Router
Toupie à course plongeante de 2 HP
Rebajadora de columnas de 2 HP

INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y PÓLIZA
DE GARANTIA. ADVERTENCIA: LEASE ESTE INSTRUCTIVO ANTES
DE USAR EL PRODUCTO. SI TIENE DUDAS, POR FAVOR LLAME.

English

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 flammable 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

• Double insulated tools are equipped with a polarized plug
(one blade is wider than the other.) This plug will fit in a
polarized outlet only one way. If the plug does not fit fully in
the outlet, reverse the plug. If it still does not fit, contact a
qualified electrician to install a polarized outlet. Do not
change the plug in any way. Double insulation eliminates the

need for the three wire grounded power cord and grounded power
supply system.

• Avoid body contact with grounded surfaces such as pipes,
radiators, ranges and refrigerators. There is an increased risk of
electric shock if your body is grounded.

• Don’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

0.8

0.6

5/8

1

/2

3/4

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS
OR ANY D

EWALT TOOL, CALL US TOLL FREE AT:

1-800-4-DEWALT (1-800-433-9258)

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. An 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.

Minimum Gage for Cord Sets

Volts Total Length of Cord in Feet

120V 0-25 26-50 51-100 101-150
240V 0-50 51-100 101-200 201-300

Ampere Rating

More Not more AWG

Than Than
0- 6 18 161614
6- 10 18 16 14 12
10 - 12 16161412
12 - 16 14 12 Not Recommended

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.

• Avoid accidental starting. Be sure switch is off before
plugging in. Carrying tools with your 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 left 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.

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English

• 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 platform. Holding the work by hand or

against your body is unstable and may lead to a loss of control.

• Do not force tool. Use the correct tool for your application. The
correct tool will do the job better and safer and 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 condition 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 another tool.

2

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 Safety Rules

• Hold tool 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.

• Keep handles dry, clean, free from oil and grease. It is
recommended to use rubber gloves. This will enable better control
of the tool.

• The label on your tool may include the following symbols.

• The label on your tool may include the following symbols.

V ............................volts

A ............................amperes

Hz ..........................hertz

W ..........................watts

min ........................minutes

..........................alternating current

......................direct current

n

o ..........................no load speed

..........................

Class II Construction

…/min ....................revolutions or reciprocation per minute

..........................earthing terminal

..........................safety alert symbol

Motor

Be sure your power supply agrees with nameplate marking.
120 AC means your tool may be operated only with alternating

current and never with direct current.
Voltage decrease of more than 10% will cause loss of power and

overheating. All tools are factory tested; if this tool does not operate,
check the power supply.

Bit Installation and Removal

TURN OFF AND UNPLUG ROUTER
NOTE: Always snap the collet firmly into the collet nut, (past the

retainer spring) before installing a bit.
Use the supplied wrench and the spindle lock as necessary to loosen

(counterclockwise) the collet nut, (Fig. 1).
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". Hold the
spindle shaft by depressing the spindle lock button, while firmly
tightening the collet nut with the wrench provided.

Your router has a unique locking system for retaining the bit. When
removing a bit, the collet nut must be loosened with the wrench. The

English

FIG. 1

SPINDLE LOCK

COLLET NUT

collet nut will turn approximately 3/4 of a turn and then become tight
again. At this point the bit can’t be removed. Using the same
procedure, loosen the nut a second time.This lifts the collet and
makes it easy to remove the bit.

NOTE: Your router is equipped with a clear plastic cap over the
cutting area. This cap assists with dust extraction. When installing a
router bit over 1-1/8" in diameter, ensure the plastic cap is removed
or positioned above the cutting portion of the bit (Fig. 2).To remove
the cap, push it from the bottom of the router. To re-install the cap,
align the tabs (Fig. 2) and snap it into place.

Collets

NEVER TIGHTEN THE COLLET ON THIS TOOL WITHOUT FIRST
INSTALLING A ROUTER BIT IN IT. TIGHTENING AN EMPTY
COLLET CAN DAMAGE THE COLLET.

To change collet sizes, unscrew the collet assembly, as described
above. The collet and the collet nut are connected. Do not attempt to
remove the collet from the collet nut.

Controls

ELECTRONIC SPEED CONTROL DIAL

The speed of your router is variable. Use the electronic speed control
(Fig. 3) dial to produce uniform cutting results in wood, plastics and
aluminum. Use the lower settings (1-3) for large diameter cutters and
the higher settings for small diameter cutters. See Table A for more
information.

Adjusting the Depth of Cut

QUICK ADJUSTMENT USING RACK AND PINION HEIGHT
ADJUSTMENT (FIG. 4)

1) UNPLUG THE ROUTER. It may be necessary to remove the
plastic cap before making adjustments.

3

English

0.

0.6

5/8

1/2

3/4

FIG. 4

FIG. 3

SPEED CONTROL

DIAL

FIG. 2

PLASTIC CAP

FINE

ADJUSTMENT

KNOB

PLUNGE LOCK

HANDLE

HEIGHT

ADJUSTMENT KNOB

QUICK ADJUSTER

DEPTH STOP

LOCKING

BOLT

TABS

4

FINE ADJUSTMENT (FIG. 6)

Use the fine adjuster when not using a depth template, or if the depth
of cut needs readjustment.

1) Adjust the depth of cut as described above.

2) Set the fine adjuster to zero using the inner ring. Hold the top
portion while setting the lower ring to zero.

3) Rotate the fine adjuster to the required position. Graduations are
on the top of the fine adjustment knob.

Lock-On/Lock-Off Switch (Fig. 7)

The lock-on/lock-off switch is located in the handle on the right side.
The router is normally locked-off.

To start the router, press the thumb lock and squeeze the trigger. To
lock the switch on, squeeze the trigger, press the thumb lock forward
and release the trigger. To turn the router off, release the switch. If the
tool is locked-on, press the trigger again and release the switch.

NOTE: Loosen the plunge limiter and allow the router carriage to
return to its rest position before switching off.

English

0.

0.6

FIG. 6

FIG. 7

2) Unlock the plunge lock handle.

3) Lower the router carriage until the cutter is in contact with the
workpiece

4) Tighten the plunge lock handle by turning it clockwise.

5) Turn the height adjustment knob counterclockwise until it hits the
revolver depth stop (Fig. 5).

6) Set the quick adjuster to zero, by turning the inner ring knob
clockwise.

7) Adjust the depth of cut by rotating the height adjust knob clockwise
to the desired depth of cut. The adjustment range is indicated by
the arrow.

8) Tighten the plunge limiter by turning the depth stop bolt clockwise.

TRIPLE DEPTH ADJUSTMENT USING THE REVOLVER DEPTH
STOP (FIG. 5)

The revolver depth stop can be used to set three different depths. This
is useful for deep cuts, performed in steps.

1) Place a depth template between the depth stop and the revolver
depth stop to adjust the exact cutting depth.

2) If required, set all three screws.

5/8

1/2

3/4

REVOLVER DEPTH

STOP

FINE

ADJUSTMENT

KNOB

FIG. 5

TRIGGER

PRESS TO LOCK ON

THUMB LOCK

Operation

After setting the cutting depth as described, locate the router such
that the bit is directly over the place you will be cutting. With the
router running, lower the unit smoothly down into the workpiece.
(DO NOT JAM THE ROUTER DOWN). When the tool reaches the
pre-set depth, tighten the plunge lock. When you have finished
routing, loosen the plunge lock and let the spring lift the router directly
out of the workpiece.

NOTE: Always feed the router opposite to the direction in which the cutter
is rotating.

Direction Of Feed

Figs. 8 and 9 show proper direction of feed for some typical cuts.
Mold the outside edge of a piece of stock by a) mold the end grain,

left to right, b) do the straight grain side moving left to right, c) finish
the other end grain side, and d) do the remaining straight grain edge.

The direction of feed is important in router usage. Be sure the cutter
is rotating into the stock by moving left to right on outside edges and
clockwise on inside cuts.

Dust Collection and Extraction

TO SET THE ROUTER FOR DUST EXTRACTION:

1. Unplug router from power supply.

2. If required, insert the dust extraction hose adapter into the dust
extraction port (Fig. 10).

2. Slip the end of any standard vacuum cleaner tube into the hose
adapter.

3. When using dust extraction, be sure that the vacuum cleaner is out
of the way and secure so that it will not tip over or interfere with the
router or workpiece. The vacuum hose and power cord must also
be positioned so that they don't interfere with the router or

5

English

A

D

C

B

FIG. 9

FIG. 8

FIG. 10

DUST EXTRACTION

HOSE ADAPTER

EXTRACTION

PORT

6

workpiece. If the vacuum cleaner or vacuum hose cannot be
positioned properly, it should be removed.

4. Turn on vacuum cleaner before router.

5. Empty the vacuum cleaner as necessary.

NOTE: The router comes with a clear plastic removable guard over
the cutting area. Do not attempt to plunge cut through the plastic
guard. The guard is used to assist the dust collection.

Your router includes a dust extraction cap. Be sure it is in place over
the dust extraction port if you are not using a vacuum.

Maintenance

CLEANING & LUBRICATION

Use only mild soap and damp cloth to clean the tool. Never let any
liquid get inside the tool; never immerse any part of the tool into a
liquid.

NOTE: Use only a DRY cloth to wipe the plunge rods. These rods
require no lubrication. Lubricants attract dust, reducing the
performance of your tool.

Accessories

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 another tool. 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 for your tool, contact:

D

EWALT Industrial Tool Company

626 Hanover Pike, P.O. Box 158
Hampstead, MD. 21074-0158

1-800-4-DEWALT (1-800-433-9258)

CAUTION: The use of any other accessory not recommended for
use with this tool could be hazardous.

Important

To assure product SAFETY and RELIABILITY, repairs, maintenance
and adjustment should be performed by authorized service centers
or other qualified service organizations, always using identical
replacement parts

Full Warranty

DEWALT heavy duty industrial tools are warranted for one year from
date of purchase. We will repair, without charge, any defects due to
faulty materials or workmanship. Arrangements have been made
with the Industrial Tool Division of Black & Decker to provide warranty
repairs for D

EWALT tools. Please return the complete unit,

transportation prepaid, to any Black & Decker Industrial Service
Center or Authorized Service Station listed under “Tools, Electric” in
the yellow pages. This warranty does not apply to accessories or
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, DeWalt tools are covered by our:

30 DAY NO RISK SATISFACTION GUARANTEE

If you are not completely satisfied with the performance of your
D

EWALT heavy duty industrial tool, simply return it to the participating

seller within 30 days for a full refund. Please return the complete unit,
transportation prepaid. Proof of purchase may be required.

English

See ‘Tools-Electric’

–Yellow Pages–

for Service & Sales