DeWalt DW616 Instruction Manual page 2

Two collets are included with the motor: one 1/4" (6.4 mm) and one 1/2" (13 mm). To
change collet sizes, unscrew the collet assembly as described above. Install the desired collet by
reversing the procedure.The collet and the collet nut are connected. Do not attempt to remove
the collet from the collet nut.
NOTICE: Plunge Base Only—When tightening or changing collets, 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 1)
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 (M) in the router base. Adjust as needed for parallel routing.
DIRECTION OF FEED (FIG. 11)
The direction of feed is very important when routing and can make the difference between a
successful job and a ruined project. Figure 11 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 11). 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 (DW618 ONLY) (FIG. 12)
Refer to the Speed Selection Chart to choose a router speed. Turn the speed dial (G) 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 D WALT factory or authorized service facility for repair.
E
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 to load the motor, you
could damage the motor by overheating. Reduce the depth of cut and/or slow the feed rate to
prevent tool damage.
Set-up: Fixed and D-Handle Base
MOTOR QUICK RELEASE (FIG. 1)
1. Open the locking lever (D) on the base.
2. Grasp the base with one hand while depressing the quick release latches (A).
3. With the other hand, grasp the top of the motor unit and lift it from the base.
INSERTING THE MOTOR INTO THE BASE (FIG. 1–3, 7)
1. Open the locking lever (D) on the base.
2. Thread the depth adjustment ring (B) onto the motor until the ring is about halfway between
the top and bottom of the motor. Insert the motor into the base by aligning the groove on
the motor (H) with the guide pins (X) on the base. Slide the motor down until the depth
adjustment ring snaps into the quick release latches (A).
NOTE: Guide pin grooves are located on either side of the motor so that it can be positioned
in two orientations.
3. Close the locking lever when the desired depth is achieved. For in formation on setting
cutting depth, refer to Adjusting the Depth of Cut.
For D-Handle Base Only
4. Be sure that the trigger switch (N) is released and the trigger lock button (O) is in the
unlocked and off position.
5. Unlock and disconnect the detachable cordset (L) from the motor.
6. Connect the detachable cordset (L) to bottom of D-Handle and lock the cord.
7. Connect the short cord (AA) from top of D-Handle to the motor as shown. Be sure the cord
is locked.
8. Place the toggle switch in the ON position. This allows the trigger switch on the D-handle to
control the router.
ADJUSTING THE DEPTH OF CUT (FIG. 1, 3)
1. Select and install the desired bit. See the heading Bit Installation and Removal.
2. Place the router on its base on the work piece.
3. Open the locking lever (D) and turn the depth adjustment ring (B) until the bit just touches
the work piece. Turning the ring clockwise raises the cutting head while turning it
counterclockwise lowers the cutting head.
4. Move the adjustable scale clockwise so that 0 on the scale is located exactly above the
pointer (Z) on the base.
5. Turn the depth adjustment ring along with the adjustable scale to the desired depth.
Note that each mark on the adjustable scale represents a depth change of 1/64" or
.015" (0.4 mm).
6. Close the locking lever (D).
Operation: Fixed and D-Handle Base
GRIPPING LOCATIONS (FIG. 1)
Fixed Handle Base: Grip both knob handles (E) while operating.
D-Handle Base: Grip D-Handle (U) and knob handle (E) while operating.
The D-Handle router base has two positions for the knob to accommodate right or left hand use.
TRIGGER LOCK (FIG. 1)
D-Handle Base Only
To lock the trigger, pull the trigger switch (N) completely, then push the trigger lock button (O).
The router will remain on after you remove your finger from the trigger. To unlock the trigger
lock button, pull the trigger and release. The lock button will pop out and the router will turn off.
Set-up: Plunge Base (Fig. 1, 8–10)
MOTOR QUICK RELEASE
1. Open the locking lever (D) on the base.
2. Grasp the top of the motor unit and lift it from the base.
INSERTING THE MOTOR INTO THE PLUNGE BASE
1. Remove the depth adjustment ring from the motor. It is not used with the plunge base.
2. Open the locking lever (D) on the base to ensure that the motor properly seats.
3. Ensure that the plunge lock lever (R) is locked.
4. Align the flat of the motor's end cap (BB) with pillar (CC) and insert the motor into the plunge
base until it stops.
5. Close the locking lever (D).
ADJUSTING THE PLUNGE ROUTING DEPTH (FIG. 8)
1. Unlock the plunge mechanism by pushing up the plunge lock lever (R). Plunge the router
down as far as it will go, allowing the bit to just touch the workpiece.
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 the depth adjustment rod (Q) down so that it meets the lowest turret stop (P).
5. Slide the tab (EE) on the depth adjustment rod down so that the top of it meets zero on the
pillar scale (FF).
6. Grasping the top, knurled section of the depth adjustment rod (Q), slide it up so that the tab
(EE) aligns with the desired depth of cut on the pillar scale (FF).
7. Tighten the wingscrew (DD) to hold the depth adjustment rod in place.
8. Keeping both hands on the handles, unlock the plunge mechanism by pushing the plunge
lock lever (R) up. The plunge mechanism and the motor will move up. When the router is
plunged, the depth adjustment rod will hit the turret stop, allowing the router to reach exactly
the desired depth.
FINE ADJUSTMENT OF ROUTING DEPTH
The knurled knob (GG) at the bottom end of the depth adjustment rod can be used to make
minor adjustments.
1. To decrease the cutting depth, rotate the knob clockwise (looking down from the top of the
router).
2. To increase the cutting depth, rotate the knob counterclockwise (looking down from the top
of the router).
NOTE: One complete rotation of the knob results in a change of about 5/128" or .04" (1 mm)
in depth.
USING THE ROTATING TURRET STOP (FIG. 9)
WARNING: Do not change the turret stop while the router is running. This will place your
hands too near the cutter head.
The turret depth stop can be used to set 5 different depths. One of the turret stops is adjustable.
To use the adjustable turret stop, loosen the nut (HH), then adjust the screw (II) to the desired
height. Turning the screw counterclockwise will raise the screw which will decrease the cutting
depth. The turret stop is useful for making deep cuts in several passes.
DUST EXTRACTION (FIG. 8, 10)
To connect the router to a vacuum cleaner for dust extraction, follow these steps:
1. Remove the dust cap (T) by pulling straight up.
2. Insert the dust extraction hose adapter (JJ) into the dust extraction port (KK) as shown.
3. Insert the end of a standard vacuum cleaner tube (LL) into the hose adapter.
4. When using dust extraction, be aware of the placement of the vacuum cleaner. Be sure that
the vacuum cleaner is stable and that its hose will not interfere with the work.
Operation: Plunge Base
GRIPPING LOCATIONS (FIG. 1)
Grip both knob (E) handles while operating.
CUTTING WITH THE PLUNGE BASE (FIG. 8)
CAUTION: Turn the router on before plunging the cutter head into the workpiece.
1. Unlock the plunge lock lever (R).
2. Plunge the router down until the bit reaches the set depth.
3. Lock the plunge lock lever (R).
4. Perform the cut.
5. Unlock the plunge lock lever. This will allow the router bit to disengage the work.
6. Turn the router off.
MAINTENANCE
WARNING: To reduce the risk of injury, turn unit off and disconnect it from power
source before installing and removing accessories, before adjusting or when making
repairs. An accidental start-up can cause injury.
Cleaning
WARNING: Blow dirt and dust out of all air vents with clean, dry air at least once a week.
To minimize the risk of eye injury, always wear ANSI Z87.1 approved eye protection when
performing this.
WARNING: Never use solvents or other harsh chemicals for cleaning the non-metallic parts
of the tool. These chemicals may weaken the plastic materials used in these parts. Use a cloth
dampened only with water and mild soap. Never let any liquid get inside the tool; never immerse
any part of the tool into a liquid.
NOTE FOR PLUNGE BASE ONLY: Use only a DRY cloth to wipe the plunge rods. These rods
require no lubrication. Lubricants attract dust, reducing the performance of your tool.