DW609 - Milling machine DEWALT - Free user manual and instructions

USER MANUAL DW609 DEWALT

English (original instructions)

Technical diagram of a mechanical device with labeled parts from a to h, showing assembly and mounting details.

Figure 2	Figure 3
Figure 4	Figure 5

Figure 6 t s t s

Figure 7 j i w x u v

Figure 8

Line drawing of a hand operating a small mechanical component with a handle (no text or symbols)

DANSK

LAMINATTRIMMER DW609

Tillykke!

RSEL: For at reducere

You have chosen a DEWALT tool. Years of experience, thorough product development and innovation make DEWALT one of the most reliable partners for professional power tool users.

Technical Data

DW609
Voltage V 230
Type	1
Power Input W 600
Power Output W 400
No Load Speed	min ^1	24,000
Plunge	mm	55
Collet size	8 mm
Cutters diameter, max	mm 36
Weight kg	3.7
L_ak (sound pressure)	dB(A)	82
K_ak (sound pressure uncertainty)	dB(A)	3
L_kx (sound power)	dB(A)	91
K_kx (sound power uncertainty)	dB(A)	3

Vibration total values (triax vector sum) determined according to EN 60745:

Vibration emission value a	h
a_h =	m/s2	4.3
Uncertainty K =	m/s2	1.6

The vibration emission level given in this information sheet has been measured in accordance with a standardised test given in EN 60745 and may be used to compare one tool with another. It may be used for a preliminary assessment of exposure.

WARNING: The declared vibration 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 emission may differ. This may significantly increase the exposure level over the total working period.

An estimation of the level of exposure to vibration 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 such as: maintain the tool and the accessories, keep the hands warm, organisation of work patterns.

Fuses

Europe	230 V tools	10 Amperes, mains
U.K. & Ireland	230 V tools	13 Amperes, in plugs

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.

Denotes risk of electric shock.

Denotes risk of fire.

ENGLISH

EC-DeclarationofConformity

MACHINERY DIRECTIVE

DW609

DEWALT declares that these products described under "technical data" are in compliance with: 2006/42/EC, EN 60745-1, EN 60745-2-17.

These products also comply with Directive 2004/108/EC. 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.

H. Jopsmann

Horst Grossmann

Vice President Engineering and Product Development

WARNING: To reduce the risk of injury, read the instruction manual.

General Power Tool Safety Warnings

WARNING! Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE

The term "power tool" in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

1) 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.

2) 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.

3) 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 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, clothing and gloves 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.

4) 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 the battery pack 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. 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.

5) 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.

Additional Specific Safety Rules for Cutters

• Always use cutters with a shank diameter corresponding to the size of the collet installed in your tool.
• Always use cutters suitable for a speed of 30,000 min ^-1 and marked accordingly.
• Never use cutters with a diameter exceeding the maximum diameter indicated in the technical data.

Cutters

The tooling can be used with a complete range of commercial cutters (e.g.: straight, rabbit, profile, slotter or grooved knife) with the tool.

1. Allowed shank diameter 6 mm - 8 mm.

2. Approved speed of cutter min. 30,000/min.

WARNING! DW609 Max Diameter in Use:

• Straight, rabbit or profile cutter with max shank diameter (8 mm), max diameter 36 mm, max depth 10 mm;
• Slotter cutter with max shank diameter 25 mm;
• Grooved knife with max shank diameter (8 mm): max diameter 40 mm and 4 mm cutting width.

Residual Risks

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

ENGLISH

Markings on Tool

The following pictograms are shown on the tool:

Read instruction manual before use.

DATE CODE POSITION (FIG. 1)

The Date Code (I), which also includes the year of manufacture, is printed into the housing.

Example:

2010 XX XX

Year of Manufacture

Package Contents

The package contains:

1 Laminate trimmer

1 Collet (8 mm)

2 Wrenchs

1 Copy follower

1 Guide roller

1 Instruction manual

1 Exploded drawing

- 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 (fi g. 1)

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

a. On/off switch

b. Depth stop

c. Plunge lock

d. Trimming base

e. Ventilation slots

f. Guide knob

g. Collet

h. Guide rods

i. Copy follower

j. Height adjuster

INTENDED USE

Your laminate trimmer has been designed for trimming wood and plastic laminates.

DO NOT use under wet conditions or in presence of flammable liquids or gases.

These laminate trimmer are professional power tools.

DO NOT let children come into contact with the tool. Supervision is required when inexperienced operators use this tool.

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.

Your DEWALT tool is double insulated in accordance with EN 60745; therefore no earth wire is required.

If the supply cord is damaged, it must be replaced by a specially prepared cord available through the DEWALT service organisation.

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 to 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: 13 A.

Using an Extension Cable

If an extension cable is required, use an approved extension cable suitable for the power input of this tool (see technical data). The minimum conductor size is 1 mm ^2 ; the maximum length is 30 m.

When using a cable reel, always unwind the cable completely.

ASSEMBLY AND ADJUSTMENTS

WARNING: To reduce the risk of injury, turn unit off and disconnect machine from power source before installing and removing accessories, before adjusting or changing setups or when making repairs. Be sure the trigger switch is in the OFF position. An accidental start-up can cause injury.

Inserting and Removing a Cutter (fi g. 2)

1. Hold the spindle with one of the wrenches supplied with the tool and loosen the collet nut (m) with the other.
2. Insert a cutter (y) and tighten the collet nut.

WARNING: Never tighten the collet nut without a cutter in the collet.

Replacing the Collet Assembly (fi g. 2, 3)

Your laminate trimmer is supplied with a 8 collet fitted to the tool. Two other precision collets are also available to suit the cutter used. The collet and the collet nut are inseparable.

1. Loosen the collet nut (m) completely.
2. Remove the collet assembly (n).
3. Fit a new assembly and tighten the collet nut.

Setting the Depth of Cut (fi g. 1)

1. Turn the plunge lock (c) counterclockwise to release the carriage.
2. Set the required depth of the cut using the depth stop adjuster (b)
3. Tighten the plunge lock (c).

Fitting the Optional Parallel Fence (fi g. 4)

1. Slide the parallel fence (o) over the rods (h).
2. Tighten the locking bolts (p) temporarily.

Adjusting the Parallel Fence (fi g. 4, 5)

1. Draw a cutting line on the material.
2. Lower the router carriage until the cutter is in contact with the workpiece.
3. Tighten the plunge lock.
4. Position the laminate trimmer on the cutting line. The outer cutting edge of the cutter must coincide with the cutting line.
5. Slide the parallel fence (o) against the workpiece and tighten the locking bolts (p).
6. Adjust the parallel fence using the fine adjuster (q).
7. Firmly tighten the end lock (r).

Reversing the Parallel Fence Liners (fi g. 6)

For trimming veneered or laminated panels, it is recommended to install the liners of the parallel fence as shown.

Remove the screws (s), invert the liners (t) and tighten the screws.

Mounting and Adjusting the Copy Follower (fi g. 7)

The copy follower (i) is used to trim along shaped edges. Mount the copy follower (j).

SIDE DISTANCE (FIG. 7)

1. Loosen the clamping wheel (u) and set the side distance using the fine adjustment screw (v).
2. Tighten the clamping wheel (u) again.

HEIGHT

1. Loosen the height adjuster (j) and move the copy follower (i) up or down as required.
2. Tighten the height adjuster (j).

STRAIGHT GUIDE OR GUIDE ROLLER (FIG. 7)

The plastic straight guide (w) is used to avoid copying the imperfections in the edges of the base material when using the copy follower (i).

For concave shapes, replace the straight guide of the copy follower by the guide roller supplied with the tool. To do so, loosen the screw (x).

Prior to Operation

1. Check that the cutter is correctly installed in the collet.
2. Set the cutting depth.
3. Connect a dust extractor.
4. Always make sure the plunge limiter is locked before switching on.

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.

ENGLISH

Proper Hand Position (fi g. 1, 8)

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 one hand on the side handle (f), with the other hand on the main handle (k).

Switching On and Off (fi g. 1)

Switch the tool on using the on/off-switch (a).

I = on The tool now works continuously. O = off

Trimming with Ball Bearing or Pilot Cutters (fi g. 2)

1. Remove the copy follower.
2. Start the tool using the on/off switch.
3. Move the tool at constant speed, keeping the ball bearing or pilot cutter (y) well against the base material.
4. Switch the tool off.

Trimming Shaped Edges (fi g. 1, 7)

WARNING: Always install the copy follower (i) when using cutters without ball bearing or pilot.

1. Adjust the tip of the copy follower using the fine adjustment screw (u) as required.
2. Install the guide roller on the copy follower.
3. Start the tool using the on/off switch (a).
4. Move the tool at constant speed, keeping the copy follower well against the base material.
5. Switch the tool off.

Trimming Straight Edges (fi g. 7)

Install the straight guide (w) on the copy follower (i) as described above. Proceed as for shaped edges. It is also possible to trim straight edges using the copy follower only.

Trimming Edge Strips Using the Optional Parallel Fence DE6913 (fi g. 4, 5, 6)

When working parallel to the outer edge of a workpiece, it is advisable to use the parallel fence. Install the parallel fence as described above. For delicate laminates, invert the liners (t) on the parallel fence as shown.

MAINTENANCE

Your DEWALT 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 injury, turn unit off and disconnect machine from power source before installing and removing accessories, before adjusting or changing set-ups or when making repairs. Be sure the trigger switch is in the OFF position. An accidental start-up can cause injury.

Lubrication

Regularly grease the carriage column.

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.

These include a parallel fence DE6913.

Consult your dealer for further information on the appropriate accessories.

Protecting the Environment

Separate collection. This product must not be disposed of with normal household waste.

Should you find one day that your DEWALT product needs replacement, or if it is of no further use to you, do not dispose of it with household waste. Make this product available for separate collection.

Separate collection of used products and packaging allows materials to be recycled and used again. Re-use of recycled materials helps prevent environmental pollution and reduces the demand for raw materials.

Local regulations may provide for separate collection of electrical products from the household, at municipal waste sites or by the retailer when you purchase a new product.

DEWALT provides a facility for the collection and recycling of DEWALT products once they have reached the end of their working life. To take advantage of this service please return your product to any authorised repair agent who will collect them on our behalf.

You can check the location of your nearest authorised repair agent by contacting your local DEWALT office at the address indicated in this manual. Alternatively, a list of authorised DEWALT repair agents and full details of our after-sales service and contacts are available on the Internet at:

www.2helpU.com.

GUARANTEE

DEWALT is confident of the quality of its products and offers an outstanding guarantee for professional users of the product. This guarantee statement is in addition to and in no way prejudices your contractual rights as a professional user or your statutory rights as a private non-professional user. The guarantee is valid within the territories of the Member States of the European Union and the European Free Trade Area.

• 30 DAY NO RISK SATISFACTION GUARANTEE •

If you are not completely satisfied with the performance of your DEWALT tool, simply return it within 30 days, complete with all original components, as purchased, to the point of purchase, for a full refund or exchange. The product must have been subject to fair wear and tear and proof of purchase must be produced.

• ONE YEAR FREE SERVICE CONTRACT •

If you need maintenance or service for your DEWALT tool, in the 12 months following purchase, it will be undertaken free of charge at an authorised DEWALT repair agent. Proof of purchase must be produced. Includes labour. Excludes accessories and spare parts unless failed under warranty.

• ONE YEAR FULL WARRANTY •

If your DEWALT product becomes defective due to faulty materials or workmanship within 12 months from the date of purchase, DEWALT guarantees to replace all defective parts free of charge or – at our discretion – replace the unit free of charge provided that:

• The product has not been misused;
- The product has been subject to fair wear and tear;
• Repairs have not been attempted by unauthorised persons;
• Proof of purchase is produced;
- The product is returned complete with all original components.

If you wish to make a claim, contact your seller or check the location of your nearest authorised DEWALT repair agent in the DEWALT catalogue or contact your DEWALT office at the address indicated in this manual. A list of authorised DEWALT repair agents and full details of our after-sales service is available on the Internet at: www.2helpU.com.

ESPAÑOL

DISTANCE AU CÔTÉ (FIG. 7)

Vice President Engineering and Product Development

BEWAAR ALLE WAARSCHUWINGEN EN INSTRUCTIES ALS TOEKOMSTIG REFERENTIEMATERIAAL

1) SIKKERHET PÅ ARBEIDSOMRÅDET

Vice President Engineering and Product

Development

DEWALT, Richard-Klinger-Strasse 11,

D-65510, Idstein, Germany

31.12.2009

DATUMKODPLACERING (FIG. 1)

$$ 1 = \text { p\AA } $$

LAMINAT DÜZELTICI DW609

Tebrikler!