DeWalt DW628 Instruction Manual

DEWALT Industrial Tool Company, P.O. Box 158, 626 Hanover Pike, Hampstead, MD 21074 Printed in U.S.A. (JULY97-CD-1) Form No. 384404
DW628 Copyright © 1997

Garantía completa

Las herramientas industriales DEWAL Testán garantizadas durante un
año a partir de la fecha de compra. Repararemos, sin cargos,
cualquier falla debida a material o mano de obra defectuosos. Para
obtener información sobre reparaciones en garantía, llame por favor al
326-7100. Esta garantía no se aplica a los accesorios ni a daños
causados por reparaciones efectuadas por terceras personas. Esta
garantía le otorga derechos legales específicos, y usted puede tener
otros derechos que pueden variar de estado a estado.

En adición a la garantía, las herramientas DEWALT están amparadas
por nuestra:

GARANTÍA DE SATISFACCIÓN SIN RIESGO POR 30 DÍAS

Si usted no se encuentra completamente satisfecho con el desempeño
de su herramienta industrial D

EWALT, sencillamente devuélvala a los

vendedores participantes durante los primeros 30 días después de la
fecha de compra para que le efectúen un reembolso completo. Por
favor regrese la unidad completa, con el transporte pagado. Se puede
requerir prueba de compra.

384404/DW628 5/2/02 1:39 PM Page 2

INSTRUCTION MANUAL
GUIDE D'UTILISATION
MANUAL DE INSTRUCCIONES

DW628

3.5 HP Router
Toupie de 3,5 HP
Rebajadora de 3,5 HP

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

384404/DW628 5/2/02 1:39 PM Page 3

Important Safety Instructions

WARNING: When using electric tools, basic safety precautions
should always be followed to reduce risk of fire, electric shock, and
personal injury, including the following:

READ ALL INSTRUCTIONS

Grounding Instructions

This tool should be grounded while in use to protect the operator from
electric shock. The tool is equipped with a 3-conductor cord and 3­prong grounding type plug to fit the proper grounding type receptacle.
The green (or green and yellow) conductor in the cord is the
grounding wire. Never connect the green (or green and yellow) wire
to a live terminal. If your unit is intended for use on less than 150 V,
it has a plug that looks like that shown in sketch A. If it is for use on
150 to 250 V, it has a plug that looks like that shown in sketch D. An
adapter, sketches B and C, is available for connecting sketch A type
plugs to 2-prong receptacles. The green-colored rigid ear, lug, or the
like, extending from the adapter must be connected to a permanent
ground, such as a properly grounded outlet box. No adapter is
available for a plug as shown in sketch D. ADAPTER SHOWN IN
FIGURES B and C IS NOT FOR USE IN CANADA.

English

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)

SWITCH PROBE

END CAP

RING LOCK

SCRIBE LINE

CLAMP
LEVER

COLLET
ADAPTER

COLLET NUT

SUB BASE

BASE

MOTOR

UNIT

SWITCH

ADJUSTING
RING

AB CD

GROUNDING PIN

GROUNDED

OUTLET

BOX

GROUNDING

MEANS

GROUNDING PIN

ADAPTER

384404/DW628 5/2/02 1:39 PM Page 4

Safety Instructions For All Tools

• 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. Do not use tool in presence of flammable liquids
or gases.

• GUARD AGAINST ELECTRIC SHOCK. Prevent body contact
with grounded surfaces. For example; pipes, radiators, ranges, and
refrigerator enclosures.

• KEEP CHILDREN AWAY. Do not let visitors contact tool or
extension cord. All visitors should be kept away from work area.

• STORE IDLE TOOLS. When not in use, tools should be stored in
dry, and high or locked-up place — out of reach of children.

• 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.

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

• USE SAFETY GLASSES. Also use face or dust mask if cutting
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
times.

• MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for
better and safer performance. Follow instructions for lubricating
and changing accessories. Inspect tool cords periodically and if

damaged, have repaired by authorized service facility. Inspect
extension cords periodically and replace if damaged. Keep
handles dry, clean, and free from oil and grease.

• DISCONNECT OR LOCK OFF TOOLS when not in use, before
servicing, and when changing accessories, such as blades, bits,
cutters.

• 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 tool with finger
on switch. Be sure switch is off when plugging in.

• EXTENSION CORDS. Use only 3-wire extension cords that have
3-prong grounding-type plugs and 3-pole receptacles that accept
the tool’s plug. Replace or repair damaged cords. Make sure your
extension cord is in good condition. 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 American Wire Gage (AWG)
Than Than
0- 6 18161614
6 - 10 18 16 14 12
10- 1216161412
12 - 16 14 12 Not Recommended

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

1

English

384404/DW628 5/2/02 1:39 PM Page 1

removing the motor unit from the base. ALWAYS BE SURE THAT
THE CLAMP LEVER IS IN THE LOCKED (DOWN) POSITION
WHEN ROUTING.

The orientation of the lever can be changed if desired by loosening
the lock nut that fastens it to the router and rotating the lever to the
desired position. Retighten the lock nut.

Sub Base

Turn Off and Unplug Router
The sub base on your router has been specifically designed to permit

better visibility than conventional routers but retain the ability to use
template guides. The guide adapter, if not needed, can be easily
removed for even more visibility. To remove the adapter raise the
Clamp Lever and lift the motor assembly out of the router base. This
will enable you to reach and remove the two screws in the base
which hold the guide adapter in place, as shown in Figure 2.

When you reinstall the motor unit, be sure to align the Guide Screw
(Figure 3) with the slot in the router base.

LOCKING

LEVER

2

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 an authorized service
center unless otherwise indicated elsewhere in this instruction
manual. Have defective switches replaced by authorized service
center. Do not use tool if switch does not turn it on and off.

SAVE THESE INSTRUCTIONS

Motor

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

120 Volts 60Hz or “AC/DC” means your tool may be operating with
alternating or direct current.

Voltage decrease of more than 10% will cause loss of power and
overheating. All D

EWAL Ttools are factory tested; if this tool does not

operate, check the power supply.

Clamp Lever

Turn Off and Unplug Router.
In order to lock the position of the router motor unit in the router base,

a lever has been provided on the side of the tool, as shown in Figure

1.

To lock the motor unit in place, push the lever all the way down; to
release the motor, raise the lever up to about a right angle to the
tool. Use this loosened position for making depth adjustments and

English

FIG. 1 FIG. 2

SUB BASE

GUIDE

ADAPTER

384404/DW628 5/2/02 1:39 PM Page 2

Sub Base Alignment For Template Routing

The guide adapter is aligned with the collet at the time of
manufacture, but the two may become misaligned during shipping
and handling, particularly if the tool is dropped. To properly align the
collet with the guide adapter follow the steps below.

1. Turn Off and Unplug Router.

2. Raise the Clamp Lever and remove the motor unit from the router
base.

3. Remove the Guide Screw and the Adjusting Ring shown in Figure 3.

4. Loosen the 4 screws in the Sub Base, as shown in Figure 4.

5. Re-insert the Guide Screw (not the Adjusting Ring) in the motor
unit and insert the motor unit into the router base. (Make sure
that you align the Guide Screw with the slot in the router base.)

6. Lower the motor unit until the collet adapter extends through the
guide adapter, as shown in Figure 4. Adjust the Sub Base until the
collet adapter fits through it.

7. Tighten the four screws in the Sub Base and remove the motor
unit from the router base.

8. Remove the Guide Screw and re-install the Adjusting Ring.

9. Install the Guide Screw and re-insert the motor unit into the router
base. (Be sure to align the guide screw with the slot in the base.)

10. The template guide is now aligned with the collet.

NOTE: When installing the guide screw in the above section
remember that it must be tightened firmly so that the head is flush
against the side of the motor unit.

Attaching Bits and Cutters

Turn Off and Unplug Router
Insert the shank of the desired bit or cutter into the collect as far as it

will go, then pull it out slightly (about 1/32”,.793 mm). Use the
wrenches provided to securely tighten the collet nut. One wrench
holds the collet adapter and the other tightens the collet nut.

A special coating has been put on the collet and collet nut to increase
the bit holding power. Use only the wrenches provided with your
router to tighten the collet nut. Other tools may damage the coating
through overtightening.

Depth Adjustment

Turn Off and Unplug Router
Loosen the Clamp Lever by raising it fully. Adjust the depth setting of

the router bit by turning the Adjusting Ring shown in Figure 5. To
raise the bit away from the work surface, turn the ring clockwise (as
viewed from the top of the tool) and to lower the bit into the work, turn
it counterclockwise.Directly over the Clamp Lever pivot point is a
line scribed into the aluminum housing, as shown in Figure 5. As the
ring is rotated, the raised lugs on the ring will pass over this line. Each
time a lug passes the line, the bit is raised or lowered 1/64" (.396
mm). Every full revolution of the Adjusting Ring accounts for

3

English

FIG. 3

GUIDE SCREW

ADJUSTING

RING

GUIDE

ADAPTER

COLLET

ADAPTER

FIG. 4

SCREWS

384404/DW628 5/2/02 1:39 PM Page 3

1/8"(3.175 mm) of adjustment either up or down.
The lugs are consecutively numbered for convenience. For faster

adjustments, lift the motor housing slightly and spin the Adjusting
Ring.

Duplicating specific depths of cut, such as hinge butt mortises, can
be done quickly and accurately by following the steps below.

1. TURN OFF AND UNPLUG ROUTER.

2. Lower the router bit until it just touches the workpiece. (Refer to
preceding section on “DEPTH ADJUSTMENT.”)

3. Lock the Clamp Lever

4. Raise the Adjusting Ring by rotating it counterclockwise until the
hinge will just fit between the top edge of the router base and the
bottom of the Adjusting Ring, as shown in Figure 6.

5. Remove the hinge and invert the router to prevent the bit from
marring the work surface.

6. Unlock the Clamp Lever and allow the base to fall to the new
setting. Lock the Clamp Lever in place and the depth is set. The
router will now cut to the exact thickness of the hinge.

Adjusting Ring Lock

Turn Off and Unplug Router.
To prevent the Adjusting Ring from rotating due to vibration of the

router, a nylon set screw has been provided in the ring. When the ring
is set as desired, tighten this set screw, shown in Figure 7. Be careful
to avoid overtightening which will strip the soft nylon screw. The set
screw can be used whenever desired, or never at all.

On/Off Switch

The on/off switch is located on the side of the router, just above the
hand grip, Figure 8. T o turn on the router , raise the on/of f switch lever
with your thumb while gripping the tool. T o turn of f the router, pull the
switch lever down. When the router is running, you will notice a probe

4

English

FIG. 7

OFF

OFF

FIG. 5

FIG. 6

CLAMP
LEVER

ADJUSTING

RING

HINGE

NYLON RING

LOCK

384404/DW628 5/2/02 1:39 PM Page 4