Dewalt DWE625 3 Peak HP Electronic Variable Speed Plunge Router Instruction Manual

DEWALT DWE625 3 Peak HP Electronic Variable Speed Plunge Router

Technical Data

The vibration and/or noise emission level given in this information sheet has been measured in accordance with a standardised test given in EN62841 and may be used to compare one tool with another. It may be used for a preliminary assessment of exposure.
WARNING: The declared vibration and/or noise emission level represents the main applications of the tool. However if the tool is used for different applications, with different accessories or poorly maintained, the vibration and/or noise emission may differ. This may significantly increase the exposure level over the total working period. An estimation of the level of exposure to vibration and/or noise should also take into account the times when the tool is switched off or when it is running but not actually doing the job. This may significantly reduce the exposure level over the total working period. Identify additional safety measures to protect the operator from the effects of vibration and/or noise such as: maintain the tool and the accessories, keep the hands warm (relevant for vibration), organization of work patterns.

EC-Declaration of Conformity

Plunge Router
DEWALT declares that these products described under Technical Data are in compliance with: 2006/42/EC, EN62841‑1:2015 + AC:2015; EN62841‑2‑17:2017. These products also comply with Directive 2014/30/EU and 2011/65/EU. For more information, please contact DEWALT at the following address or refer to the back of the manual. The undersigned is responsible for compilation of the technical file and makes this declaration on behalf of DEWALT.

Definitions: Safety Guidelines
The definitions below describe the level of severity for each signal word. Please read the manual and pay attention to these symbols.

• DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
• WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
• NOTICE: Indicates a practice not related to personal injury which, if not avoided, may result in property damage.

GENERAL POWER TOOL SAFETY WARNINGS

WARNING: Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.

Work Area Safety

• a ) Keep work area clean and well lit. Cluttered or dark areas invite accidents.
• b ) 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.
• c ) Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

Electrical Safety

• a ) Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.
• b ) Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
• c ) Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
• d ) Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock.
• e ) When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock. f ) If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.

Personal Safety

• a ) Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.
• b ) Use personal protective equipment. Always wear eye protection. Protective equipment such as a dust mask, non‑skid safety shoes, hard hat or hearing protection used for appropriate conditions will reduce personal injuries
• c ) Prevent unintentional starting. Ensure the switch is in the off‑position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energising power tools that have the switch on invites accidents.
• d ) Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.
• e ) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
• f ) Dress properly. Do not wear loose clothing or jewellery. Keep your hair and clothing away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts.
• g ) If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust‑related hazards.
• h ) Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.

Power Tool Use and Care

• a ) Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.
• b ) Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
• c ) Disconnect the plug from the power source and/ or remove the battery pack, if detachable, from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.
• d ) Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.e ) Maintain power tools and accessories. Check for  misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
• f ) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
• g ) Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.
• h ) Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

Service

• a ) Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

Safety Instructions for Routers

• a ) Hold the power tool by insulated gripping surfaces only, because the cutter may contact its own cord. Cutting a “live” wire may make exposed metal parts of the power tool “live” and could give the operator an electrical shock.
• b ) Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by your hand or against the body leaves it unstable and may lead to loss of control.c ) Keep handles dry, clean and free from oil and grease. This will enable better control of the tool.
• d ) Maintain a firm grip with both hands on the tool to resist starting torque. Maintain a firm grip on the tool at all times while operating.
• e ) Keep hands away from cutting area above and  below the base. Never reach under the workpiece for any reason. Keep the router base firmly in contact with the workpiece when cutting.
• f ) Never touch the bit immediately after use. It may be extremely hot.
• g ) Be sure that the motor has stopped completely before you lay the router down. If the bit is still spinning when the tool is laid down, it could cause injury or damage.
• h ) Be sure that the router bit is clear of the workpiece before starting the motor. If the bit is in contact with the workpiece when the motor starts, it could make the router jump, causing damage or injury.
• i ) The permitted speed of the cutting bit must be at least equal to the maximum speed marked on the power tool. If cutting bits run faster than their rated speed, they may break and fly off.
• j ) 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.
• k ) Do not use router bits with a diameter in excess of 50 mm (2″) in this tool.

Residual Risks
WARNING: We recommend the use of a residual current device with a residual current rating of 30mA or less.
In spite of the application of the relevant safety regulations and the implementation of safety devices, certain residual risks cannot be avoided. These are:

• Impairment of hearing.
• Risk of personal injury due to flying particles.
• Risk of burns due to accessories becoming hot during operation.
• Risk of personal injury due to prolonged use.

Electrical Safety
The electric motor has been designed for one voltage only. Always check that the power supply corresponds to the voltage on the rating plate.

Mains Plug Replacement (U.K. & Ireland Only)
If a new mains plug needs to be fitted:

• Safely dispose of the old plug.
• Connect the brown lead t o the live terminal in the plug.
• Connect the blue lead to the neutral terminal.

WARNING: No connection is to be made to the earth terminal. Follow the fitting instructions supplied with good quality plugs. Recommended fuse for 230V U.K. plug: 13 A.

Fitting a Mains Plug to 115 V Units (U.K. and Ireland Only)

• The plug fitted should comply with BS EN 60309 (BS4343), 32 Amps.

WARNING: Always ensure that the cable clamp is correctly and securely fitted to the sheath of the cable.

Using an Extension Cable
If an extension cable is required, use an approved 3–core extension cable suitable for the power input of this tool (see Technical Data).The minimum conductor size is 1.5 mm2; the maximum length is 30 m. When using a cable reel, always unwind the cable completely.

Package Contents

The package contains:

• 1 Router
• 1 Collet 12 mm (1/2″ UK & ROI)
• 1 Parallel fence
• 2 Guide rods
• 1 Guide bush (30 mm)
• 1 22 mm wrench
• 1 SA Dust extraction tube
• 1 Remote Switch Box (DWE627 only) 1 Instruction manual
• 1 Fine adjustment
• Check for damage to the tool, parts or accessories which may have occurred during transport.
• Take the time to thoroughly read and understand this manual prior to operation.

Description

WARNING: Never modify the power tool or any part of it. Damage or personal injury could result.

1. Speed control wheel
2. Main handles
3. On/off trigger switch
4. Thumbwheel
5. Height stop rod
6. Plunge lock lever
7. Quick-release button
8. Spindle lock button
9. Collet assembly
10. Baseplate
11. 11 Multiple position turret stop
12. Depth stop bar
13. 22 mm wrench
14. Quick zero-reset ring
15. Quick height adjuster lock
16. Quick height adjuster
17. Pointer
18. Fine adjuster
19. Fine zero-reset ring
20. Lock-on button switch

Intended Use
The DWE625 and DWE627 routers have been designed for professional heavy duty routing of wood, wood based materials and plastics. These routers are intended for routing grooves, edges, profiles and slots as well as copy routing.
DO NOT use under wet conditions or in the presence of flammable liquids or gases. The DWE625 and DWE627 are professional power toolsl. The DWE627 is designed so that it can be installed into a router table. The router may only be installed in tables that meet the legal safety requirements for router tables.
DO NOT let children come into contact with the tool. Supervision is required when inexperienced operators use this tool.

• Young children and the infirm. This appliance is not intended for use by young children or infirm persons without supervision.
• This product is not intended for use by persons (including children) suffering from diminished physical, sensory or mental abilities; lack of experience, knowledge or skills unless they are supervised by a person responsible for their safety. Children should never be left alone with this product.

Plunge Lock Lever (Fig. B)

The plunge lock lever  6  allows you to stop the working bit at a specified height.

1.  Press down the plunge lock lever  6  until you hear an audible “Click” when you want to lower the router bit into the workpiece.
2.  You can lower the unit until it reaches your preset stop.
3.  To lock the tool in place along its vertical travel, press quick release button  7 .

Collets (Fig. C)

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.
CAUTION: Never tighten the collet without first installing a router bit in it. Tightening an empty collet, even by hand, can damage the collet. A collet is included with this router.

• 12 mm : Europe
• 1/2” : Great Britain

1.  To change collets  35 , unscrew the collet assembly  9 .
2.  Sharply pull the old collet out of the collet nut  36  and insert the new collet  35 .
3.  Push firmly so that the new collet snaps past the retainer spring in the collet nut.

Multiple Position Turret Stop (Fig. E)

WARNING: Do not change the turret stop while the router is running. This will place your hands too near the cutter head. The turret stop  11  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  12 .

1.  Routing depth can be set by selecting the screw of the appropriate length on the turret.
2.  The turret is rotatable with detent stops to properly align the screws.
3.  It is the interaction of the depth stop bar and the turret stop that determine the routing depth.
4.  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 with the an 8 mm wrench  55  .
5.  Refer to section Setting the Routing Depth for instructions on how to use the turret stop in an actual operation.

Height Stop Rod and Height Stop Thumb Wheel (Fig. G)
The height stop rod  5  and thumb wheel  4  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 80 mm (3‑5/32″) above the workpiece. For convenience, the thumb wheel is equipped with a quick release button  23  that allows you to disengage the threads for fast positioning by simply depressing the button in the side of the wheel.
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.

ASSEMBLY AND ADJUSTMENTS

WARNING: To reduce the risk of serious personal injury, turn tool off and disconnect tool from power source before making any adjustments or removing/installing attachments or accessories. An accidental start‑up can cause injury.

Installing and Removing a Cutter (Fig. C, F)

• WARNING: Do not tighten the collet without a cutter fitted.
• WARNING: Always use cutters with shanks which match the diameter of the collet.
• WARNING: Do not use cutters larger than 50 mm (2″) unless the router is fitted in a router table.
• CAUTION: Care should be taken when removing cutter to avoid cuts to fingers.

Installing a Cutter

1.  Insert at least three fourths of the shank length of the cutter into the collet assembly  9 .
2.  Press the spindle lock  8  forward until the router spindle is locked. NOTE: You may need to turn the spindle slightly to engage it.
3.  Turn the collet nut  36  counterclockwise with the supplied 22 mm wrench  13  to tighten it.

Removing a Cutter

1.  Press the spindle lock button  8  forward until the router spindle is lock.
2.  Turn the collet nut  9  clockwise with the supplied 22 mm wrench  13  to loosen.
3.  Keep turning the wrench until the collet nut tightens and then loosens again. This is the fail‑safe mechanism releasing the collet.
4.  The cutter should now slide out. NOTE: Each time you finish using a cutter, remove it and store it in a safe place.

Fine Height Adjuster (Fig. A, D, E)

CAUTION: Ensure that the plunge locking lever is unlocked. Never use unnecessary force to rotate the fine height adjuster mechanism.
CAUTION: Do not remove the screw on hex nuts. The fine height adjuster can be used in portable mode or when the router is held inside a table

Adjusting the Depth of Cut 
Your router is equipped with a high‑precision depth adjustment system including a zero reset ring for both the quick height adjuster and the fine height adjuster. Quick Adjustment Using the Graduation with Zero Reset Ring

1.  Loosen the depth stop quick height adjuster knob  15 .
2.  Unlock the plunge limiter by pushing the release lever 6 down.
3.  Lower the router carriage until the cutter is in contact with the workpiece.
4.  Press the quick locking button  7 .
5.  Set the quick height adjuster  16  to zero and reset the fine adjust reset ring  19  to zero. The depth stop bar  12  must be in contact with the turret stop  11 .
6.  Adjust the depth of cut using the quick height adjuster  16  and the corresponding graduation. The adjusted depth of cut is indicated by the pointer  17 .
7.  Tighten the quick height adjuster lock  15 .

Fine Adjustment
When not using a depth template, or if the depth of cut needs readjustment, it is recommended to use the fine height adjuster 18 .

1.  Adjust the depth of cut as described in Adjusting the Depth of Cut.
2.  Set the fine height adjuster to zero using the fine zero reset ring 19
3.  Rotate the fine height adjuster  18  to the required position: one turn corresponds to approximately 1 mm and 1 mark to 0.1 mm.

Fitting a Guide Bush (Fig. H)

Together with a template, guide bushes play a valuable part in cutting and shaping to a pattern.

• Fit the guide bush  24  to the router base  10  using the screws  25  as shown.

Fitting the Parallel Fence (Fig. I, J)

1.  Fit the guide rod  26  to the router base  10 .
2.  Slide the parallel fence  27  over the rods.
3.  Tighten the wing bolts  28  temporarily.

Adjusting the Parallel Fence (Fig. A)

1.  Draw a cutting line on the material.
2.  Lower the router carriage until the cutter is in contact with the workpiece.
3.  Push quick release button  7  and limit the carriage return using the thumb wheel  4 .
4.  Position the router on the cutting line.
5. Slide the parallel fence  27  against the workpiece and tighten the wing bolts  28 .
6.  Adjust the parallel fence using the fine adjustment knob  29 . The outer cutting edge of the cutter must coincide with the cutting line.
7.  If required, loosen the screws  30  and adjust the strips  31  to obtain the desired guiding length.

Dust Extraction (Fig. K, P)
Dust from materials such as lead‑containing coatings and some wood types, can be harmful to one’s health. Breathing in the dust can cause allergic reactions and/or lead to respiratory infections of the user or bystanders. Certain dust, such as oak or beech dust, is considered carcinogenic, especially in connection with wood‑treatment additives. Observe the relevant regulations in your country for the materials to be worked. The vacuum cleaner must be suitable for the material being worked. When vacuuming dry dust that is especially detrimental to health or carcinogenic, use dust class M vacuum cleaner.

Connecting Dust Extraction Adaptor (Fig. K)
The dust extraction adaptor consists of a main section  32 , a cover  33 , an extraction tube adaptor  34  , one extraction tube screw  37 , two base screws  52  and two nuts  53  .

1.  Slide the cover  33  onto the main section  32  until it clicks into place.
2.  Place the main section  32  on the base and secure with two screws  52  and nuts  53 .
3.  Remove screw  37  from the top of the router and use this screw to assemble the extraction tube adaptor  34  to the router.

Connecting Dust Extractor Hose (Fig. P)
WARNING: Risk of dust inhalation. To reduce the risk of personal injury, ALWAYS wear an approved dust mask. A dust extraction tube adaptor  34  is supplied with your tool. Vacuum hoses on most vacuum extractors will fit directly into the dust extraction spout.
WARNING: ALWAYS use a vacuum extractor designed in compliance with the applicable directives regarding dust emission when sawing wood. Vacuum hoses of most common vacuum cleaners will fit directly into the dust extraction outlet.

1.  Connect a dust extractor hose  38  to the extraction tube adaptor  34  using the DEWALT AirLock system.

NOTE: When using dust extraction, be sure that the dust extractor is out of the way and secure so that it will not tip over or interfere with the router or workpiece. The dust extractor hose and power cord must also be positioned so that they do not interfere with the router or workpiece. If the dust extractor or dust extractor hose cannot be positioned properly, it should be removed.

OPERATION

Instructions for Use
WARNING: Always observe the safety instructions and applicable regulations.
WARNING: To reduce the risk of serious personal injury, turn tool off and disconnect tool from power source before making any adjustments or removing/installing attachments or accessories. An accidental start‑up can cause injury.

Proper Hand Position (Fig. O)

WARNING: To reduce the risk of serious personal injury, ALWAYS use proper hand position as shown. 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 main handles 2.

Using the Router (Fig. L)
CAUTION: Turn the router on before plunging the cutter head into the workpiece.

• Excessive cutting may cause an overload of the motor or difficulty in controlling the tool, the depth of cut should not be more than 15 mm (19/32″) at a pass when cutting grooves with a 8 mm (5/16″) diameter bit.
• When cutting grooves with a 20 mm (25/32″) diameter bit, the depth of cut should not be more than 5 mm (3/16″) at a pass.
• For extra deep grooving, make two or three passes with progressively deeper bit settings.
• After long periods of working at low speeds, allow the machine to cool down by running it for three minutes at maximum speed, with no load.

All common routing tasks can be performed with the plunge cut router on all types of wood and plastic:

• Grooving
• Rabbeting
• Recessing
• Veining
• Profiling

To prevent overload of the tool by using the wrong speed selection, follow the reccommended settings below:

NOTE: Only carbide‑tipped cutters should be used on panels faced with plastic laminates. The hard laminates will quickly dull steel cutters.
NOTE: For better plunge sliding movement, frequently clean the columns of dust or debris. If the plunging movement is not moving as smooth as desired, lubricate the columns with a dry teflon lubricant.

1.  After setting the cutting depth as described, locate the router such that the bit is directly over the place you will be cutting.
2.  With the router running, lower the unit smoothly down into the workpiece. DO NOT JAM THE ROUTER DOWN.
3.  When the tool reaches the pre‑set depth, push the quick release button  7  to lock.
4.  When you have finished routing, push the plunge lock lever  6  to unlock and let the spring lift the router directly out of the workpiece.
5.  Always feed the router opposite to the direction in which the cutter is rotating. Refer to Fig. L.

On/Off Trigger Switch (Fig. A)

WARNING: To reduce the risk of serious personal injury, turn unit off and disconnect it from power source before making any adjustments or removing/installing attachments or accessories. An accidental start‑up can cause injury.

1.  To turn the unit on, squeeze the on/off trigger switch  3 . Continue to squeeze the trigger switch or press the lock-on button switch  20  for continuous running.
2.  To turn the unit off:
   • A . If the lock on the trigger is engaged, release the lock on the button by squeezing and releasing the trigger.
   • B . If the lock on switch is not engaged, fully release the trigger.

Variable Speed Dial
WARNING: If the speed control ceases to operate, or is intermittent, stop using the tool immediately. Take it to a DEWALT 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.
Refer to the Speed Selection Chart to choose a router speed. Turn the speed dial  1  to control router speed. The speed is variable from 9000 to 22000 rpm using the speed dial  1 .

1.  Turn the speed dial to the required position. The dial is numbered from 1 –7 and corresponds to router speeds of 9000 rpm to 22000 rpm.
2.  Use the slower settings for large diameter cutters and the faster settings for small diameter cutters.
3.  The correct setting will also depend on the density of the material, depth of cut and feed speed of the router. NOTE: A noticeable loss of motor rpm means
   motor overload.

SPEED SELECTION CHART

The speeds in this chart are approximate and are for reference only. Your router may not produce the exact speed listed for the dial setting.
WARNING: Always follow the bit manufacturer’s speed recommendations as some bit designs require specific speeds for safety or performance.

Setting Plunge Lock System
The plunge is fully automatic locking for all cuts. For heavy cut operations, ensure to push the lever towards the tool body. The plunge lock lever  6  position is set at the factory so the lever does not touch the motor body, if the plunge lock lever begins to hit the body when the quick-release lever is pushed, readjust the locking lever position as follows:

1.  Push in the quick-release button  7 . The plunge lever lock will unlock automatically.
2.  Using a Torx 20 star bit  39 , loosen the shoulder screw  54  on the plunge lock lever  6  with six counterclockwise turns. Do not fully remove.
3.  Lift the plunge lock lever, rotate and reposition the plunge lock lever at position 2 (at eleven o’clock).
4.  Tighten the shoulder screw.
5. If after setting to position 2 sliding is not correct, repeat steps 1 to 3 and reposition the lock lever at position 1. Tighten the shoulder screw.

Setting the Routing Depth

1.  Place the router with the cutter fitted on to the workpiece.
2.  Set the multiple position turret stop  11  as required.
3.  Loosen the knob quick adjustment  15  securing the depth stop 12 .
4.  Push down the plunging lock lever  6  to start plunging.
5.  Lower the router slowly until the cutter touches the workpiece and secure it in place by pushing quick release button 7 .
6.  Rotate the quick height adjuster  16  until the depth stop bar  12  touches multiple turret stop  13  . Secure in position by tightening the quick height adjuster lock  15 .
7.  If the depth of cut needs re‑adjustment, it is recommended to use quick depth adjuster  16  for gross settings, or the fine height adjuster for accurate settings.
8.  Adjust the depth of cut using the fine height adjuster  18  NOTE: One turn of the fine height adjuster  18  corresponds to 1 mm (3/64″), one turn of the quick height adjuster  15  corresponds to 40 mm (1‑1/2″)
9.  Read the depth of cut using the quick zero reset ring  14  and fine zero reset ring  19 .
10.  The distance between the top of the revolving depth stop and the bottom of the depth stop is the required depth of cut.
11.  The rotating turret stop screws  11  can be used for setting up to three depths of cut. The height can be adjusted using a flat screwdriver and a 8 mm (5/16″) wrench.
    NOTE: By rotating the turret stop, three depth settings can be quickly made.

Fine Height Adjuster (Fig. D)
This router has a built in fine height adjuster. This should be used when fine height adjustment of the cutter is required. This is especially recommended when using dovetail jigs or router tables.

Direction Of Feed (Fig. L)

WARNING: Avoid climb‑cutting (cutting in direction opposite than shown in Fig. L). 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. The direction of feed is very important when routing and can make the difference between a successful job and a ruined project. Fig. L show proper direction of feed for most cuts. When routing along an edge, the direction of the router  travel should be against that of the rotation of the cutter. This will create the correct cutting action and prevent the cutter from snatching. It will also pull the router towards the workpiece and the side fence or guide bearing will be less likely to wander from the edge of the workpiece.

Feed Speed
The speed at which the cutter is fed into the wood must not be too fast that the motor slows down, or too slow that the cutter leaves burn marks on the face of the wood.
NOTE: Practice judging the speed by listening to the sound of the motor when routing.

Sequence of Plunging
WARNING: When routing always lock the plunge locking lever.

1.  Plunge down and lock the motor carriage, by pushing quick-release button  7.
2.  Perform the desired routing operation.
3.  Push down the plunge lock lever  6  and the motor carriage returns to the normal position.

Using a Side Fence (Fig. M)

CAUTION: Ensure working position is comfortable and at a suitable working height.

1.  Ensure the wing bolts  28  are fully released. Slide the guide rods  26  into the routing base  10  and tighten the wing bolts.
2.  Adjust the fence fine adjustment knob  29  to the required distance and clamp in place with the wing bolts  28 .
3.  Then lower the cutter height until the cutter is just above the workpiece.
4.  Fine adjustments are possible by loosening the wing bolt  28  and adjusting the side fence fine adjustment knob 29 .
5.  Tighten the wing bolt  28  to secure the position.
   NOTE: One revolution of the side fence fine adjustment knob  29  equals 3/64″ (1.0 mm) of side feed.
6.  Lower the cutter onto the workpiece and set the cutter height by to the required distance. Refer to Setting the Router Depth.
7.  Switch the router on and after the cutter reaches full speed, gently lower the cutter into the workpiece and lock the plunge.
8.  Feed along the workpiece, keeping sideways pressure to ensure the side fence does not wander away from the workpiece edge and downward pressure on the inside hand to prevent the router from tipping.
9.  When finished, raise the router, secure with the plunge locking lever  6  and switch the router off.
   NOTE: When starting the cut, keep the pressure on the front cheek until the back cheek contacts the workpiece edge. NOTE: At the end of the cut, keep pressure on the back cheek until the cut is finished. This will prevent the router cutter swinging in at the end of the workpiece and nipping the corner.

Side Fence Routing (Fig. I, J)
The side fence is used to guide the router when moulding, edge profiling or rebating the edge of a workpiece or when routing grooves and slots in the center of the workpiece, parallel to the edge.
The edge of the workpiece must be straight and true. Strips 31  are adjustable and should be set ideally with a 1/8″ (3 mm) gap each side of the cutter.

Guiding Off a Batten
Where an edge guide cannot be used, it is also possible to guide the router along a batten clamped across the workpiece (with an overhang at both ends.)

Table Mode (Fig. Q)

(DWE627 ONLY)

WARNING: Before DWE627 is installed into the router table, check that the router table meets all of the legal safety requirements for router tables. Read all safety warnings, instructions, and specifications provided with the router table. Failure to follow all instructions and safety rules may result in electric shock, fire and/or serious injury.
WARNING: To reduce the risk of serious personal injury, turn unit off and disconnect it from power source before making any adjustments or removing/installing attachments or accessories. An accidental start‑up can cause injury.
WARNING: Do not use the DWE627 as a handheld router if the power switch box is connected.
CAUTION: If there is dust inside the power switch socket, clean it out before using the power switch box.

1.  To connect the power switch box  42  to the router, disconnect the tool from its power source.
2.  Attach the power switch box  42  to the workbench in a position easily accessible by hand and where unintentional switching on is prevented.
   NOTE: The external switch can be secured to the router table with the four mounting holes.
3.  The cable must be installed and fastened in such a way that it cannot be squeezed or touch sharp edges.
4.  Push in on the lock button  43  located on the left side handle  44  with a pen or a small screwdriver to unlock the handle cap  45 .
   NOTE: If there is dust inside the power switch socket, clean it out before using the power switch box.
5.  Keep pushing the lock button  43  in and rotate the handle cap  45  to access the power switch socket  46 .
6. Ensure the paddle switch of the power switch box is in the off position before connecting to the power switch socket.
7. Connect power switch box plug  47  to the power switch socket 46 .
8.  Thread the ring nut  48  of power switch box plug  47  to the power switch socket  46  to lock it securely in place.
9.  Attach the plunge router under the workbench, as required per your application or the instruction for the router table.
10.  Plug the tool back into its power source. The router can now switched on and off by acting on paddle  49  on the power switch box  42 .
11. Pull out the paddle  49  to start the tool and push in the paddle to switch it off.

Depth Adjustment with the Router Installed in Inverted Position (Fig. G)
WARNING: For installing the router in inverted position, refer to the relevant instruction manual on the stationary tool.

1.  Remove the cap nut  51  and the thumb wheel  4  and replace it with the height adjusting tool (DE6966) available as an option.
2.  Screw the threaded end of the height adjusting tool to the height stop rod  5 .
3.  Set the depth of cut using the adjuster on the height adjusting tool.

MAINTENANCE

Your power tool has been designed to operate over a long period of time with a minimum of maintenance. Continuous satisfactory operation depends upon proper tool care and regular cleaning.
WARNING: To reduce the risk of serious personal injury, turn tool off and disconnect tool from power source before making any adjustments or removing/installing attachments or accessories. An accidental start‑up can cause injury.

Repairs

WARNING: To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including power cord repairs, and brush inspection and replacement, when applicable) should be performed by a DEWALT factory service center or a DEWALT authorized service center. Always use identical replacement parts.

Cleaning
WARNING: Blow dirt and dust out of the main housing with dry air as often as dirt is seen collecting in and around the air vents. Wear approved eye protection and approved dust mask when performing this procedure.
WARNING: Never use solvents or other harsh chemicals for cleaning the non‑metallic parts of the tool. These chemicals may weaken the materials used in these parts. Use a cloth dampened only with water and mild soap. Never let any liquid get inside the tool; never immerse any part of the tool into a liquid.

Optional Accessories

WARNING: Since accessories, other than those offered by DEWALT, have not been tested with this product, use of such accessories with this tool could be hazardous. To reduce the risk of injury, only DEWALT recommended accessories should be used with this product. Consult your dealer for further information on the appropriate accessories.