DeWalt DW616 User manual

G
L.
o
.eH
al rq
=(E
rEgE
=69
o
-_ >\vtt
qU,9
G
(c'hEtr
5Ef,fi
ocaa
DEWALT
IndustrialTool
Co.,
701
EastJoppaRoad,
Baltimore,MD
21286
(MAR05)
Form
No.631103-00 DW616,DW61B Copyright@2003,2005
DeWALT
Thetollowing
are
trademarks
for
oneormoreDeWALT
power
tools;the
yellow
and
blackcolor
scheme;
the
"D"
shap€o
ajrintake
grill;
the
arrayolpyramids onthehandgrip;
thekitbox
configuration;andthe
arrayoflozenge-shaped
humps
onthesurfaceofthetool.
tF YOUHAVEANY
QUESTTONS
ORCOMMENTSABOUTTHIS.
OR ANYDTWALTTOOL.
CALL
USTOLL FREEAT 1-800-4-D:WALT
(1-800-4s3-92s8).
fi9
XF
.Y()
>(r
9b
vz
ffu
a'a
r.!Lu
o
g,a
E{
z-
tu..
()<.i
;6F
.-zo
=uJf
L2FO
scEo
!+uJc
HJ>(L
6?;
H .rr
O'- co
>2)
F < r.,LJ
O(rO
I {.n
troIi
rL
9wz
4O<
a
lu
z
o
J(J)
5=3
z=E
=ED
z==
O=ut
trbo
3nd
,YIJ5
Fa=
9=<
4(,=
t:
o
o
.i*
ies
E
q$
s.gF
EE$
$i3
gi$
EgE
$H;
:
E

SAVE TH
ESE
"VSTH
UCTIONS
General Safety lnstructions
WARNING!
Beadand understandall instructions.Failure
tofottow
allinstruc-
tionslisted
below,mayresult
inelectric
shock,fire
and/or
serious
personatinjury.
sAvE THESETwSTRUCTTOwS
Salety Instructions For AII Tools
WORK
AREA
A Xep your work areaclean andwetl tit.Ctuttered
benches
anddark areasinvite acci-
dents.
A D,onotoperatepower tools in explosive atmospheres,suchas in the presence
of
flammableliquids, gases,
or dust.Powertools
createsparks
whichmayignitethedust
orfumes.
A' xep bystanders, children, and visitors away while operating a power tool.
Distractions
cancause
youto lose
control.
ELECTRICAL
SAFETY
A Grounded tools mustbe plugged into an outlet
property instatled and
groundd in
accordance with all codesand ordinances. Neverremove thegroundlng prong or
modity theplug in any way.Do not useany adapter ptugs. check with a quatitia
electrician if you are in doubt as to whether the outletis properly grounded. tf the
toolshouldelectrically
malfunction
or breakdown, grounding
provides
a low resistance
pathtocarry
electricity
awayfromtheuser.This
tooluses
grounded
construction
(Sprong
plug)
to
provide
a means totransfer
electrical
energy
safetyaway
fromtheuserinthe
event
thetoo!
electrically
malfunctions,
breaksdown,orthetoolcasebecomeslive.Damage
to,or
lossof, one of the 3 plug blades;damageto the plug or cord,or failureto have the toot
pluggedinto a verifiedand continuously
groundedelectrical
system,
may resultin electric
shock,seriousiniury,
ordeath.To
avoidtheserisks
ofinjury,thetool must,
at atttimes,
be
maintained
andinproperworking
order(cord,plug blades)
andptuggedinto
a continuously
grounded
electricdsystem.
(See
also"Cleaning"
intheMaintenance
section.)
A Avoid body contact with grounded surtaces suchas pipes, radiators, ranges
and
. refrigerators.Thereisanincreasedrisk
ofelectricshockifyourbody
isgrounded.
A Do not expose
power tools to rain or wet conditions. Water
enteringapower tootwitt
increase
the risk
of electric
shock.
A, Do not abuse thecord. Neveruse thecord to carry tools or pult theplug from an
outlet.Kep cord away from heat, oil, sharpedges or moving parts. Replace
dam-
aged cords immediately.Damaged
cordsincrease
the risk
of electricshock.
A, Wnen
operatinga power tool outside,usean outdoor extension
cord markd -W 4',
or "W." These
cords
areratedforoutdooruse
and
reduce
the risk
ofelectric
shock.
EXTENSION
CORDS
A Make sure
your extensioncord is in good condition. When
using an extension
cord,
be sureto useone heavyenough to carry thecurrent your product wilt draw.A vott-
agedecrease
ofmore than10%
willcause
a loss ofpower
andoverheating.
An undersized
cord willcausea drop in line voltageresultingrn /ossof power and overheating.Thefot-
lowing
table
showsthe
correctsizetousedepending
oncordlength
andnameplate
ampere
rating.
lfindoubt,usethenext
heavier
gage.
The
smallerthe
gage
number,
theheavier
the
cord.
Volts
120V
Minimum
Gage
lor Cord
S,ets
Total
Length
ofCordin Feet
0-25 26-50 51-.100 101_150
240V 0_50 51_100 101-200 ?01_300
Ampere
Rating
More Not
more American
Wire
Gage
Than Than
10- 12 16
12 - 16 14 to
12 14 12
Not
Recommended

PERSONAL
SAFETY
A, Stay alert,watch what you are doing and use common sense when operating a
power toot.Do not usetool white tired or under the influence of drugs, alcohol, or
'medication.A moment
of inattention
whileoperating
powertoolsmayresultin serious
personatiniury.
A Dress properly. Do not wear loosectothing or iewelry. Contain long hair. Kep your
hair,ciotiing , and gloves
awayfrom moving parts.Looseclothes,
iewelry,
orlonghair
canbecaught
inmoiing parts.
Airvents
often
cover
moving
parts
and
should
alsobe
avoided.
A Avoid accidental starting. Be sure switch is off before plugging in. Carrying
toolswithyour fingeron theswitchor plugging
in tools thathavethe switchon invites
accidents.
A, Remove adjusting keys
or wrenchesbetore turning thetool on.A wrench
orkeythat
is leftattached
toa rotating
partof thetoolmayresult
inpersonaliniury.
A, Do notoverreach. Keepproper footing and balanceat all times.Properfooting
and
balance
enables
better
control
of thetoolin unexpected
situations.
A gse satety equipment. Always wear eye protection. Dust mask, non-skidsafety
shoes,
naia nat,orhearing
protectionmustbe usedforappropriate
conditions'
TOOL
USE
ANDCARE
A Use clampsor other practical ways to secureand support the workpiece to a sta'
ble platform. Hotding
theworkby handor against
yourbodyis unstable
andmaylead
to/ossof control.
A Do nottorce tool. lJsethecorrect toot for your application. Thecorrect
toolwilldo
the
job better
andsaterandtherateforwhich
it is designed.
A Do not use tool if switch does notturn it on or off. Anytoolthatcannot
becontrolled
withtheswitch
is dangerous
andmust
berepaired'
A, Disconnect the ptug from the power source betore making any adiustments'
changing accessories,
or storing thetool. Such
preventative
safety
measures
reduce
the riskof starting
thetoolaccidentally.
A Storeidte tootsout of reach of children and other untrained persons.Toolsaredan-
gerous
inthe
hands
ofuntrained
users.
L Maintain toots with care. Keep cutting tools sharp and clean. Propeilymaintained
tools,
withsharp
cutting
edges
are less
likelytobindandareeasier
tocontrol.
A Cnec* for misalignment or binding of moving parts, breakage of parts, and any
other condition that may affect the tootsoperation. lf damaged,have the tool serv'
iced betore using.Manyaccidents
arecaused
bypoorly
maintained
tools.
A Use only accessories thatare recommended by the manutacturer for your model.
Accessories
thatmay be suitabte
for one tool may becomehazardous
whenused on
another
tool.
SERVICE
A Toot service mustbe pertormed onty by quatifiedrepair personnel.
Service
ormain-
tenance
pertormed
byunqualified
personnelcould
resultina riskofiniury.
A Wnenservicinga tool, useonlyidenticatreplacement
parts.
Follow instructionsin the
Maintenance
sectionof this manual.Useof unauthorized
parts
or failuretofollowmain-
tenance
instructions
maycreatea riskof electric
shockor iniury.
Specitic Salety Fules lor Bouters
A UoU toot by insutated
gripping surfaceswhen pertorming an operation where the
cutting tool may contact hidden wiring or its own cord. Contactwitha "live"wire will
makeexposed
metalparts ofthetool"live"
andshock
theoperator.
A, Uetat cuttingwith router: lfusing
routerformetalcufting,cleanouttooloften.
Metal
dust
andchipsoften
accumulateon interiorsurfaces
andcouldcreatea risk of serious
injury,
electricalshock
ordeath.
A Never
run themotor unit whenit is not inserted
in oneof therouter bases.The
motor
is notdesignedtobe handheld.
A Xep handtes
dry,clean,and tre from oit andgrease. This
wittenable
bettercontrol
of
thetool.
A' Xep handsaway from cutting area. Neverreach under theworkpiece for any rason.
Kep the router base firmly in contact with the workpi*e when cutting. Hold the
routeronly by thehandles.These precautions
willreduce
the risk
ofpersonal injury.
A Usesharp cutters.Dullcuftersmay causetherouter
toswerveor stall
underpressure.
A Never
touch the bitimmdiately after use.lt maybeextremetyhot.
L Besure that themotor hasstopped
completety
betoreyou lay therouter down. tfthe
cutterhead is stillspinningwhen thetoplis laiddown,it co_uld
causeinjuryor damage.

il Be surethat therouter bitis clearof theworkpiecebefore starting the
motor.lf the
bit
isincontactwith
theworkpiece when
themotorstarts itcouldmake
therouter
jump,caus-
^ ingdamageor injury.
IICAUTION: Wear
appropriate hearing protectiol, during use.IJnder
someconditions
and
durationof use,noisefromthis
product
maycontribute
tohearingloss.
AWARNTNG:
Somedustcreated
bypower
sanding,sawing,
grinding,
dritling,
andother
con-
structionactivities
containschemicalsknown
tocause
cancer,
birlhdefectsorotherreproduc-
tiveharm.
Someexamplesof these
chemicalsare:
. lead
fromlead-based
paint.
. crystallinesilicafrom
bricksandcement
andother masonry
products.
. arsenicandchromiumfrom
chemicallylreatedlumber
(CCA)
Yourrisk
fromthese
exposuresvaries,
dependingon howoften
you do thistypeof work.To
reduceyour exposureto these chemicals: work in a well ventilatedarea, and work with
approved
safetyequipment,such
as thosedustmasks
thatarespeciallydesigned
tofilterout
microscopic
pafticles.
. Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling,
and other construction activities.Wear protective clothing and washexposedareas
with soapand water.
Allowing
dusttogetintoyourmouth,eyes,
or layon the skin may
promote
absorptionofharmful
chemicals.
AWARNTNG:
tJse
of this tootcan
generate
and/or
disbursedust,whichmay cause
serious
and
permanent
respiratory
orotherinjury.Always
useNIOSH/OSHA
approvedrespiratory
pro-
tectionappropriatefor thedustexposure.Direct
particlesawayfromfaceandbody.
' Thelabelonyour toolmayincludethefollowing
symbols.Thesymbolsanddefinitionsare
as follows:
V ............vo\ts
A ............amperes
Hz ..........hert2
W............watts
min..........minutes
A ..........rufety
atertsymbot
FAM'LTAN',ZATTON
Motor
YourDeWALT
toolis
powered
by
a DEWALT-built motor.
Besure
yourpower
supplyagrees
with
thenameplatemarking.
"120
V-" means
your
toolmaybe
operatedwithalternating
current
only.
Do
notconnect
your
tooltoadirectcurrent
power
supply.
All
DTWALTtools
arefactorytested;
ifthistool
doesnot
operate,checkthe
power
supply.
Switch
To
turnthetool
on,
push
thetoggle
switchtothe
on
position
indicated
onthetool.To
turnthe
tool
off,
push
thetoggle
switchtothe
off
position
indicated
onthetool.
Detachable Cord Eet (Fig. IJ
Insert
thedetachable
cordset
plug
sothat
thekey
(W)
isalignedwiththenotch
(V)
in
the
socket.
Turn
the
plug
clockwise
one
quarter
turn
tolock.
A' CnUnOU: Alwaysturnoff thetootand removetheplug from thepowersupplybefore
detachingthecordsetfromthetool.
L CeUnOU: Alwaysleave
thetoggleswitchin theoff position
when
removing
or attaching
thecordfromthemotor.lf thetoggle
switchis in theonpositionwhenthecordsetis attached,
thetoolwillstaftunexpectedly,
causing
loss
ofcontrol,
personal
injuryand/ordamagetothe
toolor workpiece.
FIG,1
........
alternating
current
- ......direct
current
t1o..........no
load
speed
14)...... CtassllConstruction
a ..........earthing
terminat
.../min..revolutions
perminute

SET-IJP:
FIXED BASE
Motor Quick Refease (Fig. 2l
LCAUTION:Turn
therouter
offanddisconnect
it from
the
power
suppty.
1.Open
the
locking
lever
(D)
on
thebase.
2.Giaspthe
base;ithone
hand,
depressing
the
quick
release
latches
(A).
3.
with
the
other
hand,
grasp
the
top
of
themotor
unit
and
lift
itfrom
thebase'
F'|G;----\
( \i ,t=<-'.*
;->
tr
'@l=ryls
lnserting the Motor into the Fixed Base (Fig. 3)
LcAuTtoN: Turn
the
router
offanddisconnect
it from
the
power
suppty.
1.Open
the
locking
lever
(D)
on
the
base'
2.lfthedepth
adjustment
ring
(B)isnot
onthemotor,
thread
the
depth
adjustment
rt19
t!)
onto
the
motor
untiliii" iing
ii"oout halfway
between
the
top
and
bottom
ofthe
motor
as
shown.
Insert
themotor
inio thebase
Oy
itrgning
thegrowe on themotor
(H)
with
the
ouide
pins(x)on
tne
base.
slide
the
mofor
d6wn
until
the
Depth
Adjustment
Ring
snaps
into
tnb
quick
release
latches
(A)'
NOTE:
Guide
pin
grooves
are
located
on
either
side
of
themotor
so
that
itcan
bepositioned
intwo
orientations.
3.Adjust
the
depth
ot
cul
qv-!ultlgl|*9!:l adjustment
rins
.qg9
the
headins
Adjustins
the
- d6ii oifri in
the
OP-ERAT;ON:
FIXED
BASE
section
of
this
manual'
4.close
the
locking
tever
(D)when
the
desired
depth
is-achieved'
For
information
on
set-
ting
the
cutting
O"pin,
t.j" ine
neaOing
AOiuitinfi
theDepth
ofCut
in
the
OPERATION:
FIXED
BASE
section
of
this
manual'
Fired Ease'Ease lixe'Baxe tija
A. OUICK FELEASE
LATCH
B DEPTH
ADJUSTMENT
RING
C ADJUSTABLESCALE
D LOCKING
LEVEB
E.HANDLE
F.SUBBASE
G.SPEED
DIAL
(618
ONLY)
H,GUIDE
PINGROOVE
I SPINDLE
LOCKBUTTON
(618
ONLY)
J.COLLET
NUT
K.TOGGLE
SWITCH
L DETACHABLE
CORDSET
M,HOLES
FORUN1VERSAL
EDGEGUIDE
N.TRIGGER
SWITCH
O TRIGGERLOCK
BUTTON
P TURRETSTOP
O DEP
THADJUSTi/ENT
ROD
R PLUNGELOCK
LEVER
S DUSTSHROUD
T DUSTCAP
U CENI-ERING
TOOL
Hotor - Btoc motour - "nidtd dct motor
l\
-i-,1
l,i
',,a.**'',-".',
t(
l\
,i \
':a :
ii .' -- ' :'i,
".r't
I ll--- --=
j . -tt. '. - H
" a.L il
i l.-''
E
L='
il 1- -J
l\,,',r ''_.--
it i'- .^'':'.

Locking Lever Adiustment (Fig. 4)
LCAUTION: Turn
therouteroffanddisconnect
it fromthe
power
supply.
Youshould
beable
toclamp
thelocking
leverwithout
excessive
force.Excessive
forcemay
damage
the
base.
You
should
notbeable
tomove
themotor
inthebase
whenthe
locking
leverisclamped.
To
adjust
thelocking
lever'sclamping
force,open
thelocking
lever
(D)
and
turn
thenut
(Y)
in
small
increments.
Turningthe
nutclockwise
tightens
the
lever,whileturning
thenutcounter-
clockwise
loosens
the
lever.
Centering the Subbase (Fig. 5)
LCnUnOn: Turn
the
router
offand disconnect
it from
the
power
supply'
lf
you
need
to
adjust,
change,
orreplace
the,subbase,
acentering
tool
is
provided'The
cen-
ifii"g ioil"onsisis
oia con"JanO
a'pin.
To
adjust
the
subbase,
follow
the
steps
below'
1.Loosen
but
donot
remove
the
subbase
screws
So
that
the
subbase
can
move
freely'
2.Insert
the
pin
into
the
collet
and
tighten
the
collet
nut'
3.|nsertthemotorintothebaseandc|ampthelocking|everonthebase,
4.Place
the
cone
on
the
pin
and
lightly
press
down
on
the
cone
until
itstops
asshown'
This
will
center
the
subbase.
5.
While
holding
down
on
the
cone,
tighten
the
subbase
screws'
FIG.
5
OPERATIONT
FIXED BASE
Bit lnstallation and Removal (Fig. 6)
ACaUflOU: Turntherouter
offanddisconnectit fromthe
power
supply.
1.Toinstall
a bit,
insert
theround
shank
ofthe
desired
router
bit
into
the
loosened
colletas
far
as
itwill
go
andthen
pull
itoutabout1/16".
Using
thewrench(es)
provided,
turnthecol-
letnut(J)
clockwisewhileholdingthespindle shaftwiththesecond wrench.
[On
the
DW618,depressthe
spindle
lock
button
(l)to
hold
thespindleshaft.l
2.Toremove
a bit,holdthespindleshaftwhileturningthecolletnut
(J)
counterclockwise
withthewrench
provided.
[Hold
the
spindle
bydepressingthe
spindle
lock
button
(l)
on
theDW618.lThe
self-releasingcolletnutwillturnapproximately3/4ofa turnandthen
becometightagain.
At
this
point
thebitcannotberemoved.Continueturningthecollet
nut
counterclockwise.
Thislifts
thecollet,allowinothe
bit's
removal.
FIG.6
Collets
NOTE:Never
tightenthe
colletwithoutfirst
installing
arouter bitinit.Tightening
anemptycol-
let,
evenbyhand,
candamage
thecollet.
Two
collets
areincluded with
the motor:
one1/4"and
one 112". Tochangecollet
sizes,
unscrew
thecollet
assembly
asdescribed
above.Installthe
desiredcollet
byreversing the
procedure.
Thecollet
andthecolletnut
areconnected.
Donot
attempttoremove
thecollet
from
the
colletnut.

Adiusting the Depth ol Cut (Fig. 2, 3)
LCAUTION: Turntherouteroffanddisconnect
it fromthe
power
supply.
1.Select
and
installthedesired
bit.See
the
headingBit
lnstallation
and
Removal.
2.Place
therouter
onitsbase
onthe
work
piece.
3.Open
thelocking
lever
(D)
and
turnthedepth
adjustment
ring
(B)
until
thebit
just
touches
the
work
piece.
Turning
theringclockwise
raises
thecutting
head
whileturning
it
counter-
clockwise
lowers
thecutting
head.
4. Movetheadjustable
scale
clockwise
(C)
sothat0 onthescale
islocatedexactly
above
the
pointer(Z)
onthebase.
5.
Turnthedepth
adjustment
ringalong
with
theadjustable
scale
tothedesired
depth.
Note
thateach
markon theadjustable
scale
represents
a depth
change
of 1164"or.015"
(.4mm).
6.Close
thelocking
lever
(D).
FIG.
3
Using a Parallel Fence
Aparallel
fence
(DW6913)
isavailable
from
your
local
retailerorservice
centerat
extracost.
Followtheassembly
instructions
included
withthe
fence.Insertthe
twobarsthrough
theedge
guide
holes
intherouterbase.
Adjustas
needed
for
parallel
routing.
SET-UPI D-HANDLE BASE
Motor Quick Befease
LCAUTION: Turntherouteroffanddisconnect
it fromthe
power
supply.
1.Open
thelocking
lever
(D)
on
thebase.
2.
Grasp
thebase
withone
hand
while
depressing
the
quick
release
latches
(A).
3.Withtheother
hand,
grasp
thetopofthemotorunit
and
liftitfromthebase.
D-llandle Base ' Base de ta Poign6e l€tmee
Base con mango en
A. OUICK
RELEASE
LATCH
B.
DEPTH
ADJUSTMENT
RING
C ADJUSTABLE
SCALE
D.LOCKING
LEVER
E.
HANDLE
F SUBBASE
G SPEED
DIAL
(618ONLY]
H.GUIDE
PIN
GROOVE
I,SPINDLE
LOCK
BUTTON
(618
ONLY)
J. COLLET
NUT
K.TOGGLE
SWITCH
L.OETACHABLE
CORDSET
M.
HOLES
FOR
UNIVEBSAL
EDGE
GUIDE
N.TRIGGER
SWITCH
O,TRIGGEB
LOCK
BUTTON
P.TURRET
STOP
Q, DEPTH
ADJUSTMENT
ROD
R.PLUNGE
LOCK
LEVER
S.
DUST
SHROUD
T' DUST
CAP
U CENTERING
TOOL
, ,/

Inserting the Motor into the D-Handle Base (Fig. 7l
LCAUTION: Turntherouteroffanddisconnectit fromthe
power
supply.
1.
Openthe
lockinglever
(D)
onthebase.
2.Threadthe
depthadjustment
ring
(B)
ontothe
motor
untilthe
ringis
about
halfway
between
thetopandbottomofthemotor.Insert themotorinto thebasebyaligning
the
groove
on
the
motor
(H)
withthe
guidepins(X)
on
the
base.Slide
themotor
down
untilthe
depth
adjustment
ring
snaps
intothe
quick
releaselatches
(A).
3.Close
thelockingleverwhenthe
desireddepth
is
achieved.
Forinformationonsettingcut-
tingdepth,seethe
headingAdjustingtheDepth
ofCut
in
theOPERATION:
D-HANDLE
BASE
sectionof
thismanual.
4.Be
sure
thatthetrigger
switch
(N)
isreleased
and
thetriggerlockbutton
(O)
isinthe
unlockedandoff
position.
5.Unlock
and
disconnect
the
detachable
cordset
(L)
fromthemotor.
6.Connect the
detachablecordset
(L)
tobottomofD-Handle
and
lockthe
cord.
7.Connect the
short
cord
(AA)
fromtop
ofD-Handle to
themotor
asshown.
Be
sure
the
cord
islocked.
8.Place
thetoggle
switchintheon
position.
Thisallowsthetrigger
switchontheD-handle
tocontroltherouter.
FIG 7
Locking Lever Adjustment (Fig. 4)
LCAUTION: Turn
therouter
offanddisconnect
itfrom the power
supply.
You
should
be
ableto
clamp
thelocking
lever
without
excessive
force.
Excessive
force
mav
damage
the
base.
You
should
not
beable
tomove
the
motor
inthe
base
when
the
locking
lever
is
clamped.
To
adjust
thelocking
lever's
clampinglorce,
open
thelocking
lever
(D)
a-ndturn
the
nut
(y) in
smallincrements.
Turning
thenut
clockwise
tightens
thelever
while
turning
thenut
counier-
clockwise
loosens
the
lever.
Centering the Subbase (Fig. S)
AC{UnON: Turn
therouter
offand disconnectit from
the
power
supply.
lf
you
need
to
adjust,change,
or
replace
the
subbase,
acentering
toolis
provided.
The
cen-
tering
tool
consists
ofa cone
anda pin.
To
adjustthe
subbase,follow
the
stepsbelow.
1.Loosen
butdonot
remove
thesubbase
screws
sothat
the
subbase
canmove
freely.
2.Insert
the
pin
into
the
collet
andtighten
the
coltetnut.
3.Insert
themotor
into
the
base
andclamp
thelocking
lever
onthe
oase.
4.Place
the
cone
onthe
pin
andlightly
press
downon
coneuntil
it
stops
asshown.
This
will
center
the
subbase.
5.While
holding
down
onthe
cone,
tighten
the
subbase
screws FIG.
5

OPEBATTON:
D-HANDLE BASE
Knob Locations
Grip
theD-Handle
withone
handancJ
place
theother
frandcnthethe
krtob.The
D-Handle
routerbase
hastwo
positions
for
theknobtoaccommodate
riEhtorlefthand
use.
A,
CAUTION:
IJseboth
handsatall timestamaintaincontrol.
Trigger Lock
Tolock
thetrigger,
pull
ihetriggerswitch
(N)
completely,
then
push
thetrigger
lockbutton
(O).
Therouterwilf
remainonafter
you
remove
your
finger
fromthe
trigger.To
unlockthe
trigger
lock
button,
pull
thetriggerand
release.
Thelockbutton
will
pop
outand
therouter
willturn
off.
Bit lnstallation and Removal (Fig. 6)
ACAUTION: Turntherouteroffanddisconnect
it fromthe
power
supply.
1.Toinstallabit,
insert
theroundshank
ofthedesired
routerbit
intotheloosened
collet
as
far
asitwillgoand
then
pull
itoutabout
1/16".
Usingthe
wrench(es)
provided,
turn
thecollet
nut
(J)
clockwise
while
holdingthespindle
shaft
with
thesecond
wrench.
[On
the
DW618,
depress
thespindle
lockbutton
(l)
to
holdthespindle
shaft.l
2.Toremoveabit,
holdthespindle
shaft
while
turningthecollet
nut
(J)
counterclockwise
with
thewrench
provrded.
[Hold
thespindle
bydepressing
thespindle
lockbutton
(l)
on
the
DW618.l
Theself-releasing
collet
nutwill
turnapproximately
314of
aturnand
then
become
tightagain.
Atthis
point
thebitcannot
be
removed.Continue
turning
thecollet
nutcounter-
clockwise.
Thislifts
thecollet,allowing
thebit's
removal
CoIIets
NOTE:
Nevertighten
thecollet
without
firstinstalling
arouterbit
init.Tightening
anempty
col-
let,
even
by
hand,
can
damage
thecollet.
Twocollets
are
included
withthe
motor:one
114"andone
112".
To
change
collet
sizes,
unscrew
the collet
assembly
as described
above.
Install
the desired
colletby reversing
the
procedure.The
colletand
thecollet
nutare
connected.
Donotattempt
toremovethecollet
lrom
thecollet
nut.
FIG.
6
D-tlan.lte Ease - Ease de ta Poign6e lam6c
| .-r -:,.'/
ti.f.
/ . r--!
/--{
.$ r. Ll
E! -. -[',
t--
-F- -1 )
Base con mango en O

Adjusting the Depth ol Cut (Fig. 3)
LCAUTION: Turn therouteroffanddisconnect
it from the
power
supply.
1.Select
andinstallthedesiredbit.
Seethe
headingBitlnstallationand
Removal.
2.Place
therouter
onits base
onthe
work
piece.
3.Open
thelockinglever
(D)
and
turnthedepthadjustment
ring
(B)
until
thebit
just
touches
thework
piece.
Turningthe
ring
clockwise
raises
thecutting
headwhileturningitcounter-
clockwise
lowersthecutting
head.
4.Movetheadjustablescale
clockwisesothat 0 onthescale
is locatedexactlyabove
the
pointer(Z)
on
the
base.
5.Turn
the
depth
adjustment
ringalongwith
the
adjustable
scaleto
thedesireddepth.
Note
that
each
markon theadjustablescale
representsa depthchangeof 1/64"or.015"
(.4mm).
6.Close
thelockinglever
(D).
Using a ParaIIeI Fence
Aparallel
fence
(DW6913)
is
available
from
your
localretailerorservicecenter
atextra
cost.
Followtheassembly
instructions
includedwiththe
fence.Insertthetwobars
throughthe
holes
intherouterbase.
Adjustasneeded
for
parallel
routing.
SET-UP: PLUNGE BASE (Fig. 8)
Motor Quick Fefease
A,CnUnOlt: Turntherouter
offanddisconnect
it fromthe
power
suppty.
'1.
Openthe
locking
lever
(D)
onthebase.
2.Grasp thetop
ofthe
motor
unitand
liftit
fromthebase.
Inserting the Motor into the Plunge Base
ACAUTION: Turn
therouteroffanddisconnectit fromthe
power
supply.
1.Removethe
depthadjustment
ringfrom
themotor.ltisnotusedwith
the
plunge
base.
2.
Open
thelockinglever
(D)
onthebasetoensurethatthemotor
properly
seats.
3.Ensurethatthe
plunge
locklever
(R)
islocked.
4.Align
the
flat
ofthemotor'send
cap
(BB)
with
pillar(CC)
andinsertthemotorintothe
plunge
baseuntil
it
stops.
5.Close
thelockinglever
(D).
FIG.8

Locking Lever Adiustment (Fig. 4)
A,CAUTION:
Turntherouteroffanddisconnect
it fromthe
power
supply.
Youshould
beable
toclamp
thelocking
lever
withoutexcessive
force.Excessive
force
may
damage
the
base.
Youshould
not
be
able
tomove
themotor
inthebase
when
the
lockinglever
is
clamped.
Toadjust
the
lockinglever's
clamping
force,
openthe
locking
lever
(D)
and
turn
thenut
(Y)
in
small
increments.
Turningthe
nutclockwise
tightens
the
lever,while
turning
thenut
counterclockwise
loosens
thelever.
Centering the Subbase (Fig. 5)
LCAUTION: Turn
therouter
offanddisconnect
it from
the
power
supply.
lfyouneed
to adjust,
change,
or replace
thesubbase,
a centering
tool
isprovidedThe
le?rtJring
tool
consists
ofadone
and
a pin.
Toadjust
thesubbase,
follow
the
steps
below.
1.
Loosen
but
do
not
remove
thesubbase
screws
so
that
thesubbase
can
move
freely.
2.Insert
the
pin
into
thecollet
and
tighten
thecollet
nut'
3.Insert
themotor
into
thebase
and
clamp
the
locking
lever
on
thebase.
4.place
the
cone
on
the
pin
and
lightly
press
down
on
the
cone
until
itstops
as
shown.
This
willcenter
thesubbase.
5.
While
holding
down
on
thecone,
tighten
the
subbase
screws'
FIG.
5
\ry
'...'' '. '.)
-:7'
FIG.6
l
l
OPERAT,ON:PLU,UGE BASE
Bit lnstallation and Remsval (Fig' 6)
A,CAUTION:
Turn
therouter
offanddisconnect
it from
the
power
supply.
.l
.To
install
abit,
insert
the
round
shank
of
the
desired
router
bit
into
the
loosened
collet
as
f"ratitwillgo
and
then
pullit
out
about
1/16".
Using
the
wrench(es)
provided,turn.the
col-
i"i "rt 1.ti
dlocfwise-*hit"
notoing
thes.pindle
sliaft
with
thesecond
wrench.
[On
the
DW618;depress
the
spindle
lock
[utton
(l)
to
holdthe
spindle
shaft.l
2.
To
remove
a bit,
hold
ihespindle
shaft
while
turning
the
collet
nut
(J)
counterclockwise
with
the
wrench
proro"o.
[Hold
the
spindle
by
depressing
the
spindle
lockbutton
(l)on
in" OWOre.lfnd
sert-rlleasing
collet'nut
williurn'approximately
3/4
ol a turn
and
then
6ecome
tigni
again.
AtiniJpointthe
bitcannot
beremoved.
Continue
turning
thecollet
nutcounte-rcloc-kwise.
This
lifts
the
collet,
allowing
the
bit's
removal.
Collets
NoTE:
Never
tighten
the
collet
without
first
installing
arouter
bit
rrr
it.Tightening
an
empty
col-
let,even
byhand,
can
damage
thecollet.
Twocollets
are
included
with
ihe
motor:
one
114"and
one
112".
To
change
collet
sizes'
unscrew
tn" iof
f"t assembly
as described
above.
Install
the desired
collet
by reversing.
the
procedure.The
collet
and
the
collet
nutare
connected.
Do
not
attempt
toremove
the
collet
from
the
collet
nut.
| 1 -a'/
I i'
/ ,'-. !
.& J;
1
FIG 4
l. ,l:'.
-41,

Adjusting the Plunge Routing Depth (Fig. 8)
LCAUTION: Turntherouter
offanddisconnect
itfromthe
power
supply.
1.Unlock
the
plunge
mechanism
by
pushing
up
the
plungelocklever
(R).
Plunge
therouter
down
as
faias
it
will
go,
allowing
the
bitto
just
touch
theworkpiece'
2.Lock
the
plunge
mechanism
by
pushing
the
plunge
lock
lever
(R)
down'
3.Loosen
the
depth
adjustment
rod
(Q)
by
turning
the
wingscrew
(DD)
counterclockwise.
4.
Slide
thedepth
adjustment
rod
(Q)
down
so
that
itmeets
the
lowest
turretstop
(P)'
5.
Slide
thetab
(EE)
onthe
depth
adjustment
roddown
so
that
thetopof
it
meets
zeroon
the
pillar
scale
(FF).
6.Grasping
thetop,
knurledsection
ofthe
depth
adjustment
rod
(!), slide
itupso
that
the
tab
(EEfalignswiththe
desired
depth
ofcut
on
the
pillar
scale
(FF).
7.
Tighten
the
wingscrew
(DD)toholdthe
depth
adjustment
rod
in
place.
8.Keeping
both
hands
on
the
handles,
unlock
the
plunge
mechanism
by
pushing
the
plunge
lock'levlr
(R)
up.The
plunge
mechanism
and
the
motor
willmove
up.
When
therouter
is
plunged,
thedepth
adjustment
rod
willhit
theturet
stop,
allowing
the
router
toreach
exact-
ly
thedesired
depth.
Fine Adjustment of Routing DePth
LCAUTTON:
Turntherouter
offanddisconnect
it fromthe
power
supply.
The
knurled
knob
(GG)
at
thebottom
end
of
thedepth
adjustment
rodcanbe
used
tomake
minoradjustments.
1.
Todecrease
thecutting
depth,
rotate
the
knobclockwise
(looking
down
fromthe
topof
the
router).
2.
Toincrease
thecutting
depth,
rotate
theknob
counterclockwise
(looking
down
fromthe
top
ofthe
router).
NOTE:
One
complete
rotation
of
the
knobresults
inachange
of
about
51128"
or.04"
(1
mm)
indepth.
FIG.8
Using the Rotating Turret Stop (Fig. g)
The
turret
depth
stop
can
beused
to
set5different
depths.
One
ofthe
turret
stops
is
adjustable.
]o.u9e
the
adjustable
turret
stop,loosen
the
nut
(Hnj,
then
adjust
the
screw
(li)
to
tne
oesireo
height.-Turning
the
screw
counterclockwise
will
raise
the
screw
which
will
deciease
the
cutting
depth.The
turret
stopis
usefulfor
making
deep
cuts
in
several
passes. -- -'
- --'-" i
AWARNING:
Donotchayge
theturret
stopwhile
therouter
is running.This
wilt
place
your
hands
toonear
thecutterhead.
FIG 9

Cutting with the Plunge Base (Fig. 8)
ACAUTION: Turnthe
routeronbefore
plunging
thecutter
head
intotheworkpiece.
1.Unlock
the
plunge
locklever
(R).
2.Plunge
therouterdownuntil
thebit
reachesthesetdepth.
3.Lockthe
plunge
lock
lever
(R).
4.Perform
thecut.
5.Unlock
the
plunge
locklever.
Thiswillallowthe
router
bit
todisengage
thework.
. 6.Turntherouteroff.
FIG.8
Dust Extraction (Fig. 1OI
h,CnUnOlt: Turn
therouter
offand disconnect
it from
the
power
supply.
To
connect
therouter
toavacuum
cleanerfor
dust
extraction,
follow
these
sreps:
1.
Remove
the
dustcap
(T)
by
pulling
straight
up.
2.Insert
the
dustextraction
hose
adapter
(JJ)
into
the
dust
extraction
pod
(KK)
asshown.
3.Insertthe
end
ofastandardvacuum
cleaner
tube
(LL)
into
thehose
adapter.
4.
When
using
dust
extraction,
beaware
ofthe
placement
ofthe
vacuum
cleaner.Be
surethat
thevacuum
cleanerisstableand
thatits
hose
willnot
interfere
withthe
work.
FlG.
10

OPERATION: ALL BASES
Direction OJ Feed (Fig. | |)
Thedirection
offeed
is
veryimportant
when
routing
and
can
make
the
difference
between
a
successful
job
and
a ruineil
project.Thefigures
atleftshow
the
proper
direction
olfeed.for
some
typicitcuts.
A
general
iule-to
follow
isto
movethe
router
inacounterclockwise
direction
onan
outside
cut
andaclockwise
direction
on
an
insidecut
Shape
theoutside
edge
of
apiece
of
stockby
following
thesesteps:
1.Shape
theend
grain,
left
toright
2.Shape
thestraight
grain
side
moving
lefttoright
3.
Cut
theother
end
grain
side
4.Finish
the
remaining
straight
grain
edge
SPEED SELEC7'ON C'IABT
nilEteriaf.'-- - - - !!!91!* --"*n,, -settins
zri"-ttiils affiZ-s"tti"g s :e;1i;s.^1
t,il;; tai,o6
ip. tn,ooo
iprn 18'o0o
rpm 21'ooo,rpm
24'000
rpm
Model# Dw618
Hardwood,
e.g,oak Small
(1/2")
Medrum
(1/2''1
1/B')
Large
(over-1
1/B') _- X ---II
r^h^,^^d .,n nrne Small
(1/2')
Softwood,
c 9.,
Plne
XX
Plastic-laminated
chlPboard Small
(1/2")
Medium
(1/2"-11/8')
Medium
(1/2"-11/8')
iog++;+e, x -- xI "q ; 'xx xx
-
XX
o
XXX
XX
XX
XX
XX
XX
XX
--:- ;-!ars-€ (overl!/8')
- o --+--+ - -f
prast,csrsotio
Surtace Small
(1/2")
Medium
(1/2"-11/8") - O XX XX x
Large
(over1
1/8") X XX O "
XX
X
ThistableCanserueon|yasagulde.sincewoodWaSalivingmateria|'Withlnthesan]eSpec|esofhmberhardnessanddens|tyvary
Speed
settings
areaPProxlnlate
KEY: XXvery
good X good O Satisfactory
ChoosingBouter$peed (DW6lI only)
(Fig' 12)
Refer
to
thechart
above
tochoose
a router
speed.
Turn
thespeed
dial
(G)
tocontrol
router
speeo.
MA',NTENANCE
Cleaning
LWnnUWel Blowingdust
andchips
outof themotor
housing
using
clean,
drycompressed
air
is a necessary
regular
maintenance
procedure'
Dust
andchips
containing
metal
particles
often
accumulate
onintterior
surlaces
andcould
create
an electrical
shock
or electrocution
il
,i6i'iriqi"ittv cteaned
out.
ALWAYS
WEAR
SAFF'TY
GLAssEs'
LCnirtOi, Never
usesolvents
or other
harsh
chemicals
forcleaning
thenon'metallic
pafts
of thetool.Usea clean,dryragonlY'
NOTE
FOR
PLUNGE
BASEbttLY:
Use
only
a DRYcloth
to
wipe_the
plunge.rods..These
rods
require
no
lubrication.
Lubricants
attract
bust,
reducing
the
pedormance
of
your
tool'

Accesso ries
Recommerrded
accessories
loi Lrse
wittr
1,11g1-to(,i
.lrc avail.ibie
at extra
cosl trorn your locat
dealer or authorized servic^e
cetrter.
11
yoLr
rrcei assist:rnce
in locating ai-ry
accessory for your
tool,
cali
ustollfree
at:1-800-4-DcWALT
(1
800433-9258)
orcurttaclDTWALT
Industriatiool
Co.,701
East
Joppa
Road,
Baltimore,
MD2|286.
A CAUTION:
Theuse
olanyrlllrer
irct--ossory
rtot
taL:()nttncttded
t'or
use
wtlt-t
1lstoot
coud
behazardous.
Hepairs
Toassure product
SAFETY
and REI-lAt3lL-il'Y,
repairs,
mairrtenance
arrd
adjustment(includ-
ingbrush
inspection
andreplacement)
should
be perfor
medbyauthorized
service
centers
or
other
qualified
service
personnel,
always
using
identical
replacement
pafts.
Three Year Limited Warranty
DEWALT
will
repair,
without
charge,
any
de{ects
duetofaulty
rnaterials
orworkmanship
for
threeyears
from
the
date
of
purchase.
This
warranty
does
not
coverpafi
failure
due
tonormal
wear
ortool
abuse.For
further
detail
ofwarranly
coverage
and
warranty
repair
information,
visit
www.dewalt.com
or
call
'l-800-4-DTWALT
(1-b00-,13S-bzSai.
This
warranty
does
not
appiy
to
accessories
ordamage-.caused
where
reparrs
have
been
made
orattempteA
by
others.
this
warrantygives
you
specificlegal
rights
and
you
may
have
other
rights
wnicn
v'ary
in
certain
states
orprovinces.
ln
addition
to
thewarranty,
DEWALT
roots
are
covered
byour:
1YEAR
FREE
SERViCE
DEWALT
will
maintain
the
tool
antlreplace
worn
parts
caused
bynorrnal
use,for
free,
anytime
during
thefirst
year
after
purchase.
90DAY
MONEY
BACK
GUARANTEE
lfyou
are,not
completely
satisfied
with
the
perlonnance
of
your
DcWALT
power
Tool,
Laser,
or Naile-r
for
anyreason,you
canreturn
itwithin
90
daysfrom
the
date
ofpurcfrase
witfr-a
receipt
for
afull
refund
- no
questions
asked
RECONDITIONED
PRODUCT
Reconditioned
product
is covered
under
the I yearFree
Service
Warranty.
The
90Day
Money
Back
Guarantee
and
the
Three
Year
Limited
Warranty
donot
apply
toreconditioned
product.
FREE
WARNING
LABEL
REPLACEMENT:
lf
your
warning
labels
become
ittegibte
or
are
missing,
call
1-800-4-DTWALT
tor
alree
reolacement.