Dexter 510PR2.5 Palm Router

Product Overview

The Dexter 510PR2.5 is a palm router designed for woodworking and plastic applications, suitable for tasks such as cutting grooves, removing hollows, and replicating curves and logos. It is powered by a 220V-240V, 50Hz supply and features a 510W motor with a no-load speed of 32000/min.

Symbols Used

• [Double Insulation Symbol]: Protection class II (double insulation).
• ⚠️ [Read Instructions]: WARNING - To reduce the risk of injury, user must read instructions carefully.
• CE Mark: In accordance with essential applicable safety standards of European directives.
• ?️ [Eye Protection]: Always wear eye protection.
• ? [Mask Protection]: Always wear mask protection.
• ? [Ear Protection]: Wear ear protection.
• ♻️ [Recycling Symbol]: Faulty and/or discarded electrical or electronic apparatus have to be collected at the appropriate recycling locations.
• ❗ [Danger Symbol]: Denotes risk of personal injury, loss of life or damage to the tool in case of non-observance of the instructions in this manual.
• [Ukraine Conformity Mark]: Conformity marking that product complies with applicable Ukraine technical regulations.

Contents

• General Power Tool Safety Warnings
• Safety Instructions for Routers
• Residual Risks
• Intended Use
• Technical Data
• Initial Operation and Setting
• Recycling
• Exploded View & Part List
• Warranty

1. 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. Save all warnings and instructions for future reference.

1) Work Area Safety

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

2) Electrical Safety

• 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 the risk of electric shock.
• 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.
• Do not 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 for carrying, pulling, or unplugging the power tool. Keep the cord away from heat, oil, sharp edges, or moving parts. Damaged or entangled cords increase the risk of electric shock.
• 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.
• 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

• 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.
• 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.
• Prevent unintentional starting. Ensure the switch is in the off-position before connecting to the power source and/or battery pack, picking up, or carrying the tool. Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.
• 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.
• Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
• 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.
• 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.
• 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.

4) Power Tool Use and Care

• 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.
• 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.
• 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.
• 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.
• 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.
• Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
• 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.
• 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.

5) Service

• 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.

2. Safety Instructions for Routers

• 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 electric shock.
• 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.

3. Residual Risks

Even when the power tool is used as prescribed, it is not possible to eliminate all residual risk factors. The following hazards may arise in connection with the power tool's construction and design:

• Health defects resulting from vibration emission if the power tool is being used over a longer period of time or not adequately managed and properly maintained.
• Injuries and damage to property due to broken accessories that are suddenly dashed.

Warning! This power tool produces an electromagnetic field during operation. This field may, under some circumstances, interfere with active or passive medical implants. To reduce the risk of serious or fatal injury, it is recommended that persons with medical implants consult their physician and the medical implant manufacturer before operating this power tool.

4. Intended Use

The router is ideal for machining wood and plastic, and also for cutting out knots, cutting grooves, removing recesses, copying curves, and logos, etc. The router must not be used for machining metal, stone, etc.

The equipment is to be used only for its prescribed purpose. Any other use is deemed to be a case of misuse. The user/operator, and not the manufacturer, will be liable for any damage or injuries of any kind caused as a result of this.

Please note that this equipment has not been designed for use in commercial, trade, or industrial applications. The warranty will be voided if the machine is used in commercial, trade, or industrial businesses or for equivalent purposes.

Special Safety Instructions

• Pull the mains plug out of the socket before making any adjustments, changing tools, carrying out maintenance, or cleaning. After finishing all related adjustments, changes, maintenance, or cleaning, you can plug into the socket before switching on the machine for use.
• The tommy nut (3) must always be tightened well when working with the machine.
• Do not try to machine extremely small workpieces. Smaller workpieces must be secured in such a way that they do not get loose when working with the machine (e.g., using screw clamps).
• Check the workpiece for foreign bodies. When working, always make sure that no nails or other similar materials are being cut into. Ensure no obstruction of objectives or workpiece during working.
• Keep your hands away from the rotating tool!
• Remove debris and similar material only when the machine is at a standstill.
• Do not touch the cutter straight after use. It can be very hot and cause burns to your skin.
• Danger of injury from the sharp edges of the cutter.
• If needed, set the stand all the way down for protection.
• Materials that generate dusts or vapours that may be harmful to health (e.g., asbestos) must not be processed.
• Do not operate the machine in a holder.
• Always use the tool in dry and suitable temperature ambient conditions.

5. Technical Data

Recommendation: Operator should wear hearing protection.

Warning: Vibration and noise emissions during actual use may differ from declared values depending on usage and workpiece type. Safety measures should be based on estimated exposure in actual conditions.

6. Initial Operation and Setting

Before commissioning, check that the rated mains voltage and mains frequency stated on the type plate match your power supply.

Important: Always install an RCD with a maximum trip current of 30 mA upstream.

Pull the mains plug out of the socket before proceeding.

Assembly

To adjust the distance between the cutter and workpiece, loosen the Tommy nut (3) and rotate the setting screw (4) to move the machine body up or down. The stand (9) supports the machine body, provides a grip for holding, and guards hands from touching the moving blade.

1. Inserting the Cutter

The high speed of the machine requires high-quality cutters (HSS or carbide). Use only cutters suited to the machine's speed (refer to Technical Data). Ensure the cutter shaft diameter matches the collet bore. The collet chuck nut may only be tightened by hand if no cutters are used. Do not use blunt or damaged cutters.

Procedure:

1. Unplug power cable.
2. Undo the tommy nut (3) and pull the stand (9) downwards.
3. Insert the cutter with its full shank length into the router bit adapter (6).
4. Press the blurt button (17).
5. Lock with a 17mm open-end wrench.

2. Adjusting the Cutting Depth

Clean and safe cutting is achieved with a maximum cutting depth of 3 mm, which also protects the motor from overloading. Greater cutting depths can be achieved with several passes.

Procedure:

1. Pull the mains plug out of the socket.
2. Undo the tommy nut (3).
3. Turn the setting screw (4) to adjust the stand (9) so the cutter lightly touches the workpiece surface.
4. Observe the scale (2) and adjust the stand (9) by turning the setting screw (4) to the desired cutting depth.
5. Firmly tighten the tommy nut (3) to secure the stand (9).

3. Replacing the Router Bit Adapter

This machine is suitable for 6.0mm and 6.35mm router bit adapters and bits.

Procedure:

1. Pull the mains plug out of the socket.
2. Unscrew the router bit adapter (6).
3. Replace with the appropriate router bit adapter (6.0mm or 6.35mm).
4. Screw on the router bit adapter by hand only; do not overtighten.

4. Fit Fender

Procedure:

1. Pull the mains plug out of the socket.
2. Mount the fender (11) as shown in the diagram.

Working Directions

Machine Use

Firmly hold the machine by the grip surface (8). Place the machine onto the workpiece without the cutter touching it. Switch on the machine and wait until it reaches full speed, then allow the cutter to penetrate the workpiece. The footplate (7) glides on the workpiece.

Feed Direction

Always work in the opposite direction, pushing the machine forwards as indicated in the diagram. The direction of cutter rotation is shown by an arrow (12) on the machine. Guide the machine evenly at a speed suitable for the material being processed.

Putting Down After Use

After finishing the cutting process, switch off the machine and set it down only when the motor has come to a standstill.

Special Working Methods

Cutting with Straight Guide

Procedure:

1. Attach the straight guide (13) to the machine using screws (b).
2. Undo the wing screw (a) and adjust the distance to the cutter. Tighten the wing screw (a).

Attention: Refer to Assembly IM for mounting instructions.

Stop with Curved Edge Guide

The curved edge guide is used for cutting along a curved edge.

Procedure:

1. Attach the curved edge guide (14) to the machine with screw (c).
2. Undo the clamping screw (a).
3. Using the adjusting screw (b), set the desired distance to the cutter.
4. Tighten the clamping screw (a).

Attention: Refer to Assembly IM for mounting instructions.

Guide Bush

For cutting according to a template fixed on the workpiece.

Procedure:

1. Undo screws (10) to remove the footplate (7). Insert the guide bush (15) and screw the footplate (7) back on.
2. Attach a template (b) to the workpiece (c). Place the machine on the template and guide it so that the guide bush (15) glides along the edge of the template (b).

Attention: Refer to Assembly IM for mounting instructions.

Milling Along a Strip / Straight Marking

Attach a strip to the workpiece and guide the machine with a straight edge of the foot plate along the strip (always use the same edge).

Profile Milling

• When working with profile cutters, first remove a larger chip, then a smaller chip.
• The feed rate must not be too low, otherwise the wood will scorch.

Cutting Bit Compatibility: Ensure the cutting bit is adaptable to the maximum working speed of the palm router and is securely fixed by the router bit adapter (6).

Cleaning and Maintenance

Always pull out the mains power plug before starting any cleaning work.

1. Cleaning

• Keep all safety devices, air vents, and the motor housing free of dirt and dust as far as possible. Wipe the equipment with a clean cloth or blow it with compressed air at low pressure.
• It is recommended to clean the device immediately after each use.
• Clean the equipment regularly with a moist cloth and mild soap. Do not use cleaning agents or solvents, as these could damage the plastic parts of the equipment. Ensure that no water can seep into the device. Water ingress into an electric tool increases the risk of electric shock.

2. Carbon Brushes

In case of excessive sparking, have the carbon brushes replaced. Inspect and change the brushes periodically to ensure safe operation and a long service life. First, unscrew the brush cap with a screwdriver. Change the worn brush and then tighten the brush cap.

3. Maintenance

1. Replace the milling cutter if it is damaged or worn out.
2. Inspect tool cords periodically and, if damaged, have them repaired at your nearest Service Center.

4. Accessories

Carbon brush, 17mm Wrench, Guide bush, Curved edge guide, Straight guide, Corer round bit Ø6.0, Straight bit Ø6.0, Flush trim bit Ø6.0.

Replacing the Power Cable

If replacement of the supply cord is necessary, it must be done by the manufacturer or their agent to avoid a safety hazard.

Disposal and Recycling

The equipment is supplied in packaging to prevent damage during transit. The raw materials in this packaging can be reused or recycled. The equipment and its accessories are made of various materials, such as metal and plastic. Never place defective equipment in your household refuse. The equipment should be taken to a suitable collection center for proper disposal. If you do not know the location of such a collection point, ask your local council offices.

7. Recycling

The packaging consists of environmentally friendly material and can be disposed of in local recycling containers.

CAUTION! This product is marked with a symbol relating to the disposal of electric and electronic waste (WEEE Directive). This means the product must not be discarded with household waste but returned to a collection system conforming to the WEEE Directive. Contact your local authorities or retailer for recycling advice. It will then be recycled or dismantled to reduce environmental impact. Electric and electronic equipment can be hazardous to the environment and human health due to hazardous substances.

Environmental Protection: Waste electrical products must not be disposed of with household waste. Please recycle where facilities exist. Check with your local authorities or retailer for recycling advice. It will then be recycled or dismantled to reduce environmental impact.

8. Exploded View & Part List

The exploded view diagram shows the internal components of the palm router, with numbered parts corresponding to the part list below. This aids in understanding assembly and for replacement purposes.

Part List

Kits

9. Warranty

Dexter products are designed based on rigorous quality standards. This palm router is covered by a 5-year warranty from the date of purchase, covering manufacturing or material defects.

In case of breakdown, first refer to the troubleshooting section in the brochure. If the problem persists, contact the nearest store. Repairs and part replacements do not extend the initial warranty period.

The warranty does not cover breakdowns resulting from normal wear and tear, improper use, or unauthorized modifications. Specific warranty terms may vary by country; check with your point of sale.

For warranty claims, proof of purchase is required. Claims are void if unauthorized repairs, modifications, or improper use (including overloading or using non-approved accessories) have occurred, or if damage resulted from external causes or failure to follow safety and usage instructions.

The product is intended for normal, non-professional use. Products used for commercial, trade, industrial applications, or by rental companies are excluded from this warranty.