DEWALT DCW620NT 20V MAX XR Brushless Cordless 2-1/4 Peak HP Plunge Router

1. Introduction

The DEWALT DCW620NT 20V MAX* XR® Brushless Cordless 2-1/4 Peak HP Plunge Router is a high-performance power tool designed for precision woodworking tasks. This manual provides essential information for the safe and effective operation, maintenance, and troubleshooting of your router. Please read this manual thoroughly before first use and keep it for future reference.

Note: This product is sold as a tool-only unit. Batteries and chargers are excluded and must be purchased separately.

2. Safety Information

Always follow basic safety precautions to reduce the risk of fire, electric shock, and personal injury when using power tools.

General Power Tool Safety Warnings:

• Work Area Safety: Keep your work area clean and well-lit. Cluttered or dark areas invite accidents. Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust.
• Electrical Safety: Power tool plugs must match the outlet. Never modify the plug in any way. Do not expose power tools to rain or wet conditions.
• Personal Safety: Always wear eye protection. Use hearing protection when operating for extended periods. Dress properly; avoid loose clothing or jewelry. Keep hair, clothing, and gloves away from moving parts.
• Tool Use and Care: Do not force the power tool. Use the correct power tool for your application. Disconnect the plug from the power source and/or remove the battery pack before making any adjustments, changing accessories, or storing power tools.
• Specific Router Safety: Ensure the router bit is securely fastened before operation. Always hold the router firmly with both hands. Keep hands clear of the cutting area.

3. Package Contents

Upon opening your DEWALT DCW620NT package, please verify that all items are present and undamaged. The standard package includes:

• DEWALT DCW620NT 20V MAX XR Brushless Cordless Plunge Router (Tool Only)
• TSTAK Compatible Storage Case
• Collet (e.g., 1/2 inch, 1/4 inch - specific sizes may vary by region/kit)
• Wrench for bit changes
• Dust Extraction Adapter
• Parallel Fence/Guide
• Template Guide Bushing Adapter

Image: DEWALT DCW620NT Plunge Router with included accessories and TSTAK case.

4. Setup

4.1 Battery Installation

1. Ensure the router is switched off.
2. Align the battery pack with the battery port on the router.
3. Slide the battery pack into the port until it clicks securely into place.
4. To remove, press the release button on the battery pack and slide it out.

Image: DEWALT DCW620NT Plunge Router with a 20V MAX XR battery installed.

4.2 Router Bit Installation

1. Ensure the router is disconnected from the battery.
2. Loosen the collet nut using the provided wrench.
3. Insert the router bit into the collet, ensuring at least 3/4 of the shank is inserted. Do not bottom out the bit.
4. Tighten the collet nut firmly with the wrench.

4.3 Depth Adjustment

The DCW620NT features a precise depth adjustment system for accurate cuts.

1. Place the router on a flat surface with the desired bit installed.
2. Loosen the plunge lock lever.
3. Lower the router until the bit touches the workpiece.
4. Use the fine adjustment knob or scale to set the desired cutting depth.
5. Securely tighten the plunge lock lever before operation.

Image: Close-up view of the router's depth adjustment mechanism.

4.4 Dust Collection Setup

For a cleaner workspace and improved visibility, attach a dust extractor to the integrated dust collection port.

1. Connect the dust extraction adapter to the router's dust port.
2. Attach a compatible dust extractor hose (e.g., DEWALT DWV015) to the adapter.

Image: Close-up of the router showing handles and the dust port.

5. Operating Instructions

5.1 Powering On/Off

• To turn ON: Press the power switch.
• To turn OFF: Release the power switch.

5.2 Variable Speed Control

The router features a variable speed dial (11,000-23,000 RPM) to match the speed to the application and material. Adjust the dial before starting the cut.

• Lower speeds are generally used for larger diameter bits, harder materials, or when more control is needed.
• Higher speeds are suitable for smaller bits and softer materials.

5.3 Making a Plunge Cut

1. Set the desired depth of cut (refer to Section 4.3).
2. Position the router over the workpiece, ensuring the bit is clear of the material.
3. Turn on the router and allow it to reach full speed.
4. Firmly grasp both handles and slowly plunge the router into the material.
5. Once the desired depth is reached, engage the plunge lock lever.
6. Guide the router along the desired path.
7. Upon completion, release the plunge lock, lift the router clear of the workpiece, and turn it off.

Image: A worker performing a plunge cut with the DEWALT DCW620NT router.

5.4 Edge Profiling and Other Applications

The DCW620NT is suitable for various applications including Dados, Grooves, Flutes, Edge Profiling, Inlays, Flush Trimming, Rabbeting, and Mortising.

• Edge Profiling: Use appropriate bits and guides (e.g., parallel fence or bearing-guided bits) to create decorative edges.
• Dados/Grooves: Utilize the parallel fence or a straight edge guide to make straight, consistent cuts.
• Dust Collection: For optimal dust removal, ensure the dust extractor is connected and operating during all routing tasks. The integrated dust collection with AIRLOCK™ compatibility collects up to 97% of dust.

Image: A worker using the router for edge profiling on a wooden board.

Image: A worker operating the router with a dust collection system attached for a cleaner work environment.

5.5 PERFORM & PROTECT™ ANTI-ROTATION System

This router is equipped with an ANTI-ROTATION system that senses the motion of the tool and shuts it down if the motion is excessive, enhancing user safety during operation.

6. Maintenance

6.1 Cleaning

• Always disconnect the battery before cleaning.
• Use a soft brush or compressed air to clean dust and debris from the motor vents and plunge mechanism.
• Wipe the exterior with a damp cloth. Do not use harsh chemicals or solvents.

6.2 Bit Care

• Regularly inspect router bits for sharpness and damage. Dull or damaged bits can cause kickback and poor cut quality.
• Clean bits after each use to remove resin and pitch buildup, which can affect performance.
• Store bits in a protective case to prevent damage to cutting edges.

6.3 General Inspection

• Check all screws and fasteners for tightness.
• Inspect the power switch and variable speed dial for proper function.
• Ensure the plunge mechanism operates smoothly.

7. Troubleshooting

8. Specifications

9. User Tips

• Test Cuts: Always make test cuts on scrap material before routing your final workpiece to ensure correct depth and speed settings.
• Bit Selection: Use sharp, high-quality router bits appropriate for your material and application.
• Feed Rate: Maintain a consistent feed rate. Feeding too fast can strain the motor and leave a rough finish, while feeding too slow can burn the wood.
• Multiple Passes: For deep cuts, make several shallow passes instead of one deep pass. This reduces strain on the tool and bit, and improves cut quality.
• Clamping: Always securely clamp your workpiece to prevent movement during routing.
• Dust Management: Utilize the dust collection feature for a cleaner and safer work environment.

10. Warranty and Support

DEWALT provides a limited warranty for its products. For detailed warranty information, service, or technical support, please refer to the official DEWALT website or contact your local authorized DEWALT service center. Keep your proof of purchase for warranty claims.