FIG. 1
H
E
F
C
B
A
D
G
or DC .....direct current
or AC/DC......alternating or direct current
...................Class I Construction
no .......................no load speed
.......................(grounded) n
.........................rated
speed
...................Class II Construction
.......................earthing terminal
(double insulated)
........................safety alert symbol
…/min ............per minute
BPM ...................beats per minute
IPM .................impacts per minute
RPM ...................revolutions per minute
SPM ...............strokes per minute
sfpm ...................surface feet per minute
SAVE THESE INSTRUCTIONS FOR FUTURE USE
Motor
Be sure your power supply agrees with the nameplate marking. Voltage decrease of more than
10% will cause loss of power and overheating. D
E
WALT tools are factory tested; if this tool does
not operate, check power supply.
COMPONENTS (Fig. 1)
A. Motor
E. Collet
B. Depth adjusting ring
F. Subbase
C. Fixed base
G. Variable speed switch
D. Clamp
H. OFF/ON switch
INTENDED USE
This heavy-duty router has been designed for professional routing at various work sites (i.e.,
woodworking shops).
DO NOT
use under wet conditions or in presence of flammable liquids or
gases.
This heavy-duty router is a professional power tool.
DO NOT
let children come into contact with
the tool. Supervision is required when inexperienced operators use this tool.
ADJUSTMENTS
WARNING: To reduce the risk of injury, turn unit off and disconnect it from power
source before installing and removing accessories, before adjusting or when making
repairs.
An accidental start-up can cause injury.
WARNING:
To reduce the risk of injury, never modify the power tool or any part of it.
Damage or personal injury could result.
Installing and Removing the Bit (Fig. 2, 3)
WARNING:
Maximum bit capacity is 3-1/2" when used in a table or machining station, and
2-1/2" when hand-held. Keep speed at 10,000 rpm when using bits larger than 3", and no higher
than 13,000 RPM when using bits from 2-1/2" to 3".
WARNING: 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.
NOTICE:
Avoid possible damage to the collet. Never tighten the collet without a bit.
This router can accommodate bits with 1/2” diameter shanks that are installed directly into the
power unit collet. Collets are available that will allow the use of bits having 1/4” and 3/8” diameter
shanks.
1. To remove motor unit from base unit:
(a) Open the clamp screw (D).
(b)
While holding base, turn motor unit counterclockwise until lower pin (I) in motor housing
is disengaged from groove in base.
(c) Lift motor free from base unit.
2. Clean and insert shank of bit into collet at least 3/4" (19 mm). If shank “bottoms” in router,
then back it out approximately 1/16" (16 mm) to allow proper tightening.
3. Lay the motor on its side on a bench with the collet pointing AWAY from you.
4. Place one wrench on flats on chuck with the opposite end of the wrench resting on the bench
to your left.
5. Place other wrench on collet and tighten counterclockwise as shown in fig. 3. Tighten securely.
6. To remove the bit, reverse the above procedure. If bit does not remove easily, tap the collet
nut with wrench to release.
Installing the Motor (Fig. 2)
1. Loosen the clamp screw (D) to allow the motor to be set in the base unit.
2. Insert motor unit into base aligning lower pin (I) with groove in base.
3. Rotate motor unit clockwise into base until upper guide pins are rigidly set in the groove of
the base.
4. Tighten clamp screw firmly.
Adjusting the Depth of Cut (Fig. 4)
1. Loosen clamp screw (D).
2. While holding base (C), turn motor unit (A), counterclockwise until the tip of the bit is above
bottom surface of base.
3. Set router on flat wood surface.
4. Turn motor unit (A) clockwise until bit touches the wood surface.
5. Tighten clamp screw (D).
6. Rotate depth adjusting ring (B) until its zero-line is opposite the index line (J) on the housing.
7. Loosen clamp screw (D).
8. Tip the router so bit is clear of the wood surface. Turn motor unit (A), clockwise until the index
line (J) on the motor housing reaches the desired depth indicated on the ring.
9. Tighten clamp screw (D) firmly.
NOTE:
Setting the index line to 1/4" on the ring means the cutting edge of the bit is exposed
1/4" (6.4 mm) below the base.
OPERATION
WARNING: To reduce the risk of injury, turn unit off and disconnect it from power
source before installing and removing accessories, before adjusting or when making
repairs.
An accidental start-up can cause injury.
WARNING:
To reduce the risk of injury, avoid “Climb-Cutting” (cutting in direction opposite that
shown in Fig. 5). “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.
CAUTION:
To reduce the risk of injury, always be sure the work is rigidly clamped or otherwise
secured before making a cut. Since the cutter rotates clockwise (when viewing router from top),
move the router from left to right as you stand facing the work. When working on the inside of a
template, move the router in a clockwise direction. When working on the outside of a template,
move the router in a counter-clockwise direction.
Connecting to Power Source
CAUTION:
To reduce the risk of injury, before connecting tool to power source, check to see
that the switch is in the "OFF" position. Also, check the power circuit to see that it is the same
as that shown on specification plate of the tool.
Starting and Stopping the Motor (Fig. 1)
CAUTION:
To reduce the risk of injury, before starting the tool, clear the work area of all foreign
objects. Also keep firm grip on tool to resist starting torque.
CAUTION:
To avoid personal injury and/or damage to finished work, always allow the motor
to come to a COMPLETE STOP before putting the tool down.
The router is started and stopped by depressing the rocker switch (H), into the "ON" or "OFF"
position.
Proper Hand Position (Fig. 1)
WARNING:
To reduce the risk of serious personal injury,
ALWAYS
use proper hand position
as shown.
WARNING:
To reduce the risk of serious personal injury,
ALWAYS
hold securely in anticipation
of a sudden reaction.
Proper hand position requires both hands on the both handles of the fixed base (C), with the
router's subbase flat against the workpiece.
Overload Protection (Fig. 1)
WARNING:
To avoid accidental start-up and personal injury, confirm that the switch is OFF and
tool is disconnected from the power source before resetting the circuit breaker.
This router is equipped with overload protection that will shut the motor off if prolonged overload
conditions are encountered. If the motor stops during use, follow these steps:
1. Turn rocker switch (H) to the "OFF" position.
2. Determine cause of overload (i.e. dull bit, low voltage, excessive feed rate, etc.) and correct
before continuing.
3. Restart router following the instructions in
Starting and Stopping the Motor.
Soft Start
The router has a “Soft Start” feature designed to minimize startup reaction torque.
Speed Control (Fig. 1)
WARNING: 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.
WARNING:
Do not operate tools rated “AC only” on a DC supply. Loss of speed control may
result, causing tool damage and possible hazard to the operator.
WARNING:
If the speed control ceases to operate, or is intermittent, stop using the tool
immediately. Take it to a D
E
WALT factory or authorized service facility for repair.
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 variable speed switch (G) control is located as shown. Five operating speeds from
10,000 RPM to 21,000 RPM are available by moving the switch (G). It is recommended that the
speed be set prior to engaging the router bit into work. Should it be necessary to change the
speed after work has begun, stop router, remove router clear of work, and adjust speed setting.
NOTE:
The speeds listed are approximate and are for reference only. Your router may not exactly
produce the speed listed for the dial setting.
The Edge Guide (Fig. 6)
An edge guide is available as an accessory to aid in routing operations such as: straight edge
planing, parallel grooving, dado or slotting operations.
To Assemble:
Insert the guide rods (K) into the holes in the base, Fig. 6, and secure with screws (L). The guide (M)
is adjusted on the rods and secured in desired position with thumb screws (N).
Template Guides (Fig. 7)
A wide variety of template guides are available for use in pattern and template routing operations.
Fig. 7 shows a typical combination bit, template guide, and locknut for the router.
To install, insert template guide in center hole in router base and secure in place with the locknut.
NOTE:
Before connecting the router to the power source, install, the bit, adjust depth of cut, and
rotate the router chuck by hand to be sure the bit or the collet do not contact the template guide.
Router Tables
Your router can be used in a router table. Refer to the router table manual for complete, detailed
set-up instructions.
FIG. 3
FIG. 5
D
FIG. 2
I
B
C
D
A
J
FIG. 4
FIG. 7
1. ROUTER BASE
2. SUB-BASE
3. ROUTER BIT
4. TEMPLET GUIDE
5. LOCKNUT
1. BASE DE LA TOUPIE
2. SOUS-BASE
3. MÈCHE DE TOUPIE
4. GUIDE DE GABARIT
5. CONTRE-ÉCROU
1. BASE DEL REBAJADORA
2. SUB-BASE
3. BROCA
4. GUIA DE PATRON
5. TUERCA INAFLOJABLE
5
2
1
4
3
L
N
FIG. 6
N
M
L
K
