INSTRUCTION MANU
AL
DW682-
XE
PL
A
TE JOINER
D
E
WALT Industrial Tool Co.,
701 East Joppa Road, Baltimore, MD 21286 • 20 Fletcher Road, Mooroolbark, VIC 3138 Australia
(MAR06) Form No. 561836-00 DW682-XE Copyright © 1997, 2006 D
E
WALT
The following are trademarks for one or more D
E
WALT power tools: the yellow and black color scheme; the “D” shaped
air intake grill; the array of pyramids on the handgrip; the kit box configuration; and the array of lozenge-shaped humps
on the surface of the tool.
IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY D
E
WALT TOOL, CALL US AT:
1800 654 155
(Aust)
or
09 526 2556
(NZ).
SAFETY INSTRUCTIONS FOR POWER TOOLS
When using power tools, always observe the safety regulations applicable in your country to reduce the risk of fire, electric
shock and personal injury. Read the following safety instructions before attempting to operate this product. Keep these
instructions in a safe place.
General Safety Rules
WARNING! Read all instructions.
Failure to follow all instructions listed below may result in electric shock, fire and/or
serious injury. The term “power tool” in all of the warnings listed below refers to your mains operated (corded) power tool
or battery operated (cordless) power tool.
SAVE THESE INSTRUCTIONS
1. WORK AREA
a.
Keep work area clean and well lit.
Cluttered and 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 elec-
tric 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 suit-
able for outdoor use 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 inatten-
tion while operating power tools may result in serious personal injury.
b.
Use safety equipment. Always wear eye protection.
Safety equipment such as dust mask, non-skid safety
shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.
c.
Avoid accidental starting. Ensure the switch is in the off position before plugging in.
Carrying power tools
with your finger on the switch or plugging in 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 con-
nected and properly used.
Use of these devices 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 before making any adjustments, changing accessories, or stor-
ing 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 tools 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 and in the manner
intended for the particular type of power tool, 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.
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. 230 V AC means your tool will operate on alternating current. As little as 10% lower voltage
can cause loss of power and can result in overheating. All D
E
WALT tools are factory tested; if this tool does not operate,
check the power supply. Your D
E
WALT tool is double insulated, therefore no earth wire is required.
•
Young children and the infirm.
This appliance is not intended for use by young children or infirm persons without
supervision. Young children should be supervised to ensure that they do not play with this appliance.
•
Replacement of the supply cord.
If the supply cord is damaged, it must be replaced by the manufacturer or an
authorised D
E
WALT Service Centre in order to avoid a hazard.
Extension Cords
CAUTION:
Use only extension cords that are approved by the country’s Electrical Authority. Before using extension
cords, inspect them for loose or exposed wires, damaged insulation and defective fittings. Replace the cord if necessary.
Additional Safety Instructions
•
Hold tool by insulated gripping surfaces when performing an operation where the cutting tool may contact
hidden wiring or its own cord.
Contact with a “live” wire will make exposed metal parts of the tool “live” and
shock the operator.
WARNING:
Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains
chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:
• lead from lead-based paints,
• crystalline silica from bricks and cement and other masonry products, and
• arsenic and chromium from chemically-treated lumber (CCA).
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these
chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are
specially designed to filter out microscopic particles.
•
Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling, and other construction activities.
Wear protective clothing and wash exposed areas with soap and water.
Allowing dust to get into your mouth, eyes,
or lay on the skin may promote absorption of harmful chemicals.
WARNING:
Use of this tool can generate and/or disburse dust, which may cause serious and permanent respiratory or
other injury. Always use NIOSH/OSHA approved respiratory protection appropriate for the dust exposure. Direct particles
away from face and body.
CAUTION: Wear appropriate personal hearing protection during use.
Under some conditions and duration of use,
noise from this product may contribute to hearing loss.
• The label on your tool may include the following symbols. The symbols and their definitions are as follows:
V ................volts
A ..............amperes
Hz................hertz
W ..............watts
min..............minutes
..........alternating current
..........direct current
no..............no load speed
..............Class II Construction
............earthing terminal
..............safety alert symbol
.../min........revolutions per minute
sfpm............surface feet per minute
SAVE THESE INSTRUCTIONS
Introduction
Examine Figure 1 and your plate joiner for a few minutes to become familiar with the various features and the names used
to describe them. The following sections will discuss the various controls and you will need to know where they are.
Overview
You have purchased a precision woodworking tool. The function of the plate joiner is to enable you to make extremely
strong and accurate joints in wood and wood by products.
The tool works by a plunging action to precisely cut crescent shaped slots for the placement of flat wooden dowels or
“biscuits” like those shown in Figure 2.
The various adjustments on the patented base/fence assembly will enable you to make virtually any biscuit joint imag-
inable. The tool may be further enhanced by some simple jigs and fixtures that can be easily made. Some of the more
common biscuit joinery applications are shown in Figure 3 and are discussed in detail in the applications section of
this manual.
Switch
Your plate joiner has a trigger switch located on the underside, as shown in Figure 1. To turn the tool on, depress the
trigger. To turn the tool off, release the trigger. To lock the tool on for continuous operation, there is a lock on button
located at the rear of the tool just above the cord. When cutting always hold the tool with one hand on the switch handle
and one hand on the auxiliary handle. To lock the tool on, depress and hold the trigger as you depress the lock button.
Hold the lock button in as you gently release the trigger. The tool will continue to run. To turn the tool off from a locked
on condition, depress and release the trigger once.
Blade Replacement
In time your saw blade will wear out and need replacement. To remove the blade, follow the steps below.
1. Turn off and unplug the plate joiner.
2. Remove the four torx head screws from the bottom of the shoe, using the T20 torx screwdriver provided.
3. Rotate the shoe out of the way.
4. Use the spanner wrench provided to loosen (counterclockwise) the blade nut. Depress the spindle lock pin on the
top of the gear case to hold the spindle while you unscrew the nut.
5. Remove the blade and have it sharpened or replace it with a new one.
6. Reinstall the blade by reversing the steps above. Be sure blade teeth point counterclockwise as shown in Figure 4.
7.
IMPORTANT:
Always check the fine depth adjustment when sharpening or replacing the blade. Adjust if necessary.
(See "Controls" section).
The Controls
The heart of your plate joiner is the base/fence assembly. All of the controls that let you make a variety of precision cuts
are located on this assembly. Take a few minutes to become familiar with the various controls.
ALWAYS TURN OFF AND UNPLUG PLATE JOINER BEFORE MAKING ANY ADJUSTMENTS.
1. ADJUSTABLE FENCE
The adjustable fence provides a sturdy, precise reference surface to determine the point at which the slots for the
biscuits will be cut. Its adjustable height feature allows you to position biscuit slots as close as 4.76 mm (3/16") and
as distant as 35 mm (1-3/8") measured from the workpiece surface to the centerline of the blade (see Figure 6). The
adjustable angle feature allows a full range of settings from 0° to 90 as well as a reverse 45° bevel which allows
outside registration on miter joints. (See Applications section under Miter Joints, Figure 26.)
The height adjustment is accomplished by first loosening the lock knob on the right side of the fence and then rotating
the knurled adjustment knob until the desired height is reached (see Figure 5).
Tightening the lock knob will then automatically align the fence parallel to the blade and lock it in position. The vertical
scale and pointer located directly under the lock knob can be used to assist in setting this height. The scale readings
indicate distance from the blade centerline to the fence surface when the fence is set at 90° (see Figure 6). The fence
angle can be set simply by loosening the lock knob on the left side of the tool, aligning the protractor scale with the
pointer and tightening the lock knob.
2. PLUNGE DEPTH ADJUSTMENT
The depth of cut can be set to match the dimensions of the particular size biscuit you will be using. The numbers on
the depth adjustment knob (0, 10, 20, M) coincide with the three sizes of biscuits shown in Figure 2. The letter M
stands for the maximum depth capacity of the tool which is 20 mm (25/32"). This depth is obtainable only with
a new blade and by backing out the fine adjustment screw (see next section).
NOTE:
The M setting has been provided for future use and will not be necessary for most biscuiting operations. To
select a depth, align the appropriate number with the red mark scribed in the tool’s housing, as shown in Figure 7.
Rotate the depth adjustment knob to the desired position and it will “click” into place.
3. FINE DEPTH ADJUSTMENT
You may encounter situations where you want to leave a little looseness in your joint so that you can move it slight-
ly before the glue sets up. For these instances a fine depth adjustment has been provided. To adjust, you must first
raise the adjustable fence to its uppermost position. Then insert the T20 torx wrench provided into the opening as
shown in Figure 8. Turn the depth adjustment screw clockwise for less depth and counterclockwise for increased
depth. Each full turn causes a change in depth of 1 mm (0.04"). Always check the depth adjustment by first mak-
ing test cuts in scrap wood.
4. ANTI-SLIPPAGE PINS
Plate Joiners tend to slide to the right with respect to the workpiece when making a cut. This tendency is increased
with a dull blade or when plunging very rapidly. Anti-slippage pins have been provided to reduce this tendency and
are located on the front registration surface on either side of the blade opening slot. When making some joints, you
may wish to retract the anti-slippage pins so as not to scratch your workpiece in a visible area. For this purpose,
