DeWalt DW660 User Manual

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL,
CALL US TOLL FREE AT:

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

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 flam-
mable 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

• Grounded tools must be plugged into an outlet properly installed and grounded in
accordance with all codes and ordinances. Never remove the grounding prong or
modify the plug in any way. Do not use any adaptor plugs. Check with a qualified elec­trician if you are in doubt as to whether the outlet is properly grounded. If the tools

should electrically malfunction or break down, grounding provides a low resistance path to
carry electricity away from the user. Applicable only to Class I (grounded) tools.

• 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 elim-

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

Applicable only to Class II (double insulated) tools.

• 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 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 16 16 14

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. Air vents often cover moving parts and should also be avoided.

• 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 wrenches before turning the tool on. A wrench or a 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 bal-
ance enables better control of the tool in unexpected situations.

• 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 loss of

control.

• Do not force tool. Use the correct tool for your application. The correct tool will do the
job better and safer at 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, chang-
ing 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 tool’s 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.

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 Specific Safety Instructions for Cut-Out Tools

• Hold tool by insulated gripping surfaces when performing an operation where the 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.

WARNING: After changing bits or making any adjustments, make sure the collet nut is

securely tightened to avoid injury.

WARNING: Do not press spindle lock or collet lock buttons while motor is running. The oper-

ator may lose control and drop the tool. Personal injury or serious tool damage may result.

WARNING: Shut off all live electric circuits to any areas where cut outs will be made, to avoid

fire or serious personal injury.

CAUTION: Wear appropriate personal hearing protection during use. Under some con-

ditions and duration of use, noise from this product may contribute to hearing loss.

CAUTION: Do not touch the bit or collet nut during or immediately after cutting material. The

bit and collet nut may be hot enough to burn bare skin.

• Always wear eye protection. Dust mask or hearing protection must be used for appropri­ate conditions. Using personal safety devices is recommended. WORK SAFE.

• Always operate the tool with the depth guide in place. The guide keeps the bit from
plunging too deeply through the material. A minimum of penetration should be maintained to
eliminate the danger of cutting into electric wiring.

• Do not use this tool with drill or screwdriver bits. This tool is not intended to be used as
a drill or screwdriver.

• Be sure your cutting bits are sharp and in good condition. Damaged bits can cause the
tool to jump, injuring the operator.

• Be sure that the motor has stopped completely before you lay the cut-out tool down. If
the cutter head is still spinning when the tool is layed down, it could cause injury or damage.

• Be sure that the cutting bit is clear of the workpiece before starting motor. If the bit is
in contact with the workpiece when the motor starts it could make the tool jump, causing
damage or injury.

• If your tool fails to function properly, take it to an authorized service center. There are
no user serviceable parts inside this tool and it should only be opened by trained service
personnel.

WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other con-

struction activities contains chemicals known to cause cancer, birth defects or other reproduc­tive harm. Some examples of these chemicals are:

• lead from lead-based paints,

• crystalline silica from bricks and cement and other masonry products, and

• arsenic and chromium from chemically-treated lumber (CCA).

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 pro-

mote absorption of harmful chemicals.

WARNING: Use of this tool can generate and/or disburse dust, which may cause serious and

permanent respiratory or other injury. Always use NIOSH/OSHA approved respiratory protection
appropriate for the dust exposure. Direct particles away from face and body.

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

V ......................volts A ......................amperes

Hz ....................hertz W......................watts

min ..................minutes ....................alternating current

..................direct current no....................no load speed

......................Class II Construction ......................earthing terminal

....................safety alert symbol .../min ..............revolutions per minute

To Maintain Safe Tool Control

• Make sure the work surface is free of nails or screws. Cutting into a nail or screw may
cause the tool to jump, damaging the bit.

• Never operate the tool with one hand while holding the workpiece with the other hand.

Always clamp the material and guide the tool with both hands.

• Do not cut material lying on a hard surface. Clearance behind material to be cut must be
allowed for protruding bit.

• Disconnect plug from power supply before making adjustments, changing bits or cleaning
tool.

• Do not start the tool with bit engaged in the material. The bit may grab the material.

Motor

Be sure your power supply agrees with nameplate marking. 120 volts AC means your tool may
be operated only with alternating current and never with direct current.

Switch

To start the motor, slide the switch (A) to “I” position. To stop the motor, slide the switch to “O”
position (Fig. 1).

Installing and Removing the Bit (Fig. 2)

This tool has a tool-free bit change system. To change bits, FIRST turn off the tool and discon­nect from power supply. Remove the guide.

DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286

(OCT04-CD-1) Form No. 626760-00 DW660 Copyright © 2000, 2004 D

EWALT

The following are trademarks for one or more D

EWALT power tools: the yellow and black color scheme;

the “D” shaped air intake grill; the array of pyramids on the handgrip; the kit box configuration; and the
array of lozenge-shaped humps on the surface of the tool.

DW660

Heavy-Duty Cut-Out Tool

Outil a Decouper à Service Intensif

Recortadora industrial

Questions? See us in the World Wide Web at www.dewalt.com

INSTRUCTION MANUAL

GUIDE D'UTILISATION

MANUAL DE INSTRUCCIONES

INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y PÓLIZA

DE GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUCTIVO ANTES

DE USAR EL PRODUCTO.

FIG. 5

H

L

M

N

FIG. 6

1. To replace bit, depress both spindle lock (C) and collet lock (B) and turn collet grip counter­clockwise.

2. Insert bit.

WARNING: The bits are sharp and should be handled with great care.
CAUTION: When replacing bits, do not insert cutting flutes into the collet. This may result in

broken bits.

3. While depressing both spindle and collet locks, turn the collet grip clockwise to firmly tighten
the collet. For some heavy duty applications, it may be necessary to use a wrench to further
tighten the nut (D) while depressing the spindle lock (C).

4. Attach guide.

CAUTION: Never tighten the collet without a bit installed.

This tool comes with both 1/8" and 1/4" collets. To change collets, remove the collet nut and
insert the desired collet.

Depth Guide (Fig. 3)

To attach depth guide to the motor unit,

TURN OFF TOOL AND DISCONNECT FROM POWER

SUPPLY.

Depth guide snaps onto locators as shown. Keep depth guide in place at all times during oper­ation of the tool. For best results, adjust the guide using knob (E) to allow the bit to protrude
about 1/8" past the material to be cut.

Side Handle DW6619 (Fig. 4)

When operating the tool, use the side handle for optimum control. To attach the side handle to
the motor unit,

TURN OFF TOOL AND DISCONNECT FROM POWER SUPPLY.

1. Remove depth guide.

2. Loosen knob (F) until the collar of the tool is able to fit into the strap (G) of the side handle.

3. Align the locator on the tool with the locator on the side handle. (Detail) Tighten knob (F).

4. Snap the depth guide over the side handle strap (G) from the opposite side. Keep the depth
guide in place at all times during operation of the tool.

5. For best results, adjust the guide using knob (E) to allow the bit to protrude about 1/8"
through the material to be cut.

6. To remove the side handle, remove the depth guide, loosen the knob (F) until the tool can
come off the locator and slip out of the strap (G).

7. Reattach the depth guide.

Circle Cutter DW6621 (Fig. 5)

To attach the circle cutter to the motor unit,

TURN OFF THE TOOL AND DISCONNECT FROM

POWER SUPPLY.

1. Remove the depth guide.

2. Loosen knob (H) until the collar of the tool is able to fit into the strap (J) of the circle cutter.

3. Align the locator on the tool with the locator on the circle cutter. (Detail) Tighten knob (H).

4. Disassemble the depth guide collar. Snap the upper half (M) onto the strap (J).

5. Loosen knob (L) and extend circle cutter frame to the limit of travel.

6. Insert knob (E) through the frame (N).

7. Set depth of cut for your material and tighten knobs (E) and (L).

8. Measure to the center of the circle you wish to cut and adjust the length of the guide to that
radius.

9. Tighten the knob (O) holding the centerpoint in position.

10. Drill a 5/32" hole in the material to be cut at the center of the radius.

11. Plug in the tool, start the motor and allow the tool to spin up to speed.

12. Position the center point into the hole and plunge the cutter into the material.

13. With firm pressure, hold the center point in place and move the cutter counterclockwise
around to the finish.

CAUTION: At the finish of the circle, the material may drop out. Hold the tool with both hands

to maintain control.

14.To remove the circle cutter, loosen knob (H) until the tool can come off the locator and slip
out of the strap (J).

15.Reassemble the depth guide and reattach.

Operation

CUTTING A HOLE FOR AN ELECTRICAL OUTLET (FIG. 6)

WARNING: Shut off all live electric circuits to any areas where cut outs will be made.

1. Push any wiring deeply into the outlet box to avoid damage from the cutting bit.

2. Before hanging the sheet covering the outlet, mark the approximate location of the center of
the outlet on the wall board. Check the cutting bit depth against the side of the board to be
sure it will cut entirely through the material.

3. Tack the sheet in place with a few fasteners avoiding the stud holding the outlet. This allows
the wall board to flex slightly around the protruding fixture box.

4. Turn the cut-out tool on. Holding the tool firmly with both hands, (Fig. 6) plunge the bit
straight into the center of the outlet.

5. Cut to the right until the edge of the box is touched. Pull out just enough for the bit to clear
the edge of the box. Plunge in again holding the bit gently against the outside of the box.

6. Follow the outside of the box as shown keeping slight pressure against the box. This will
minimize wandering and give you a clean precise cut.

7. Remove the waste and dust from the outlet. Finish fastening the sheet of wall board.

Maintenance

The tool should be cleaned with a blast of air at least once a week, to eject as much dust as
possible. This will increase the life of the brushes and bearings inside the motor. Always use
appropriate safety equipment when using compressed air to clean a tool.

Although the tool’s plastic case is solvent resistant, you should never use solvents or harsh
chemicals to clean it. Wipe the non-metallic parts of the tool with a dry cloth.

Lubrication

All bearings are factory lubricated for the life of the tool.

Accessories

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 Co., 701 East Joppa Road, Baltimore, MD 21286.

CAUTION: Do not use double ended bits. The use of any other accessory not recommended

for use with this tool could be hazardous.

Repairs

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

Three Year Limited Warranty

DEWALT will repair, without charge, any defects due to faulty materials or workmanship for three
years from the date of purchase. This warranty does not cover part failure due to normal wear
or tool abuse. For further detail of warranty coverage and warranty repair information, visit
www.dewalt.com or call 1-800-4-D

EWALT (1-800-433-9258). 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, D

EWALT tools are covered by our:

1 YEAR FREE SERVICE

D

EWALT will maintain the tool and replace worn parts caused by normal use, for free, any time

during the first year after purchase.

90 DAY MONEY BACK GUARANTEE

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

EWALT Power Tool, Laser, or

Nailer for any reason, you can return it within 90 days from the date of purchase with a receipt
for a full refund – no questions asked.

FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are miss­ing, call 1-800-4-D

EWALT for a free replacement.

FIG. 1 FIG. 2

D

C

B

A

“O”

“I”

COLLET GRIP

DOUILLE DE

SERRAGE

ABRAZADERA

DEL COLLAR

GUIDE

GUIDE

GUÍA

FIG. 3

FIG. 4

E

LOCATOR

POSITIONNEUR

LOCALIZADOR

POUR TOUTE QUESTION OU REMARQUE AU SUJET DE CET OUTIL OU DE TOUT
AUTRE OUTIL D

EWALT, COMPOSER LE NUMÉRO SANS FRAIS : 1 800 4-DEWALT

(1 800 433-9258)

Directives de sécurité d’ordre général

AVERTISSEMENT! S’assurer de lire et de bien comprendre toutes les
directives. Le non-respect des directives décrites ci-après pourrait être la

cause de chocs électriques, d’incendies et/ou de blessures graves.

CONSERVER CES DIRECTIVES

AIRE DE TRAVAIL

• L’aire de travail doit être propre et bien éclairée. Les établis encombrés et le manque de

lumière peuvent entraîner des accidents.

• Ne pas faire fonctionner des outils électriques dans des atmosphères explosives,
comme en présence de liquides, de gaz et de poussières inflammables. Les outils élec­triques produisent des étincelles qui peuvent enflammer la poussière ou les vapeurs.

• Tenir les spectateurs, les enfants et les visiteurs à l’écart lorsqu’on utilise l’outil. Les
distractions peuvent entraîner une perte de maîtrise.

RÈGLES DE SÉCURITÉ RELATIVES À L’ÉLECTRICITÉ

• Les outils mis à la terre doivent être branchés dans une prise correctement installée
et mise à la terre tel que l’indiquent les codes et règlements en vigueur. Ne jamais retir­er la broche de mise à la terre ou modifier la prise en aucune façon. Ne pas utiliser de
fiche d’adaptation. Consulter un électricien qualifié s’il y a un doute en ce qui con­cerne la mise à la terre de la prise. En cas de mauvais fonctionnement ou de bris des out-

ils, la mise à la terre offre un chemin de faible résistance afin d’empêcher l’électrocution de
l’utilisateur. S’applique uniquement aux outils de classe I (mis à la terre).

• Les outils à double isolation sont pourvus d’une fiche polarisée (une lame est plus

large que l’autre). Cette fiche ne peut être branchée dans une prise polarisée que dans
un seul sens. Si la fiche ne peut être branchée dans la prise, inverser la fiche. Si on
n’arrive pas à la brancher, communiquer avec un électricien qualifié afin qu’il installe
une prise polarisée. Ne pas modifier la fiche. La double isolation élimine le besoin du

système de rallonge d’alimentation à trois fils et de bloc d’alimentation avec mise à la terre.

S’applique uniquement aux outils de classe II (à double isolation).

• Éviter tout contact corporel avec des surfaces mises à la terre, comme des tuyaux,
des radiateurs, des cuisinières et des réfrigérateurs. Le risque de choc électrique aug-

mente si le corps est mis à la terre.

• Ne pas exposer les outils électriques à la pluie ou à l’eau. L’infiltration d’eau dans un outil
électrique augmente le risque de choc électrique.

• Manipuler le cordon avec soin. Ne jamais s’en servir pour transporter l’outil ou pour
tirer la fiche hors de la prise. Tenir le cordon à l’écart de la chaleur, de l’huile, des arêtes
vives ou des pièces mobiles. Remplacer immédiatement les cordons endommagés, car ils
augmentent le risque de choc électrique.

• Lorsqu’on utilise un outil électrique à l’extérieur, il faut employer une rallongeportant
l’inscription “W-A” ou “W.” Ces rallonges sont conçues pour l’utilisation à l’extérieur et

réduisent le risque de choc électrique. S’il y a lieu d’utiliser une rallonge, s’assurer que celle­ci est de calibre suffisamment élevé pour acheminer le courant nécessaire au fonctionnement
de l’outil. Une rallonge de calibre trop faible pourrait causer une chute de tension se traduisant
par une perte de courant et une surchauffe. Le tableau qui suit indique le calibre approprié
selon la longueur de la rallonge et l’intensité indiquée sur la plaque signalétique. En cas de
doute, utiliser le calibre supérieur suivant. Plus le numéro de calibre est petit, plus le calibre
de la rallonge est élevé.

Calibre minimal des cordons de rallonge

TensionLongueur totale du cordon en meters

120 V De 0 à 7 De 7 à 15 De 15 à 30 De 30 à 45
240 V De 0 à 7 De 7 à 15 De 15 à 39 De 30 à 45

Intensité (A)

Au Au Calibre moyen de fil

moins plus

0-6 18 16 16 14

SÉCURITÉ PERSONNELLE

• Demeurer alerte, prêter attention à ce que l’on fait et faire preuve de bons sens
lorsqu’on utilise un outil électrique. Ne pas utiliser un outil lorsqu’on ressent de lafa­tigue ou après avoir consommé des drogues, de l’alcool, ou des médicaments. Un

moment d’inattention durant l’utilisation d’outils électriques peut entraîner de graves blessures.

• Porter des vêtements appropriés. Ne pas porter des vêtements amples ou des bijoux.

Les cheveux longs doivent être retenus. Tenir les cheveux, les vêtements et les gants

F

G

LOCATOR

POSITIONNEUR

LOCALIZADOR

LOCATOR

POSITIONNEUR

LOCALIZADOR

J

E

O