DeWalt DW616 User manual

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1‑800‑4‑DeWALT
DW616, DW618
Router System
Système de toupie
Sistema de rebajadora
Instruction Manual
Guide D’utilisation
Manual de instrucciones

Components
1 Quick release latch
2 Depth adjustment ring
3 Adjustable scale
4 Locking lever
5 Knob handle
6 Subbase
7 Speed dial (DW618 only)
8 Guide pin groove
9 Spindle lock button (DW618 only)
10 Toggle switch
11 Detachable cordset
12 Holes for universal edge guide
13 D‑handle trigger switch
14 Trigger lock button
15 Turret stop
16 Depth adjustment rod
17 Plunge lock lever
18 Dust shroud
19 Dust cap
20 D‑Handle
21 1/4" (6.4 mm) Insertable collet
22 1/2" (13 mm) Collet and nut
Composants
1 Verrou de déblocage rapide
2 Anneau de réglage de profondeur
3 Échelle réglable
4 Levier de verrouillage
5 Poignée bouton
6 Sous‑base
7 Bouton de réglage des vitesses
(modèle DW618 seulement)
8 Rainure de la goupille de guidage
9 Bouton de verrouillage de la broche
(modèle DW618 seulement)
10 Commutateur à bascule
11 Cordon amovible
12 Orifices pour bord‑guide universel
13 Interrupteur à gâchette
14 Bouton de verrouillage de la
gâchette
15 Butée de la tourelle
16 Tige de réglage de profondeur
17 Levier de verrouillage de plongée
18 Enveloppe anti‑poussière
19 Capuchon anti‑poussière
20 Poignée fermée
21 Pince de serrage insérable 6,4 mm
(1/4 po)
22 Pince de serrage et écrou 13mm
(1/2 po)
Componentes
1 Seguro de liberación rápida
2 Anillo de ajuste de profundidad
3 Escala ajustable
4 Palanca de seguridad
5 Mango de perilla
6 Sub base
7 Selector de velocidad (únicamente
DW618)
8 Canal para perno guía
9 Botón del seguro de la flecha
(únicamente DW618)
10 Interruptor de cambio
11 Cable desmontable
12 Orificios para guía universal para
bordes
13 Gatillo interruptor
14 Botón de seguro del gatillo
15 Tope de torreta
16 Varilla de ajuste de profundidad
17 Palanca de seguro de penetración
18 Cubierta contra polvo
19 Tapa de polvo
20 Mango en D
21 Collarín insertable de 6,4 mm (1/4")
22 Collarín y tuerca de 13mm (1/2")
English (original instructions) 5
Français (traduction de la notice d’instructions originale) 12
Español (traducido de las instrucciones originales) 20

1
Fig. A
DW618
FIXED BASE - BASE FIXE - BASE FIJA
Centering Tool - Outil de centrage -
Herramienta de centrado (DNP617)
SOLD SEPARATELY - VENDU SÉPARÉMENT -
VENDIDA EN FORMA SEPARADA
D-HANDLE BASE - BASE DE LA POIGNÉE
FERMÉE - BASE CON MANGO EN D
MOTOR - BLOC MOTEUR - UNIDAD DEL MOTOR
7
10
8
9
22
2
3
4
5
6
12
11
20
14
13
4
2
3
6
1
13
1
PLUNGE BASE - BASE PLONGEANTE - BASE PARA PENETRACIÓN
19
17
16
15
6
12
18
5
5
21

2
Fig.B Fig.C
Fig.D Fig.E
Fig.F Fig.G
38 39 1
4
23
25
2
83424
9
22
DW618

3
Fig.H
Fig.I
26
25
23
11
13
14
27
19
28
31
17
29
30
16
32 15
6
2

4
Fig.J Fig.K
Fig.L Fig.M
1
4
3
2
7
35
36
37
33
34
DW618

5
ENGLISH
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 ground fault circuit
interrupter (GFCI) protected supply. Use of a GFCI
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 a 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 energizing 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
jewelry. Keep your hair, clothing and gloves away
from moving parts. Loose clothes, jewelry 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.
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.
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.
Definitions: Safety Alert Symbols and Words
This instruction manual uses the following safety alert
symbols and words to alert you to hazardous situations and
your risk of personal injury or propertydamage.
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.
(Used without word) Indicates a safety
relatedmessage.
NOTICE: Indicates a practice not related to
personal injury which, if not avoided, may result in
propertydamage.
Intended Use
This heavy‑duty router is designed for professional
routingapplications.
DO NOT use under wet conditions or in presence of
flammable liquids orgases.
This is a professional powertool.
DO NOT let children come into contact with the tool.
Supervision is required when inexperienced operators use
thistool.
English (original instructions)
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.
WARNING: To reduce the risk of injury, read the
instructionmanual.

ENGLISH
6
Additional Safety Information
WARNING: Never modify the power tool or any part of
it. Damage or personal injury couldresult.
WARNING: ALWAYS use safety glasses. Everyday
eyeglasses are NOT safety glasses. Also use face or
dust mask if cutting operation is dusty. ALWAYS WEAR
CERTIFIED SAFETYEQUIPMENT:
• ANSI Z87.1 eye protection (CAN/CSA Z94.3),
• ANSI S12.6 (S3.19) hearing protection,
• NIOSH/OSHA/MSHA respiratoryprotection.
• Metal cutting with router: If using router for metal
cutting, clean out tool often. Metal dust and chips often
accumulate on interior surfaces and could create a risk of
serious injury, electrical shock ordeath.
• Never run the motor unit when it is not inserted in
one of the router bases. The motor is not designed to
behandheld.
• Keep handles dry, clean and free from oil and grease.
This will enable better control of thetool.
• Maintain a firm grip with both hands on the tool to
resist starting torque. Maintain a firm grip on the tool at
all times whileoperating.
• Keep hands away from cutting area above and below
the base. Never reach under the workpiece for any
reason. Keep the router base firmly in contact with the
workpiece whencutting.
• Never touch the bit immediately after use. It may be
extremelyhot.
• Be sure that the motor has stopped completely before
you lay the router down. If the bit is still spinning when
the tool is laid down, it could cause injury ordamage.
• Be sure that the router bit is clear of the workpiece
before starting the motor. If the bit is in contact with the
workpiece when the motor starts, it could make the router
jump, causing damage orinjury.
• Always follow the bit manufacturer’s speed
recommendations as some bit designs require
specific speeds for safety or performance. If you are
unsure of the proper speed or are experiencing any type of
problem, contact the bitmanufacturer.
• Do not use router bits with a diameter in excess of
2–1/2" (63mm) in thistool.
• Do not hand‑hold the router in an upside‑down or
horizontal position. The motor can separate from the
base if not properly attached according to theinstructions.
• Before starting the motor, check to see that the cord
will not snag or impede the routingoperation.
• Keep cutting pressure constant. Do not
overloadmotor.
• Provide clearance under workpiece for bit when
through‑cutting.
• Do not press spindle lock button while the motor is
running. Doing so can damage the spindlelock.
• Always make sure the work surface is free from nails
and other foreign objects. Cutting into a nail can cause
the bit and the tool tojump.
Additional Safety Rules for Routers
• Hold power tool by insulated gripping surfaces
because the cutter may contact its own cord. Cutting a
“live” wire may make exposed metal parts of the tool “live”
and shock theoperator.
• 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.
h ) 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
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 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.
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 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.
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.
h ) 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
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.

7
ENGLISH
General for All Bases
Locking Lever Adjustment (Fig. E)
You should be able to clamp the locking lever without
excessive force. Excessive force may damage thebase.
You should not be able to move the motor in the base
when the locking lever is clamped. To adjust the locking
lever’s clamping force, open the locking lever4 and turn
the nut24 in small increments. Turning the nut clockwise
tightens the lever while turning the nut counterclockwise
loosens thelever.
Detachable Cord Set (Fig. B)
WARNING: To reduce the risk of injury, turn unit
off and disconnect it from power source before
installing and removing cord set from motor
or D‑handle base. Before connecting cord set to
power source, ensure the toggle switch(10and the
D‑handle trigger switch(13 are in the OFF position. An
accidental start‑up can causeinjury.
Insert the detachable cordset plug so that the key38 is
aligned with the notch39 in the socket. Turn the plug
clockwise one quarter turn tolock.
Switch (Fig. A)
To turn the tool on, push the toggle switch10 to the ON
position indicated on the tool. To turn the tool off, push the
toggle switch to the OFF position indicated on thetool.
OPERATION
WARNING: To reduce the risk of serious personal
injury, turn unit off and disconnect it from
power source before making any adjustments or
removing/installing attachments or accessories.
An accidental start‑up can causeinjury.
Motor
Be sure your power supply agrees with the nameplate
marking. Voltage decrease of more than 10% will cause loss
of power and overheating. These tools are factory tested; if
this tool does not operate, check powersupply.
The label on your tool may include the following symbols. The
symbols and their definitions are asfollows:
BPM....................beats per minute
V.........................volts
min..................... minutes
jor DC............direct current
…/min.............. per minute
RPM....................revolutions per
minute
A.........................amperes
Hz .......................hertz
W........................watts
Wh...................... watt hours
no.......................no load speed
n.........................rated speed
c.....................safety alert symbol
h.....................wear respiratory
protection
f.....................wear eye protection
i.....................Class II Construction
(double insulated)
g.....................wear hearing
protection
a.....................read all
documentation
n.....................avoid staring at
light
lor AC............alternating current
Ah.......................amp hours
WARNING:
Some dust created by power sanding,
sawing, grinding, drilling, and other construction
activities contains chemicals known to the State
of California 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.
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.
• 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. Direct particles away from face
andbody.
• Use the appropriate dust extractor vacuum to remove
the vast majority of static and airborne dust. Failure
to remove static and airborne dust could contaminate the
working environment or pose an increased health risk to
the operator and those in closeproximity.
• Use clamps or other practical ways to secure and
support the workpiece to a stable platform. Holding
the work by hand or against your body is unstable and may
lead to loss ofcontrol andinjury.
• Air vents often cover moving parts and should be
avoided. Loose clothes, jewelry or long hair can be caught
in movingparts.
• An extension cord must have adequate wire size
(AWG or American Wire Gauge) for safety. The smaller
the gauge number of the wire, the greater the capacity
of the cable, that is, 16gauge has more capacity than
18gauge. An undersized cord will cause a drop in line
voltage resulting in loss of power and overheating. When
using more than one extension to make up the total length,
be sure each individual extension contains at least the
minimum wire size. The following table shows the correct
size to use depending on cord length and nameplate
ampere rating. If in doubt, use the next heavier gauge. The
lower the gauge number, the heavier thecord.
Minimum Gauge for Cord Sets
Volts Total Length of Cord in Feet
(meters)
120 V 25 (7.6) 50 (15.2) 100 (30.5) 150 (45.7)
240 V 50 (15.2) 100 (30.5) 200 (61.0) 300 (91.4)
Ampere Rating
American Wire Gauge
More
Than
Not
More
Than
0 6 18 16 16 14
610 18 16 14 12
10 12 16 16 14 12
12 16 14 12 Not Recommended

ENGLISH
8
To change the 1/2" (13 mm) collet and nut22, unscrew
the 1/2" (13 mm) collet and nut as described above. Install
the desired 1/2" (13 mm) collet and nut by reversing
theprocedure.
NOTE: The 1/2" (13 mm) collet and the collet nut are
connected. Do not attempt to remove the 1/2" (13 mm)
collet from the colletnut.
NOTICE: Plunge Base Only—When tightening
or changing the 1/2" (13 mm) collet and nut, do
not allow the wrenches to contact the plunge
rods. If the rods are damaged, the plunge action will
berestricted.
Using the Universal Edge Guide (Fig. A)
The universal edge guide (DW6913) is available from your
local retailer or service center at extra cost. Follow the
assembly instructions included with the guide. Insert the
two bars through the holes12 in the router base. Adjust as
needed for parallelrouting.
Direction of Feed (Fig. L)
The direction of feed is very important when routing and can
make the difference between a successful job and a ruined
project. FigureL shows the proper direction of feed for some
typical cuts. A general rule to follow is to move the router in a
counterclockwise direction on an outside cut and a clockwise
direction on an insidecut.
Shape the outside edge of a piece of stock by following
these steps:
1. Shape the end grain, left to right
2. Shape the straight grain side moving left to right
3. Cut the other end grain side
4. Finish the remaining straight grain edge
WARNING: Avoid climb‑cutting (cutting in
direction opposite than shown in FigureL).
Climb‑cutting increases the chance for loss of control
resulting in possible injury. When climb‑cutting is
required (backing around a corner), exercise extreme
caution to maintain control of router. Make smaller
cuts and remove minimal material with eachpass.
Choosing Router Speed (Fig. M)
DW618 only
Refer to the Speed Selection Chart to choose a router speed.
Turn the speed dial7 to control routerspeed.
WARNING: Do not operate tools rated “AC
only” on a DC supply. Loss of speed control may
result, causing tool damage and possible hazard to
theoperator.
WARNING: If the speed control ceases to operate, or
is intermittent, stop using the tool immediately. Take
it to a DeWALT factory or authorized service facility
forrepair.
NOTICE: The router is equipped with electronics to
monitor and maintain the speed of the tool while
cutting. In low and medium speed operation, the speed
control prevents the motor speed from decreasing.
If you expect to hear a speed change and continue
Centering the Subbase (Fig. F)
If you need to adjust, change, or replace the subbase, a
centering tool (DNP617–sold separately) is recommended
(refer to Accessories). The centering tool consists of a cone
and apin.
To adjust the subbase, follow the steps below
1. Loosen but do not remove the subbase screws so that
the subbase can movefreely.
2. Insert the pin into the 1/2" (13 mm) collet and nut22
and tighten thenut.
3. Insert the motor into the base and clamp the locking
lever on thebase.
4. Place the cone on the pin and lightly press down on cone
until it stops as shown. This will center thesubbase.
5. While holding down on the cone, tighten the
subbasescrews.
Bit Installation and Removal (Fig. G)
1. To install a bit, insert the round shank of the desired
router bit into the loosened 1/2" (13 mm) collet and
nut22as far as it will go and then pull it out about 1/16"
(1.6 mm). Using the wrench(es) provided, turn the 1/2"
(13 mm) collet and nut clockwise while holding the
spindle shaft with the second wrench. [On the DW618,
depress the spindle lock button9 to hold the spindle
shaft.] Tighten the 1/2" (13 mm) collet and nut securely
to prevent the bit fromslipping.
2. To remove a bit, hold the spindle shaft while turning
the 1/2" (13 mm) collet and nut22 counterclockwise
with the wrench provided. [Hold the spindle by
depressing the spindle lock button9 on the DW618.]
The self‑releasing 1/2" (13 mm) collet and nut will turn
approximately 3/4 of a turn and then become tight
again. At this point the bit cannot be removed. Continue
turning the collet nut counterclockwise. This lifts the 1/2"
(13 mm) collet and nut, allowing the bit’sremoval.
Collets (Fig. A)
WARNING: Projectile hazard. Only use bits with
shanks that match the supplied collets. Smaller
shank bits will not be secure and could become loose
duringoperation.
CAUTION: Never tighten the 1/2" (13 mm) collet and
nut without first installing a router bit in it. Tightening
an empty 1/2" (13 mm) collet and nut, even by hand,
can damage the1/2" (13 mm) collet andnut.
Two types of collets are included with motor: one is the 1/4"
(6.4mm) insertable collet21 and the second is the 1/2"
(13mm) collet and nut22.
• If the 1/2" (13mm) collet and nut22 is needed, remove
the 1/4" (6.4mm) insertable collet21 from the 1/2"
collet andnut.
• If the 1/4" (6.4mm) insertable collet21 is needed it can
be reassembled by fully inserting it into the 1/2" (13mm)
collet and nut22 .