DeWalt DW618 Instruction Manual

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DEWALT Industrial Tool
(MAR05) Form No. 631103-00
The following are trademarks for one or more DEWALT 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.
Co., 701 East Joppa Road, Baltimore, MD 21286
DW616, DW618 Copyright © 2003, 2005 DEWALT
IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS, OR ANY DEWALT TOOL,
CALL US TOLL FREE AT 1-800-4-DEWALT (1-800-433-9258).
SAVE THESE INSTRUCTIONS
General Safety Instructions
A ARNIN!! Read and understand all instructions. Failure to follow all instruc-
tions listed below, may result in electric shock, fire and/or serious personal injury.
SAVE THESE INSTRUCTIONS
Safety Instructions For All Tools
WORK AREA
Keep your work area clean and well lit. Cluttered benches and dark areas invite acci-
dents.
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 bystanders, children, and visitors away while operating a power tooL
Distractions can cause you to lose control
ELECTRICAL SAFETY
Grounded tools must be plugged into an outlet properly installed and grounded in
accordance with all codes and ordinances. Never remove the grounding prong or
modify the plug in any way. Do not use any adapter plugs. Check with a qualified
electrician ff you are in doubt as to whether the outlet is properly grounded. If the
tool should electrically malfunction or break down, grounding provides a low resistance
path to carry electricity away from the user. This tool uses grounded construction (3 prong
plug) to provide a means to transfer electrical energy safely away from the user in the event
the tool electrically malfunctions, breaks down, or the tool case becomes five. Damage to, or
loss of, one of the 3 plug blades; damage to the plug or cord, or failure to have the tool
plugged into a verified and continuously grounded electrical system, may result in electric
shock, serious inju84, or death. To avoid these risks of inju84, the tool must, at all times, be
maintained and in proper working order (cord, plug blades) and plugged into a continuously
grounded electrical system. (See also "Cleaning" in the Maintenance section.)
Avoid body contact with grounded surfaces such as pipes, radiators, ranges and
refrigerators. There is an increased risk of electric shock if your body is 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 to carry tools or pull the plug from an
outlet. Keep cord away from heat, oil, sharp edges or moving parts. Replace dam-
aged cords immediately. Damaged cords increase the risk of electric shock.
_& When operating a power tool outside, use an outdoor extension cord marked "'W-A"
or "'W." These cords are rated for outdoor use and reduce the risk of electric shock.
EXTENSION CORDS
Make sure your extension cord is in good condition. When using an extension cord,
be sure to use one heavy enough to carry the current your product will draw. A volt-
age decrease of more than 10% will cause a loss of power and overheating. An undersized
cord will cause a drop in line voltage resulting in loss of power and overheating. The fol-
lowing table shows the correct size to use depending on cord length and nameplate ampere
rating. If in doubt, use the next heavier gage. The smaller the gage number, the heavier the
cord.
Minimum Gaqe for Cord Sets
Volts Total Length of Cord in Feet
120V 0-25 26-50 51-100 101-150
240V 0-50 51-100 101-200 201-300
Ampere Rating
More Not more American Wire Gage
Than Than
10 - 12 16 16 14 12
12 - 16 14 12 Not Recommended
PERSONAL SAFETY
Stay alert, watch what you are doing and use common sense when operating a
power tool. Do not use tool while tired or under the influence of drugs, alcohol, or
medication. A moment of inattention while operating power tools may result in serious
personal injury.
_& Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your
hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair
can be caught in moving parts. Air vents often cover moving parts and should also be avoided.
A Avoid accidental starting. Be sure switch is off before plugging in. Carrying
tools with your finger on the switch or plugging in tools that have the switch on invites
accidents.
_& Remove adjusting keys or wrenches before turning the tool on. A wrench or key that
is left attached to a rotating part of the tool may result in personal injury.
Do not overreach. Keep proper footing and balance at all times. Proper footing and
balance enables better control of the tool in unexpected situations.
Use safety equipment. Always wear eye protection. Dust mask, non-skid safety
shoes, hard hat, or hearing protection must be used for appropriate conditions.
TOOL USE AND CARE
Use clamps or other practical ways to secure and support the workpiece to a sta-
ble platform. Holding the work by hand or against your body is unstable and may lead
to loss of control
Do not force tool Use the correct tool for your application. The correct tool will do
the job better and safer and the rate for which it is designed.
_& Do not use tool if switch does not turn it on or off. Any tool that cannot be controlled
with the switch is dangerous and must be repaired.
Disconnect the plug from the power source before making any adjustments,
changing accessories, or storing the tool Such preventative safety measures reduce
the risk of starting the tool accidentally.
Store idle tools out of reach of children and other untrained persons. Tools are dan-
gerous in the hands of untrained users.
Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained
tools, with sharp cutting edges are less likely to bind and are easier to control
_ Check for misalignment or binding of moving parts, breakage of parts, and any
other condition that may affect the tools operation, ff damaged, have the tool serv-
iced before using. Many accidents are caused by poorly maintained tools.
Use only accessories that are recommended by the manufacturer for your modeL
Accessories that may be suitable for one tool may become hazardous when used on
another tool.
SERVICE
Tool service must be performed only by qualified repair personneL Service or main-
tenance performed by unqualified personnel could result in a risk of injury.
_ When servicing a tool use only identical replacement parts. Follow instructions in the
Maintenance section of this manual Use of unauthorized parts or failure to follow main-
tenance instructions may create a risk of electric shock or injury.
Specific Safety Rules for Routers
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 "five" wire will
make exposed metal parts of the tool "live" and shock the operator.
Metal cutting with router: ff 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 un# when # 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
Keep hands away from cutting area. Never reach under the workpiece for any reason.
Keep the router base firmly in contact with the workpiece when cutting. Hold the
router only by the handles. These precautions will reduce the risk of personal injury,
Use sharp cutters. Dull cutters may cause the router to swerve or stall under pressure.
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. ff the
cutter head 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, ff the bit
is in contact with the workpiece when the motor starts it could make the router jump, caus-
ing damage or injury,
_ CAUTION: Wear appropriate hearing protection during use. Under some conditions and
duration of use, noise from this product may contribute to hearing loss.
/& WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other con-
struction activities contains chemicals known to cause cancer, birth defects or other reproduc-
tive harm. Some examples of these chemicals are:
• lead from lead-based paint.
• crystalline silica from bricks and cement and other masonry products.
• 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 pro-
tection appropriate for the dust exposure. Direct particles away from face and body.
• The label on your tool may include the following symbols. The symbols and definitions are
as follows:
V ............ volts
A ............ amperes
Hz ..........hertz
W ............ watts
min ..........minutes
_, ..........safety alert symbol
........ alternating current
.... ...... direct current
no .......... no load speed
[] .......... Class II Construction
.......... earthing terminal
.../min ..revolutions per minute
FAMILIARIZATION
Motor
Your DEWALT tool is powered by a DEWALT-built motor. Be sure your power supply agrees
with the nameplate marking.
"120 V-" means your tool may be operated with alternating current only. Do not connect your
tool to a direct current power supply. All DEWALT tools are factory tested; if this tool does not
operate, check the power supply.
Switch
To turn the tool on, push the toggle switch 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.
Detachable Cord Set (Fig. f)
Insert the detachable cordset plug so that the key (W) is aligned with the notch (V) in the
socket. Turn the plug clockwise one quarter turn to lock.
CAUTION: Always turn off the tool and remove the plug from the power supply before
detaching the cordset from the tooL
CAUTION: Always leave the toggle switch in the off position when removing or attaching
the cord from the motor, ff the toggle switch is in the on position when the cordset is attached,
the tool will start unexpectedly, causing loss of control personal injury, and/or damage to the
tool or workpiece.
SET-UP: FIXED BASE
Motor Quick Release (Fig. 2)
_ CAUTION: Turn the router off and disconnect it from the power supply,
1. Open the locking lever (D) on the base.
2. Grasp the base with one hand, 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 Fixed Base (Fig. 3)
_&CAUTION: Turn the router off and disconnect it from the power supply,
1. Open the locking lever (D) on the base.
2. If the depth adjustment ring (B) is not on the motor, thread the depth adjustment ring (B)
onto the motor until the ring is about halfway between the top and bottom of the motor as
shown. 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. Adjust the depth of cut by turning the depth adjustment ring. See the heading Adjusting the
Depth of Cut in the OPERATION: FIXED BASE section of this manual.
4. Close the locking lever (D) when the desired depth is achieved. For information on set-
ting the cutting depth, see the heading Adjusting the Depth of Cut in the OPERATION:
FIXED BASE section of this manual.
Locking Lever Adjustment (Fig. 4)
CAUTION: Turn the router off and disconnect it from the power supply,
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 (D) and turn the nut (Y) in
small increments. Turning the nut clockwise tightens the lever, while turning the nut counter-
clockwise loosens the lever.
Centering the Subbase (Fig. 5)
CAUTION: Turn the router off and disconnect it from the power supply,
If you need to adjust, change, or replace the subbase, a centering tool is provided. The cen-
tering 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 collet and tighten the collet 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 the cone until it stops as shown. This
will center the subbase.
5. While holding down on the cone, tighten the subbase screws.
OPERATION: FIXED BASE
Bit Installation and Removal (Fig. 6)
_ CAUTION: Turn the router off and disconnect it from the power supply.
1. To install a bit, insert the round shank of the desired router bit into the loosened collet as
far as it will go and then pull it out about 1/16". Using the wrench(es) provided, turn the col-
let nut (J) clockwise while holding the spindle shaft with the second wrench. [On the
DW618, depress the spindle lock button (I) to hold the spindle shaft.]
2. To remove a bit, hold the spindle shaft while turning the collet nut (J) counterclockwise
with the wrench provided. [Hold the spindle by depressing the spindle lock button (I) on
the DW618.] The self-releasing collet 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 collet, allowing the bit's removal.
Collets
NOTE: Never tighten the collet without first installing a router bit in it. Tightening an empty col-
let, even by hand, can damage the collet.
Two collets are included with the motor: one 1/4" and one 1/2". 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.
Adjusting the Depth of Cut (Fig. 2, 3)
CAUTION: Turn the router off and disconnect it from the power supply.
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 counter-
clockwise lowers the cutting head.
4. Move the adjustable scale clockwise (C) 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"
(.4mm).
6. Close the locking lever (D).
Using a Parallel Fence
A parallel fence (DW6913) is available from your local retailer or service center at extra cost.
Follow the assembly instructions included with the fence. Insert the two bars through the edge
guide holes in the router base. Adjust as needed for parallel routing.
SET-UP: D-HANDLE BASE
Motor Quick Release
CAUTION: Turn the router off and disconnect it from the power supply,
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 D-Handle Base (Fig. 7)
CAUTION: Turn the router off and disconnect it from the power supply,
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).
3. Close the locking lever when the desired depth is achieved. For information on setting cut-
ting depth, see the heading Adjusting the Depth of Cut in the OPERATION: D-HANDLE
BASE section of this manual.
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.