DeWalt 618 OM
DeWalt 618 OM
DeWalt 618 OM
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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.
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
''_.--
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.
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
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
FIG.6
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r--!
/ - .- {
/
.$ r. Ll
E! -. - [' ,
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t - -
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:'.
\ry
'...'' '. '.)
-:7'
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
FIG.8
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
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