DeWalt DW616 Instruction Manual page 11

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.
sPEED sElECTiOn ChART
DiAl sETTing
1
2
3
4
5
6
The speeds in this chart are approximate and are for
reference only. Your router may not produce the exact speed
listed for the dial setting.

WARNING: 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.
Set‑up: Fixed and D–Handle Base
Motor Quick Release (Fig. A)
1. Open the locking lever
2. Grasp the base with one hand while depressing the quick
release latches 1 .
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. A, C, D, H)
1. Open the locking lever
2. Thread the depth adjustment ring
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
pins 23 on the base. Slide the motor down until the
depth adjustment ring snaps into the quick release
latches .
1
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 (Fig. h)
1. Be sure that the trigger switch
the trigger lock button
off position.
2. Unlock and disconnect the detachable cordset
the motor.
3. Connect the detachable cordset
D‑Handle and lock the cord.
APPROX. RPM
8000
12000
14000
18000
21000
24000
on the base.
4
4 on the base.
2 onto the motor
8 with the guide
is released and
13
is in the unlocked and
14
11
to bottom of
11
4. Connect the short cord
motor as shown. Be sure the cord is locked.
5. 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. A, C, H)
1. Select and install the desired bit. See the heading Bit
Installation and Removal.
2. Place the router on its base on the workpiece.
3. Open the locking lever
ring 2 until the bit just touches the workpiece. 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
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
Operation: Fixed and D–Handle Base
Gripping Locations (Fig. A)
Fixed handle Base: Grip both knob handles
while operating.
D‑handle Base: Grip D‑Handle
while operating.
The D‑Handle router base has two positions for the knob to
accommodate right or left hand use.
Trigger Lock (Fig. A)
D‑handle Base Only
To lock the trigger, pull the trigger switch
then push the trigger lock button
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. A, I, J, K)
Motor Quick Release
1. Open the locking lever
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
motor properly seats.
3. Ensure that the plunge lock lever
4. Align the flat of the motor's end cap
and insert the motor into the plunge base until it stops.
5. Close the locking lever
from
26 from top of D‑Handle to the
4 and turn the depth adjustment
25
.
4
5
and knob handle
20
completely,
13
. The router will remain
14
4 on the base.
on the base to ensure that the
4
17 is locked.
with pillar
27
4 .
English
on
5
28
9