fi9

.XY (F)

>(r
9
v zb

ffu
a'a
r.! Lu
o
g,a
E
z-
{
tu ..
t: () <.i
o ;6F
o .-zo
=uJf
.i* L2FO

ies scEo
!+uJc

q$
HJ>(L
6?;
E
s.gF
H .rr
O'- co
>2)
F < r.,LJ
O(rO

EE$
I {.n
tr r oL I i
9
4 Ow< z

$i3
gi$
EgE a
lu
z
$H; :
J ( J )
o
E 5 =3
z = E o
G
L.

.eH
=ED
z = =
al
=(E
rq

O=ut rEgE
= 9 o
trbo -_ 6
3nd
, Y I J 5
>\vtt
qU,9 G
(c'hEtr
Fa=
9 = <
4(,=
5 Ef,fi
o c a a
DEWALTIndustrialToolCo., 701 EastJoppa Road,Baltimore,MD 21286
(MAR05)Form No. 631103-00 DW616,DW61B Copyright@ 2003,2005 DeWALT
Thetollowing aretrademarks for oneor moreDeWALT powertools;the yellowandblackcolorscheme;the "D"shap€o
ajr intakegrill;the arrayol pyramidson the handgrip;
the kit boxconfiguration;
andthe arrayof lozenge-shaped
humps
on the surfaceof the tool.

tF YOU HAVE ANY QUESTTONSOR COMMENTSABOUT THIS.OR ANYDTWALTTOOL.

CALL US TOLLFREEAT 1-800-4-D:WALT
(1-800-4s3-92s8).
 SAVE TH ESE UCT IONS
General Safety lnstructions "VSTH
WARNING!Bead and understand all instructions. Failureto fottowallinstruc-
tionslistedbelow,may resultin electricshock,fire and/orseriouspersonatinjury.
sAv E THESE TwSTRUCTTOwS
Salety Instructions For AII Tools
WORKAREA
A Xep your work area clean and wetl tit. Ctuttered benchesand dark areasinvite acci-
dents.
A D,o not operate power tools in explosive atmospheres, such as in the presenceof
flammable liquids, gases, or dust. Power toolscreate sparkswhichmay ignite the dust
or fumes.
A' xep bystanders, children, and visitors away while operating a power tool.
Distractionscan causeyou to losecontrol.
ELECTRICALSAFETY
A Grounded tools must be plugged into an outlet property instatled and groundd in
accordance with all codes and ordinances. Never remove the groundlng prong or
modity the plug in any way. Do not use any adapter ptugs. check with a quatitia
electrician if you are in doubt as to whether the outlet is properly grounded. tf the
tool should electricallymalfunctionor break down, groundingprovides a low resistance
path to carry electricityaway from the user. Thistool usesgroundedconstruction(Sprong
plug) to providea meansto transferelectricalenergysafetyaway from the userin the event
the too! electricallymalfunctions,breaksdown, or the tool case becomeslive. Damageto, or
loss of, one of the 3 plug blades; damage to the plug or cord, or failure to have the toot
plugged into a verified and continuouslygrounded electricalsystem, may result in electric
shock, seriousiniury,or death. To avoid these risksof injury,the tool must,at atttimes,be
maintainedand in proper workingorder (cord,plug blades)and ptugged intoa continuously
groundedelectricdsystem.(Seealso "Cleaning"in the Maintenancesection.)
A Avoid body contact with grounded surtaces such as pipes, radiators, ranges and
. refrigerators. Thereis an increasedriskof electric shockif your body is grounded.
A Do not expose power tools to rain or wet conditions. Waterenteringa power tootwitt
increasethe riskof electricshock.
A, Do not abuse the cord. Never use the cord to carry tools or pult the plug from an
outlet. Kep cord away from heat, oil, sharp edges or moving parts. Replacedam-
aged cords immediately. Damagedcords increasethe riskof electric shock.
A, Wnen operating a power tool outside, use an outdoor extensioncord markd -W 4',
or "W." Thesecordsare ratedfor outdooruse and reducethe riskof electricshock.
EXTENSIONCORDS
A Make sure your extension cord is in good condition. When using an extensioncord,
be sure to use one heavy enough to carry the current your product wilt draw. A vott-
age decreaseof more than 10%willcausea lossof powerand overheating.An undersized
cord will cause a drop in line voltage resulting rn /oss of power and overheating. The fot-
lowingtableshowsthe correctsize to use dependingon cord lengthand nameplateampere
rating.lf in doubt,use the next heaviergage. Thesmallerthe gage number,theheavier the
cord.
MinimumGagelor Cord S,ets
Volts TotalLength of Cord in Feet
120V 0-25 26-50 51-.100 101_150
240V 0_50 51_100 101-200 ?01_300
AmpereRating
More Not more AmericanWire Gage
Than Than
10- 12 16 to 14 12
12 - 16 14 12 Not Recommended
 PERSONALSAFETY
A, Stay alert, watch what you are doing and use common sense when operating a
power toot. Do not use tool white tired or under the influence of drugs, alcohol, or
'medication.
A moment of inattentionwhile operatingpower tools may result in serious
personatiniury.
A Dress properly. Do not wear loose ctothing or iewelry. Contain long hair. Kep your
hair, ciotiing , and gloves away from moving parts. Looseclothes,iewelry,or long hair
can be caughtin moiing parts.Air ventsoftencovermovingpartsandshouldalsobe 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.
A, Remove adjusting keys or wrenches betore turning the tool on. A wrenchor key that
is left attachedto a rotatingpart of the tool may result in personaliniury.
A, Do not overreach. Keep proper footing and balance at all times. Proper footingand
balance enablesbetter controlof the tool in unexpectedsituations.
A gse satety equipment. Always wear eye protection. Dust mask, non-skid safety
shoes,naia nat, or hearingprotectionmust be used for appropriateconditions'
TOOL USEAND CARE
A Use clamps or other practical ways to secure and support the workpiece to a sta'
ble platform. Hotding the work by hand or againstyour body is unstableand may lead
to /oss of control.
A Do not torce tool. lJse the correct toot for your application. The correct tool will do
the job better and sater and the rate for which it is designed.
A Do not use tool if switch does not turn it on or off. Any tool that cannot be controlled
with the switch is dangerousand must be repaired'
A, Disconnect the ptug from the power source betore making any adiustments'
changing accessories, or storing the tool. Such preventativesafety measuresreduce
the riskof startingthe tool accidentally.
A Store idte toots out of reach of children and other untrained persons. Toolsare dan-
gerousin the handsof untrainedusers.
L Maintain toots with care. Keep cutting tools sharp and clean. Propeily maintained
tools,with sharp cutting edges are lesslikely to bind and are easier to control.
A Cnec* for misalignment or binding of moving parts, breakage of parts, and any
other condition that may affect the toots operation. lf damaged, have the tool serv'
iced betore using. Many accidentsare caused by poorly maintainedtools.
A Use only accessories that are recommended by the manutacturer for your model.
Accessoriesthat may be suitabte for one tool may become hazardous when used on
another tool.
SERVICE
A Toot service must be pertormed onty by quatified repair personnel. Serviceor main-
tenancepertormedby unqualifiedpersonnelcouldresultin a riskof iniury.
A Wnenservicing a tool, use only identicat replacement parts.Follow instructions in the
Maintenance section of this manual. Use of unauthorizedpartsor failureto followmain-
tenanceinstructionsmay create a riskof electricshock or iniury.
Specitic Salety Fules lor Bouters
A UoU toot by insutated gripping surfaces when pertorming an operation where the
cutting tool may contact hidden wiring or its own cord. Contact with a "live" wire will
make exposedmetal partsof the tool "live"and shock the operator.
A, Uetat cutting with router: lf using routerfor metalcufting,clean out tool often.Metaldust
and chips often accumulateon interior surfacesand could create a risk of seriousinjury,
electricalshock or death.
A Neverrun the motor unit when it is not insertedin one of the router bases. Themotor
is not designed to be handheld.
A Xep handtesdry, clean, and tre from oit and grease. Thiswittenablebettercontrolof
the tool.
A' Xep hands away from cutting area. Neverreach under the workpiece for any rason.
Kep the router base firmly in contact with the workpi*e when cutting. Hold the
router only by the handles. Theseprecautionswillreducethe riskof personalinjury.
A Use sharp cutters. Dull cuftersmay causethe routerto swerveor stallunder pressure.
A Never touch the bit immdiately after use. lt may be extremetyhot.
L Be sure that the motor has stopped completety betore you lay the router down. tf the
cutter head is still spinning when the topl is laid down, it co_uldcause injury or damage.
il Be sure that the router bit is clear of the workpiece before starting the motor. lf thebit
is in contactwith the workpiecewhen the motor startsit could make the routerjump, caus-
^ ing damage or injury.
IICAUTION: Wearappropriate hearing protectiol, during use. IJndersome conditionsand
durationof use, noise from thisproductmay contributeto hearing loss.
AWARNTNG:Some dustcreatedby power sanding,sawing,grinding,dritling,and other con-
structionactivitiescontainschemicalsknownto causecancer,birlh defectsor otherreproduc-
tive harm. Some examplesof thesechemicalsare:
. lead from lead-basedpaint.
. crystallinesilica from bricksand cementand other masonryproducts.
. arsenicand chromiumfrom chemicallylreatedlumber(CCA)
Your riskfrom these exposuresvaries,dependingon how often you do this type of work. To
reduce your exposure to these chemicals: work in a well ventilated area, and work with
approvedsafetyequipment,such as thosedust masksthat are speciallydesignedto filterout
microscopicpafticles.
. Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling,
and other construction activities. Wearprotective clothing and wash exposed areas
with soap and water.Allowingdust to get into your mouth, eyes, or lay on the skinmay
promoteabsorptionof harmfulchemicals.
AWARNTNG:tJseof thistootcan generateand/or disbursedust,whichmay cause serious
and permanentrespiratoryor otherinjury.Always useNIOSH/OSHAapprovedrespiratorypro-
tection appropriatefor the dust exposure.Direct particles away from face and body.
' The label on your tool may include the followingsymbols. The symbols and definitionsare
as follows:
V ............vo\ts ........alternating
current
A ............amperes - ......direct
current
Hz ..........hert2 t1o..........noloadspeed
W ............watts 14).... . . CtassllConstruction
min..........minutes a ..........earthingterminat
A ..........rufety
atertsymbot .../min ..revolutionsper minute
FAM'LTAN',ZATTON
Motor
YourDeWALTtool is poweredby a DEWALT-built motor.Be sureyourpowersupplyagrees
withthe nameplate marking.
"120V-" meansyourtoolmay be operatedwithalternating currentonly.Do notconnectyour
toolto a directcurrentpowersupply.All DTWALT
toolsare factorytested;if thistooldoesnot
operate,checkthe powersupply.
Switch
To turnthe toolon, pushthe toggleswitchto the on positionindicated on the tool.To turnthe
tool off,pushthe toggleswitchto the off positionindicatedon the tool.
Detachable Cord Eet (Fig. I J
Insertthe detachablecordsetplug so that the key (W) is alignedwith the notch(V) in the
socket.Turnthe plugclockwiseone quarterturnto lock.
A' CnUnOU: Always turn off the toot and remove the plug from the power supply before
detaching the cordset from the tool.
L CeUnOU: Always leave the toggleswitch in the off positionwhen removingor attaching
the cord from the motor. lf the toggle switch is in the on position when the cordset is attached,
the toolwill staft unexpectedly,causing lossof control,personalinjury and/or damageto the
tool or workpiece.

FIG, 1
 SET-IJP:FIXED BASE
Motor Quick Refease (Fig. 2l
LCAUTION: Turnthe routeroff and disconnectit from the power suppty.
1. Openthe lockinglever(D)on the base.
2. Giaspthebase;ith one hand,depressing the quickreleaselatches(A).
3. with the otherhand,graspthe top of the motorunitand liftit fromthe base'

F'|G;----\

( \i ,t=<-'.*
;-> tr
'@l=ryls

lnserting the Motor into the Fixed Base (Fig. 3)

power suppty.
LcAuTtoN: Turn therouteroff and disconnectit from the
1. Openthe lockinglever(D)on the base'
the depthadjustmentrt19 t!)
2. lf the depthadjustmentring(B) is not on the motor,thread
halfwaybetween the top and bottomof the motoras
ontothe motoruntiliii" iing ii"oout
growe on the motor (H) with the
shown.Insertthe motorinio the base Oyitrgningthe Ringsnaps
until the DepthAdjustment
ouidepins(x) on tne base.slidethe moford6wn
intotnb quickreleaselatches (A)'
motorso that it can be positioned
NOTE:Guidepin groovesare locatedon eithersideof the
in two orientations.
-3. Adjustthe depthot cul qv-!ultlgl|*9!:l adjustment rins .qg9the headinsAdjustins the
d6ii oifri in the OP-ERAT;ON: FIXED BASE section of this manual'
(D) when the desireddepth is-achieved' on set-
For information
4. close the lockingtever Cut in the OPERATION:
AOiuitinfithe Depth of
tingthe cuttingO"pin,t.j" ine neaOing
FIXEDBASEsectionof thismanual'
Hotor - Btoc motour - dct motor
A. OUICKFELEASELATCH
"nidtd
B DEPTHADJUSTMENT RING
lixe'Baxe tija C ADJUSTABLE SCALE
Fired Ease'Ease
D LOCKING LEVEB
E. HANDLE
F. SUBBASE
G . S P E E DD I A L( 6 1 8O N L Y )
l\
-i-,1 t(
l \
H , G U I D EP I NG R O O V E
I SPINDLELOCKBUTTON
l,i
',,a.**'',-".', ,i \
( 6 1 8O N L Y ) ':a
:
J . C O L L E TN U T i

''_.--
K. TOGGLESWITCH
L D E T A C H A B LCEO R D S E T i" . '. - -r ' ' : ' it ,
l\,,',r M , H O L E SF O RU N 1 V E R S A L --=
I ll--- '. -
it i'- .^'':'. j . -tt. H
E D G EG U I D E
N. TRIGGER SWITCH a.L
O TRIGGER L O C KB U T T O N " il
i l.-''
P TURRET STOP
O D E PT HA D J U S T i / E NRTO D
R PLUNGE L O C KL E V E R
S D U S TS H R O U D
L='
E
T D U S TC A P
U C E N I - E R I NTGO O L il 1- -J
 Locking Lever Adiustment (Fig. 4)
LCAUTION: Turnthe routeroff and disconnectit from the power supply.
Youshouldbe ableto clampthe lockingleverwithoutexcessive force.Excessive forcemay
damagethe base.
Youshouldnot be ableto movethe motorin the basewhenthe lockingleveris clamped.To
adjustthe lockinglever'sclampingforce,openthe lockinglever(D) and turn the nut (Y) in
smallincrements.Turningthe nut clockwisetightensthe lever,whileturningthe nut counter-
clockwiseloosensthe lever.

Centering the Subbase (Fig. 5)

power supply'
LCnUnOn: Turn therouteroff and disconnectit from the
lf you needto adjust,change,or replacethe,subbase, a centering tool is provided'The cen-
a'pin. To adjust the subbase, follow the stepsbelow'
ifii"g ioil"onsisis oia con"JanO
the subbase screws So that the subbase can movefreely'
1. Loosenbut do not remove
2. Insertthe pin intothe colletandtightenthe colletnut'
3 . | n s e r t t h e m o t o r i n t o t h e b a s e a n d c | a m p t h e l o c k i n g | e v e r o n t h e b a s e , This
it stopsas shown'
4. Placethe coneon the pin and lightlypressdownon the cone until
willcenterthe subbase.
5. Whileholdingdownon the cone,tightenthe subbasescrews'
FIG. 5

OPERATIONT FIXED BASE

Bit lnstallation and Removal (Fig. 6)
ACaUflOU: Turnthe routeroff and disconnectit from the power supply.
1. To installa bit,insertthe roundshankof the desiredrouterbit intothe loosenedcolletas
far as it willgo andthenpullit outabout1/16".Usingthewrench(es) provided, turnthecol-
let nut (J) clockwisewhile holdingthe spindleshaftwith the secondwrench.[On the
DW618,depressthe spindlelockbutton(l)to holdthe spindleshaft.l
2. To removea bit, holdthe spindleshaftwhileturningthe colletnut (J) counterclockwise
withthe wrenchprovided.[Holdthe spindleby depressing the spindlelockbutton(l) on
the DW618.lThe self-releasing colletnut will turn approximately3/4 of a turn and then
becometightagain.At this pointthe bit cannotbe removed.Continueturningthe collet
nut counterclockwise. This liftsthe collet,allowinothe bit'sremoval.
FIG.6

Collets
NOTE:Nevertightenthe colletwithoutfirstinstalling
a routerbit in it.Tightening
an emptycol-
let,evenby hand,can damagethe collet.
Two colletsare includedwith the motor:one 1/4" and one 112".To changecolletsizes,
unscrewthe colletassemblyas describedabove.Installthe desiredcolletby reversingthe
procedure.The colletand the colletnut are connected.Do not attemptto removethe collet
fromthe colletnut.
Adiusting the Depth ol Cut (Fig. 2, 3)
LCAUTION: Turnthe routeroff and disconnectit from the power supply.
1. Selectand installthe desiredbit.Seethe headingBit lnstallationand Removal.
2. Placethe routeron its baseon the work piece.
3. Openthe lockinglever(D)andturnthe depthadjustment ring(B) untilthe bitjusttouches
the workpiece. Turningthe ringclockwise the
raises cuttingheadwhileturningit counter-
clockwiselowersthe cuttinghead.
4. Movethe adjustablescaleclockwise(C) so that 0 on the scaleis locatedexactlyabove
the pointer(Z) on the base.
5. Turnthe depthadjustment ringalongwiththe adjustablescaleto the desireddepth.Note
that each mark on the adjustable scale representsa depth changeof 1164"or.015"
(.4mm).
6. Closethe lockinglever(D).

FIG.3

Using a Parallel Fence

A parallelfence(DW6913)is availablefromyourlocalretaileror servicecenterat extracost.
Followthe assembly included
instructions withthefence.Insertthetwo barsthroughthe edge
guideholesin the routerbase.Adjustas neededfor parallelrouting.
SET-UPI D-HANDLE BASE
Motor Quick Befease
LCAUTION: Turnthe routeroff and disconnectit from the power supply.
1. Openthe lockinglever(D)on the base.
2. Graspthe basewithone handwhiledepressing the quickreleaselatches(A).
3. With the otherhand,graspthe top of the motorunitand lift it fromthe base.

A. OUICKRELEASELATCH
B . D E P T HA D J U S T M E NRTI N G
l€tmee C ADJUSTABLE SCALE
D-llandle Base ' Base de ta Poign6e
Base con mango en D. LOCKINGLEVER
E. HANDLE
F SUBBASE
G S P E E DD I A L( 6 1 8O N L Y ]
H . G U I D EP I NG R O O V E
I, SPINDLELOCKBUTTON
( 6 1 8O N L Y )
J. COLLETNUT
K. TOGGLESWITCH
L. OETACHABLE CORDSET
M . H O L E SF O RU N I V E B S A L
E D G EG U I D E
N. TRIGGERSWITCH
O, TRIGGEBLOCKBUTTON
P. TURRETSTOP
Q, DEPTHADJUSTMENT ROD
R. PLUNGELOCKLEVER
S . D U S TS H R O U D
T' DUSTCAP
U CENTERING TOOL

, ,/
Inserting the Motor into the D-Handle Base (Fig. 7l
LCAUTION: Turnthe routeroff and disconnectit from the power supply.
1. Openthe lockinglever(D)on the base.
2. Threadthedepthadjustment ring(B)ontothemotoruntiltheringis abouthalfwaybetween
the top and bottomof the motor.Insertthe motorintothe base by aligningthe grooveon
the motor(H) withthe guidepins (X) on the base.Slidethe motordown untilthe depth
adjustmentringsnapsintothe quickreleaselatches(A).
3. Closethe lockingleverwhenthedesireddepthis achieved. Forinformation on settingcut-
tingdepth,seethe headingAdjustingthe Depthof Cut in theOPERATION: D-HANDLE
BASE sectionof thismanual.
4. Be surethatthe triggerswitch(N) is releasedand the triggerlockbutton(O) is in the
unlockedand off position.
5. Unlockanddisconnect the detachablecordset(L)fromthe motor.
6. Connectthe detachablecordset(L) to bottomof D-Handleand lockthe cord.
7. Connectthe shortcord(AA)fromtop of D-Handleto the motoras shown.Be surethe cord
is locked.
8. Placethe toggleswitchin the on position. Thisallowsthe triggerswitchon the D-handle
to controltherouter.
FIG 7

Locking Lever Adjustment (Fig. 4)

LCAUTION: Turnthe routeroff and disconnectit from thepower supply.
Youshouldbe ableto clampthe lockingleverwithoutexcessive force.Excessive forcemav
damagethe base.
Youshouldnot be ableto movethe motorin the basewhenthe lockingleveris clamped.To
adjustthe lockinglever'sclampinglorce,openthe lockinglever(D) a-ndturn the nut (y) in
smallincrements.Turningthe nut clockwisetightensthe leverwhileturningthe nut counier-
clockwiseloosensthe lever.

Centering the Subbase (Fig. S)

AC{UnON: Turnthe routeroff and disconnectit from the power supply.
lf you needto adjust,change,or replacethe subbase,a centering tool is provided.
The cen-
teringtool consistsof a coneand a pin.To adjustthe subbase,followthe stepsbelow.
1. Loosenbutdo not removethe subbasescrewsso thatthe subbasecan movefreely.
2. Insertthe pin intothe colletandtightenthe coltetnut.
3. Insertthe motorintothe baseand clampthe lockingleveron the oase.
4. Placethe coneon the pin and lightlypressdownon coneuntilit stopsas shown.Thiswill
centerthe subbase.
FIG.5
5. Whileholdingdownon the cone,tightenthe subbasescrews
OPEBATTON: D-HANDLE BASE
Knob Locations
Gripthe D-Handlewithone handancJplacethe otherfrandcn the the krtob.The D-Handle
routerbasehas two positionsfor the knobto accommodate riEhtor lefthanduse.
A, CAUTION:IJseboth hands at all timesta maintaincontrol.
Trigger Lock
To lockthetrigger,pullihe triggerswitch(N)completely,thenpushthe triggerlockbutton(O).
Therouterwilfremainon afteryouremoveyourfingerfromthetrigger. Tounlockthetriggerlock
button,pullthetriggerand release. The lockbuttonwillpopout andthe routerwillturnoff.
Bit lnstallation and Removal (Fig. 6)
ACAUTION: Turnthe routeroff and disconnectit from the power supply.
1. To installa bit,insertthe roundshankof thedesiredrouterbitintothe loosened colletas far
as it willgo and thenpullit out about1/16".Usingthe wrench(es) provided,turnthe collet
nut (J)clockwise whileholdingthe spindleshaftwiththe secondwrench.[Onthe DW618,
depressthe spindlelockbutton(l) to holdthe spindleshaft.l
2. To removea bit,holdthe spindleshaftwhileturningthecolletnut(J)counterclockwise with
the wrenchprovrded. [Hold the spindleby the
depressing spindle lock button(l) on the
DW618.lTheself-releasing 314of a turnandthenbecome
colletnutwillturnapproximately
tightagain.At thispointthe bitcannotbe removed. turningthecolletnutcounter-
Continue
clockwise. Thisliftsthe collet,allowingthe bit'sremoval
CoIIets
NOTE:Nevertightenthe colletwithoutfirstinstallinga routerbit in it.Tighteningan emptycol-
let,evenby hand,can damagethe collet.
Twocolletsare includedwiththe motor:one 114"and one 112". Tochangecolletsizes,unscrew
the collet assembly as described above. Install the desired collet by reversingthe
procedure.The Do notattemptto removethe colletlrom
colletandthe colletnutare connected.
the colletnut.

FIG.6

| .-r -:,.'/
t i . f .
r--!
/ - .- {
/
.$ r. Ll
E! -. - [' ,

-F- -1 )
t - -

D-tlan.lte Ease - Ease de ta Poign6e lam6c

Base con mango en O
Adjusting the Depth ol Cut (Fig. 3)
LCAUTION: Turnthe routeroff and disconnectit from the power supply.
1. Selectand installthe desiredbit.Seethe headingBit lnstallationand Removal.
2. Placethe routeron its baseon the work piece.
3. Openthe lockinglever(D)andturnthe depthadjustment ring(B) untilthe bitjusttouches
the workpiece. Turning the ringclockwise the
raises cutting headwhileturningit counter-
clockwiselowersthe cuttinghead.
4. Movethe adjustablescaleclockwiseso that 0 on the scaleis locatedexactlyabovethe
pointer(Z)on the base.
5. Turnthe depthadjustment ringalongwiththe adjustablescaleto the desireddepth.Note
that each mark on the adjustablescale representsa depthchangeof 1/64"or.015"
(.4mm).
6. Closethe lockinglever(D).
Using a ParaIIeI Fence
A parallelfence(DW6913)is availablefromyourlocalretaileror servicecenterat extracost.
Followtheassemblyinstructions includedwiththefence.Insertthetwo barsthroughthe holes
in the routerbase.Adjustas neededfor parallelrouting.

SET-UP: PLUNGE BASE (Fig. 8)

Motor Quick Fefease
A,CnUnOlt: Turnthe routeroff and disconnectit from the power suppty.
'1.
Openthe lockinglever(D)on the base.
2. Graspthe top of the motorunitand liftit fromthe base.
Inserting the Motor into the Plunge Base
ACAUTION: Turnthe routeroff and disconnectit from the power supply.
1. Removethe depthadjustment ringfromthe motor.lt is not usedwiththe plungebase.
2. Openthe lockinglever(D)on the baseto ensurethatthe motorproperlyseats.
3. Ensurethatthe plungelocklever(R) is locked.
4. Alignthe flat of the motor'send cap (BB)with pillar(CC)and insertthe motorintothe
plungebaseuntilit stops.
5. Closethe lockinglever(D).

FIG.8
Locking Lever Adiustment (Fig. 4)
A,CAUTION:Turnthe routeroff and disconnectit from the power supply.
Youshouldbe ableto clampthe lockingleverwithoutexcessive force.Excessiveforcemay
damagethe base.
Youshouldnot be ableto movethe motorin the basewhenthe lockingleveris clamped.
To adjustthe lockinglever'sclampingforce,openthe lockinglever(D) and turn the nut
(Y) in smallincrements.
Turningthe nut clockwise tightensthe lever,whileturningthe nut
counterclockwise loosensthe lever.

FIG 4
l. ,l:'.

Centering the Subbase (Fig. 5)

LCAUTION: Turnthe routeroff and disconnectit from the power supply.
lf you need to adjust,change,or replacethe subbase,a centeringtool is providedThe
le?rtJringtool consistsof a doneand a pin.To adjustthe subbase,followthe stepsbelow.
1. Loosenbutdo not removethe subbasescrewsso thatthe subbasecan movefreely.
2. Insertthe pin intothe colletandtightenthe colletnut'
3. Insertthe motorintothe baseandclampthe lockingleveron the base.
4. placethe coneon the pin and lightlypressdownon the coneuntilit stopsas shown.This
willcenterthe subbase.
5. Whileholdingdownon the cone,tightenthe subbasescrews'
FIG.5

\ry
'...'' '. '.)
-:7'

OPERAT,ON: PLU,UGE BASE

Bit lnstallation and Remsval (Fig' 6)
A,CAUTION: Turnthe routeroff and disconnectit from the power supply.
.l. To installa bit,insertthe roundshankof the desiredrouterbit intothe loosenedcolletas
f"r at itwillgoandthenpullitoutabout1/16".Usingthewrench(es) provided, turn.thecol-
i"i dlocfwise-*hit" notoing the s.pindlesliaft with the secondwrench.[On the
1.ti
"rt
DW618;depress the spindlelock[utton (l) to holdthe spindleshaft.l
(J) counterclockwise
2. To removea bit, holdihe spindleshaftwhileturningthe colletnut
wrench proro"o. the spindle by depressing the spindle lockbutton(l) on
withthe [Hold
collet'nut williurn'approximately 3/4 ol a turn and then
in" OWOre.lfndsert-rlleasing the collet
AtiniJ point the bit cannot be removed. Continue turning
6ecometigni again.
nut counte-rcloc-kwise.This liftsthe collet,allowing the bit'sremoval.

Collets
a routerbit rrrit.Tighteningan emptycol-
NoTE: Nevertightenthe colletwithoutfirstinstalling
let,even by hand,can damagethe collet.
Twocolletsare includedwithihe motor:one 114"andone112". To changecolletsizes'unscrew
described above. Install the desired collet by reversing. the
tn" iof f"t assemblyas from
collet
procedure.The colletandthe colletnutareconnected.Do not attempt to removethe
the colletnut.
FIG.6

| -a'/
1
I i '
/ , ' - . !

.& J;

1 l
l
-41,
Adjusting the Plunge Routing Depth (Fig. 8)
LCAUTION: Turnthe routeroff and disconnectit from the power supply.
1. Unlockthe plungemechanism by pushingup the plungelocklever(R).Plungethe router
downas fai as it willgo, allowing the bitto justtouchthe workpiece'
2. Lockthe plunge mechanism by pushing the plungelocklever(R)down'
3. Loosen the depth adjustment rod (Q) by turningthe wingscrew (DD)counterclockwise.
4. Slidethe depthadjustment rod (Q)downso thatit meetsthe lowestturretstop(P)'
5. Slidethetab (EE)on thedepthadjustment roddownso thatthetop of it meetszeroon the
pillarscale(FF).
6. Graspingthe top, knurledsectionof the depthadjustment rod (!), slideit up so thatthe
tab (EEfalignswiththe desireddepthof cut on the pillarscale(FF).
7. Tightenthe wingscrew (DD)toholdthe depthadjustment rod in place.
8. Keepingbothhandson the handles,unlockthe plungemechanism by pushingthe plunge
(R)
lock'levlr up.The plunge mechanism and the motorwill move up. Whenthe routeris
plunged, thedepthadjustment rodwillhittheturetstop,allowing the routerto reachexact-
ly the desireddepth.
Fine Adjustment of Routing DePth
LCAUTTON:Turnthe routeroff and disconnectit from the power supply.
The knurledknob(GG)at the bottomend of the depthadjustment rod can be usedto make
minoradjustments.
1. To decrease (looking
the cuttingdepth,rotatethe knobclockwise downfromthetopof the
router).
2. To increase thecuttingdepth,rotatethe knobcounterclockwise(lookingdownfromthetop
of the router).
NOTE:One completerotationof the knobresultsin a changeof about51128" or .04"(1 mm)
in depth.

FIG.8

Using the Rotating Turret Stop (Fig. g)

Theturretdepthstopcan be usedto set 5 differentdepths.Oneof theturretstopsis adjustable.
]o.u9ethe adjustable turretstop,loosenthe nut (Hnj, thenadjustthe screw(li)to tneoesireo
height.-Turning
the screwcounterclockwise will raisethe screwwhichwilldeciease
-- the
-' - cutting
--'-" i
depth.Theturretstopis usefulfor makingdeepcutsin severalpasses.
AWARNING: Do not chayge the turretstop while the router is running. Thiswiltplace your
hands too near the cutterhead.
FIG 9
Cutting with the Plunge Base (Fig. 8)
ACAUTION: Turnthe routeron beforeplungingthe cutterhead into the workpiece.
1. Unlockthe plungelocklever(R).
2. Plungethe routerdownuntilthe bit reachesthe set depth.
3. Lockthe plungelocklever(R).
4. Performthe cut.
the work.
5. Unlockthe plungelocklever.Thiswillallowthe routerbitto disengage
. 6. Turnthe routeroff.

FIG.8

Dust Extraction (Fig. 1OI

h,CnUnOlt: Turnthe routeroff and disconnectit from the power supply.
To connectthe routerto a vacuumcleanerfor dustextraction, followthesesreps:
1. Removethe dustcap (T) by pullingstraightup.
2. Insertthe dustextractionhoseadapter(JJ)intothe dustextraction pod (KK)as shown.
3. Insertthe end of a standardvacuumcleanertube(LL)intothe hoseadapter.
4. Whenusingdustextraction, be awareof theplacement of thevacuumcleaner. Be surethat
the vacuumcleaneris stableand that its hosewillnot interferewiththe work.

FlG. 10
 OPERATION: ALL BASES
Direction OJ Feed (Fig. | | )
The directionof feedis very importantwhenroutingand can makethe difference betweena
job
successful and a ruineilproject.The figuresat left show the proper ol feed.for
direction
direction
sometypicitcuts.A generaliule-tofollowis to movethe routerin a counterclockwise
on an outsidecut and a clockwise on
direction an inside cut
Shapethe outsideedgeof a pieceof stockby following thesesteps:
1. Shapethe end grain,leftto right
2. Shapethe straightgrainsidemovingleftto right
3. Cutthe otherend grainside
4. Finishthe remaining straightgrainedge

SPEED SELEC7'ON C'IABT

n
ilEteriaf.'-- - - - !!!91!* --"*n,, -settins s
zri"-ttiils affiZ-s"tti"g :e;1i;s.^1
rpm
tai,o6ip. iprn 18'o0o
tn,ooo 24'000
rpm 21'ooo,rpm
Model # Dw618
t,il;; XX
Hardwood,e.g , oak S m a l l( 1 / 2 " )
M e d r u m( 1 / 2 ' ' 1 1 / B ' )
L a r g e( o v e r - 11 / B ' ) _ - X ---II
o XX XX
r^h^,^^d c., 9.,
Softwood, n Plne
nrne Small (1/2') XX XX
X XX
M e d i u m( 1 / 2 " - 11 / 8 ' )
iog++;+e, x -- xI 'xx -
; xx
S m a l l( 1 / 2 " )
chlPboard
Plastic-laminated
M e d i u m( 1 / 2 " - 11 / 8 ' )
"q XX XX XX
(overl!/8')
- o --+--+ - -f XX
--:-
prast,csrsotio ;-!ars-€
Surtace Small(1/2") X
- O XX XX x
Medium( 1 / 2 " -1 / 8 " )
X XX O "
Large(over11/8")
ThistableCanserueon|yasagulde.sincewoodWaSalivingmateria|'Withlnthesan]eSpec|esofhmberhardnessanddens|tyvary
Speed settingsare aPProxlnlate

KEY: XX very good X good O Satisfactory

Choosing Bouter $peed (DW6l I only) (Fig' 12)

dial (G)to controlrouter
Referto the chartaboveto choosea routerspeed.Turnthe speed
speeo.
MA',NTENANCE
Cleaning clean,dry compressed
LWnnUWel Blowing dust and chipsout of the motor housingusing metalparticles
Dust and chips containing
airis a necessaryregularmaintenanceprocedure' or electrocutionil
and could create an electricalshock
often accumulateon intteriorsurlaces
,i6i'iriqi"ittv cteanedout. ALWAYSWEARSAFF'TYGLAssEs' pafts
LCnirtOi, Neveruse solventsor other harshchemicalsfor cleaningthe non'metallic
of the tool. Use a clean, dry rag onlY'
plunge.rods..These
NOTEFOR PLUNGEBASEbttLY:Useonlya DRYclothto wipe_the of yourtool'
Lubricants attractbust,reducing the pedormance
rodsrequireno lubrication.
 Accesso ries
R e c o m m e r r d e d a c c e s s o r i e s l o i L r s ew i t t r 1 , 1 1 g 1 - t o. (l r, ic a v a i l . i b i e a t e x t r a c o s l t r o r n y o u r
locat
dealer or authorized servic^ecetrter. 11yoLr rrcei assist:rnce in locating ai-ryaccessory for your
tool,calius tollfreeat: 1-800-4-DcWALT
(1 800 433-9258) or curttaclDTWALT Industriatiool
Co.,701EastJoppaRoad,Baltimore, MD 2|286.
A CAUTION:The useol any rlllrerirct--ossory
rtot taL:()nttncttded
t'or usewtlt-t1ls tootcoud
be hazardous.
Hepairs
To assure product SAFETY and REI-lAt3lL-il'Y,repairs,mairrtenancearrd adjustment(includ-
ing brush inspectionand replacement)should be performed by authorizedservicecenters
or
other qualifiedservicepersonnel,always using identicalreplacementpafts.
Three Year Limited Warranty
DEWALT will repair,withoutcharge,any de{ectsdue to faultyrnaterials
or workmanship for
threeyearsfromthe dateof purchase. Thiswarrantydoesnotcoverpafifailuredueto normal
wearor tool abuse.For furtherdetailof warranlycoverageand warrantyrepairinformation,
visitwww.dewalt.com or call'l-800-4-DTWALT (1-b00-,13S-bzSai.
Thiswarrantydoesnotappiy
to accessories or damage-.caused wherereparrs havebeenmadeor attempteA by others.this
warrantygivesyou specificlegalrightsand you may haveotherrightswnicnv'aryin certain
statesor provinces.
ln additionto the warranty,
DEWALT rootsare coveredby our:
1 YEARFREESERViCE
DEWALT willmaintain thetoolantlreplacewornpartscausedby norrnaluse,forfree,anytime
duringthe firstyearafterpurchase.
90 DAYMONEYBACKGUARANTEE
lf you are,notcompletely satisfiedwiththe perlonnanceof yourDcWALTpowerTool,Laser,
or Naile-r
for any reason,you can returnit within90 daysfromthe date of purcfrasewitfr-a
receiptfor a fullrefund- no questionsasked
RECONDITIONED PRODUCTReconditioned productis coveredunderthe I year Free
ServiceWarranty. The 90 Day MoneyBackGuarantee and the ThreeYearLimitedWarranty
do not applyto reconditioned product.
FREEWARNINGLABEL REPLACEMENT: lf yourwarninglabelsbecomeittegibte
or are
missing, call 1-800-4-DTWALT tor alree reolacement.