DeWalt DW625, DW624 Instruction Manual

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DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286 (DEC99) Printed in Switzerland Form No. 328521-01
DW624. DW625 Copyright © 1999

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INSTRUCTION MANUAL
GUIDE D’UTILISATION

INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y PÓLIZA
DE GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUCTIVO
ANTES DE USAR EL PRODUCTO.

MANUAL DE INSTRUCCIONES

DW624 Plunge Cut Router/DW625 Electronic Plunge Cut Router
DW624 Toupie à course plongeante/DW625 Toupie électronique à course plongeante
DW624 Rebajadora de columnas/DW625 Rebajadora electrónica de columnas

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IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT
THIS, OR ANY DEWALT TOOL, CALL US TOLL FREE AT 1­8 0 0 - 4 - DEWALT (1-800-433-9258).

Important Safety Instructions

W A R N I N G : When using Electric Tools, basic safety precautions
should always be followed to reduce the risk of fire, electric shock,
and personal injury, including the following:

W A R N I N G : Use of this tool can generate dust containing

chemicals known to cause cancer, birth defects or other
reproductive harm. Use appropriate respiratory protection.

C A U T I O N : Some wood contains preservatives such as copper

chromium arsenate (CCA) which can be toxic. When cutting these
materials extra care should be taken to avoid inhalation and mini ­mize skin contact.

READ ALL INSTRUCTIONS.

• KEEP WORK AREA CLEAN. Cluttered areas and benches

invite injuries

• CONSIDER WORK AREA ENVIRONMENT. Don’t expose

power tools to rain. Don’t use power tools in damp or wet
locations. Keep work area well lit.

• GUARD AGAINST ELECTRIC SHOCK. Prevent body contact

with grounded surfaces. For example: pipes, radiators, ranges,
refrigerator enclosures.

• KEEP CHILDREN AWAY. All visitors should be kept away

from work area. Do not let visitors contact tool or extension
c o r d .

• STORE IDLE TOOLS. When not in use, tools should be

stored in dry, and high or locked-up place – out of reach of
c h i l d r e n .

• DON’T FORCE TOOL. It will do the job better and safer at the

rate for which it was intended.

• USE RIGHT TOOL. Don’t force small tool or attachment to do
the job of a heavy-duty tool. Don’t use tool for purpose not
intended, for example, don’t use circular saw for cutting tree
limbs or logs.

• DRESS PROPERLY. Do not wear loose clothing or jewelry.
They can be caught in moving parts. Non-skid footwear is
recommended when working outdoors. Wear protective hair
covering to contain long hair.

• USE SAFETY GLASSES. Also use face or dustmask if
operation is dusty.

• DON’T ABUSE CORD. Never carry tool by cord or yank it to
disconnect from receptacle. Keep cord from heat, oil, and
sharp edges.

• SECURE WORK. Use clamps or a vise to hold work. It’s safer
than using your hand and it frees both hands to operate tool.

• DON’T OVERREACH. Keep proper footing and balance at all
t i m e s .

• MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean
for better and safe performance. Follow instructions for
lubricating and changing accessories. Inspect tool cords
periodically and if damaged have repaired by DeWalt certified
service center. Inspect extension cords periodically and
replace if damaged. Keep handles dry, clean, and free from oil
and grease.*

• DISCONNECT TOOLS. When not in use, before servicing,
and when changing accessories.

• REMOVE ADJUSTING KEYS AND WRENCHES. Form habit
of checking to see that keys and adjusting wrenches are
removed from tool before turning it on.

• AVOID UNINTENTIONAL STARTING. Don’t carry plugged-in
tool with finger on switch. Be sure switch is off when plugging
i n .

• EXTENSION CORDS. Make sure your extension cord is in
good condition. When using an extension cord, be sure to use

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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.

Recommended Minimum Wire Size for Extension Cords

Total Length of Cord

25 ft. 50 ft. 75 ft. 100 ft. 125 ft. 150 ft. 175 ft.

7.6 m 15.2 m 22.9 m 30.5 m 38.1 m 45.7 m 53.3 m

Wire Size

18 AWG 18 AWG 16 AWG 16 AWG 14 AWG 14 AWG 2 AWG

• OUTDOOR USE EXTENSION CORDS. When tool is used
outdoors, use only extension cords intended for use outdoors
and so marked.

• STAY ALERT. Watch what you are doing. Use common sense.
Do not operate tool when you are tired.

• CHECK DAMAGED PARTS. Before further use of the tool, a
guard or other part that is damaged should be carefully checked
to determine that it will operate properly and perform its
intended function. Check for alignment of moving parts, binding
of moving parts, breakage of parts, mounting, and any other
conditions that may affect its operation. A guard or other part
that is damaged should be properly repaired or replaced by a
DEWA L T certified service center unless otherwise indicated
elsewhere in this instruction manual. Have defective switches
replaced by a DEWA L T certified service center. Do not use tool
if switch does not turn it on and off.

• DO NOT OPERATE portable electric tools near flammable
liquids or in gaseous or explosive atmospheres. Motors in these
tools normally spark, and the sparks might ignite fumes.

SAVE THESE INSTRUCTIONS

FOR FUTURE USE.

Double Insulation

DOUBLE-INSULATED tools are constructed throughout with TWO
separate “layers” of electrical insulation between you and the tool’s
electrical system.

Tools built with this insulation system are not intended to be
grounded. As a result, your tool is equipped with a two-prong plug
which permits you to use extension cords without concern for
maintaining a ground connection.

N O T E : DOUBLE INSULATION does not take the place of normal
safety precautions when operating this tool. The insulation system is
for added protection against injury resulting from a possible
electrical insulation failure within the tool.

CAUTION: When servicing all tools, USE ONLY IDENTICAL

Polarized Plugs

Polarized plugs (one blade is wider than the other) are used on
equipment to reduce the risk of electric shock. When provided,
this plug will fit into a polarized outlet only one way. If the plug
does not fit fully into the outlet, reverse the plug. If it still does not
fit, contact a qualified electrician to install the proper outlet. Do not
change the plug in any way. REPLACEMENT PARTS. Repair or
replace damaged cords.

Motor

Your DEWA L T tool is powered by a DEWA L T-built motor. Be sure
your power supply agrees with the nameplate marking.

Volts 50/60 Hz or “AC only” means your tool must be operated only
with alternating current and n e v e r with direct current. Volts DC­60Hz or AC/DC means your tool may be operated with either
alternating or direct current.

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Voltage decrease of more than 10% will cause loss of power and
overheating. All DeWalt tools are factory tested; if this tool does not
operate, check the power supply.

Additional Specific Instructions for
Routers

The electronic motor control system has two basic features.
A. Soft start - when you turn on the router, you will notice that it

does not have the jerk from the rapid acceleration of the motor.
This router has a starting circuit which accelerates the motor up to
speed smoothly, without jerking, and allows you to maintain easier
control of the router during the start up period.

B. Constant speed cutting - as you load the router, the selected
cutting speed does not slow down during normal use. The
electronic control governs the motor and gives you a consistent
finish to your work. Only under very heavy loading will the speed of
the unit fall below the governed speed.

To set the router speed (from 8,000 rpm to 20,000 rpm) rotate the
speed control wheel shown in the large figure on page 2. The
higher the number the higher the speed. Consult TABLE 1 (page 3)
to help select the proper speed for your application.

Specifications

PREPARATION FOR USE

The motor in this router is high-powered (750 Watts, max.). Despite
this, it is advisable to cut deep grooves or remove large amounts of
material in two or more passes.

Operating Instructions

TURN OFF AND UNPLUG ROUTER
N O T E : Before installing a router bit in your unit, position the tool so

that the collet is easily accessible. To do this, rotate the height stop
thumb wheel, shown in Figure 1, counterclockwise until it is about
1/2” from the top of the threaded height stop rod. Raise the plunge

release lever, shown in Figure 2, and let the router rise to its full
height. Depress the plunge release lever to lock the tool in place.

TECHNICAL DATA

M o d e l DW624, DW625

V o l t a g e 1 2 0
Speed DW624 20,000 r.p.m.
Speed DW625 8,000- 20,000 r.p.m.
I n s u l a t i o n double insulated
C o l u m n spring loaded twin column
Plunging stroke 70mm (2-3/4”)
Routing depth 0-70 mm adjustable
Cutter mounting precision collet, size 1/2”-1/4”

Cutter cap max. 63.5 mm (2-1/2")

R o u t i n g (shallow)
Rotary depth stop 3 stage depth position

FIG. 1

2

SPEED

CONTROL

WHEEL

1/2

QUICK

RELEASE

BUTTON

HEIGHT STOP THUMB

WHEEL

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SPEED SELECTION CHART

TABLE 1: RECOMMENDATION FOR THE CORRECT CHOICE OF SPEED

Material Cutter Diam. Electronic Control Settings

Stage 1 Stage 2 Stage 3 Stage 4 Stage 5

Model #DW624/DW625 8,000 rpm 12,000 rpm 16,000 rpm 18,000 rpm 20,000 rpm

Hardwood, e.g., oak Small (1/2") – – O X XX

Medium (1/2"-1 1/8") – – O XX X

Large (over-1 1/8") X XX O – –

Softwood, e.g., pine Small (1/2") – – O X XX

Medium (1/2"-1 1/8") – O X XX XX

Large (over-1 1/8") X XX O O –

Plastic-laminated chipboard Small (1/2") – – O X XX

Medium (1/2"-1 1/8") – O X XX XX

Large (over-1 1/8") O XX X O –

Plastics Small (1/2") – O X X XX

Medium (1/2"-1 1/8") – O XX XX X

Large (over-1 1/8") X XX O – –

This Table can serve only as a guide, since wood is a living material. Even with the same species of timber there will be large differences in
hardness and density. When a high speed is employed, set the electronic control one step higher.

KEY: XX very good X good O Satisfactory – not recommended

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Switch

TO SWITCH ON THE MACHINE
N O T E : Always pull the plug on the cord set out of its receptacle

when changing a cutter or fitting the accessories in order to avoid
any chance of an accident.

CONVENIENT SWITCH ACTUATOR PUSH UP FOR “ON”
DOWN FOR “OFF”.

Bit Installation and Removal

(TURN OFF AND UNPLUG ROUTER)
IMPORTANT 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, as shown in Figure 3.
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, shown in
Figure 3, while firmly tightening the collet nut with the wrench
p r o v i d e d .

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 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 very easy to remove the bit.

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 collets, unscrew the collet assembly, as described
above, sharply pull the old collet out of the collet nut and insert the
new collet. Push firmly so that it snaps past the retainer spring in
the collet nut.

Controls

N O T E : Before operating any of the controls, read this whole
s e c t i o n .

PLUNGE RELEASE LEVER

The plunge release lever allows the router bit to be plunged
directly into the workpiece. Simply raise the plunge release lever
when you want to lower the router into the work, as shown in
Figure 2. You can lower the unit until it reaches your preset stop.
To lock the tool in place anywhere along its vertical travel, depress
the lever.

HEIGHT STOP ROD AND HEIGHT STOP THUMB WHEEL

As its name implies, the height stop rod and thumb wheel limit how
high the unit can travel up the rails. The system is adjustable from
full down where the unit cannot rise regardless of the position of
the plunge release lever to full up where the bottom of the collet is
2-7/8” above the workpiece (See Figure 4).

For convenience, the thumb wheel is equipped with a quick
release button that allows you to disengage the threads for fast
positioning by simply depressing the button in the side of the
w h e e l .

NOTE: It is easier to move the height stop thumb wheel UP if the
plunge release lever is locked and easier to move the thumb wheel
DOWN if the unit is first moved down by releasing the plunge
release lever and then tightening it.

MULTI-POSITION TURRET STOP

The turret stop limits the downward distance that the tool can be
plunged. It consists of three screws of different lengths that serve
to define the depth of cut by limiting the travel of the depth stop bar
(see Figure 5). Routing depth can be set by selecting the screw of
the appropriate length on the turret. The turret is rotatable with
detent stops to properly align the screws.

It is the interaction of the depth stop bar and the turret stop that

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PLUNGE

RELEASE

LEVER

COLLET NUT

SPINDLE LOCK

BUTTON

FIG. 2

FIG. 3

determine the routing depth.
If none of the provided screws seems close to the desired height

each can be adjusted by loosening the hex nut at the bottom and
then turning the screw either in or out to make it the proper length.
After adjusting this screw be sure to tighten the hex nut at the
bottom. (See Figure 6)

See the section “Setting the Routing Depth” for instructions on
how to use the turret stop in an actual operation.

DEPTH STOP BAR AND VERNIER

The depth stop bar is what contacts the selected screw in the
turret stop to limit the routing depth. At the bottom of the depth
stop bar is a threaded shaft, a spring and a knurled knob, as
shown in Figure 7.

A precision vernier scale is provided for extremely accurate
adjustment of the routing depth.

See the section below “Setting the Routing Depth” for instructions
on how to use the depth stop bar and vernier in an actual
o p e r a t i o n .

Familiarization

Please take a little time now and, without plugging the tool in,
practice with these adjustments and controls and become familiar
with their operation. Only with a complete, “hands on”
understanding of these systems will you be able to get the most
out of this quality router.

Setting the Routing Depth

(TURN OFF AND UNPLUG THE ROUTER)
To set the routing depth follow the steps below:

1 . Install the desired router bit as described previously.
2 . Position the height stop thumb wheel at the top of the height

stop rod. (See Figure 4) You can either turn the thumb wheel
or use the handy quick release button discussed above.

3 . Adjust the depth stop bar to the top of its travel by rotating the

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Depth Stop Control Knob shown in Figure 9.

4 . Rotate the turret stop to position the shortest screw under the

depth stop bar.

5 . Raise the plunge release lever and push the router down until

the end of the bit just touches the workpiece.

6 . Lower the depth stop bar until the knurled knob on the bottom

of it touches the selected screw in the turret stop.

7 . Raise or lower the plastic vernier to align the hairline in the

vernier with the 0 mark on the graduated scale, as shown in
Figure 8.

8 . Using the depth stop control knob, raise the depth stop bar and

align the desired mark on the graduated scale with the hairline
in the vernier, as shown in Figure 9. (Scale graduated in
1/16ths of an inch)

9 . Tighten the depth stop bar clamp.

10.The router is now set to cut to the set depth when plunged into
the workpiece.

Fine Adjustment of Routing Depth

TURN OFF AND UNPLUG ROUTER.
If, after setting the desired depth of cut, a small adjustment is

needed, it is not necessary to go through the entire procedure for
setting the depth. Minor adjustment can be easily made by
rotating the knurled knob on the bottom end of the depth stop bar,
as shown in Figure 8.

Rotating the knob clockwise (looking down from the top of the
router) will result in a more shallow cut. Rotating the knob
counterclockwise will result in a deeper cut. One complete rotation
of the knob represents about 1 mm in depth adjustment.

FIG. 4

HEIGHT STOP

THUMB

WHEEL

FIG. 6

BOTTOM OF

COLLET

HEIGHT

STOP

ROD

FIG. 5

DEPTH

STOP

TURRET

STOP

QUICK

RELEASE

BUTTON

FIG. 7

DEPTH

STOP BAR

VERNIER

6

TURRET STOP

KNURLED

KNOB

SPRING

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Using the Turret Stop for Sequential
Routing Depth Settings

TURN OFF AND UNPLUG ROUTER.
It is recommended that particularly deep grooves be cut with

several passes rather than one deep pass. In order to do this and
still maintain accuracy of depth when the job is finished, perform
the following procedure.

1 . Set the final desired routing depth as instructed above. For

the purpose of this discussion, assume that the desired
depth is 1/2”.

2 . With a depth of 1/2” set on the shortest screw in the turret

stop, adjust the second shortest screw to a point about
halfway between the bottom of the knurled knob and the top
of the shortest screw, as shown in Figure 10.

3 . Leave the vernier setting alone and turn the adjusted second

shortest screw into position under the depth stop bar.

4 . Make your first cut at this setting.

FIG. 8

KNURLED KNOB

HAIRLINE

FIG. 9

DEPTH

STOP

CONTROL

KNOB

5 . Rotate the turret stop so that the shortest screw is directly

under the depth stop bar and make your final cut.

N O T E : The third screw in the turret stop is provided if your cut is
even deeper and you want to make three cuts to achieve the final
depth, or set final depth for multiple cuts at one time.

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, depress the Plunge Lock Lever. When you
have finished routing, raise the lever and let the spring lift the
router directly out of the workpiece.

All common routing tasks can be performed with ease with the
Plunge Cut Router: Grooving, rabbeting, recessing, veining, and
profiling on all types of wood and plastic.

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

Only carbide-tipped cutters should be used on panels faced with
plastic laminates. The hard laminates will quickly dull steel cutters.

Your DeWalt certified Service center has a Router Craft Handbook
available at extra cost which covers the use of routers in great
detail and shows the various types of bits available.

Direction Of Feed (Fig. 12)

The direction of feed is very important when routing and can make
the difference between a successful job and a ruined project.
Figures 11 and 12 show proper direction of feed for some typical
c u t s .

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.

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