Question about Dewalt DW618 Router

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Dewalt DW618 router operating at continious high speed

While doing a project at my router table, 1/2 round at speed 4, the router suddenly began operating at full speed and it cannot be adjusted to lower speeds with the dial. I fear safety would be a concern. How can I fix this and what is the cause.

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Posted on Jan 02, 2017

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SOURCE: Dewalt 621 fine height adjuster

I would go to and in the middle of the page at the bottom type in your model number and you can go to either a breakdown or the instruction manual. On page 6 and 7 it talks about th fine height adjuster. Hope this helps

Posted on Mar 28, 2009

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SOURCE: i have a dewalt 2

could be brushes stuck, the tubes might have been smashed a little not allowing them to contact the armature or other major electrical problems, Check for continuity thru the brush tubes and see what you get.

Posted on Oct 06, 2009

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I would get a needle file, pair of magnifying glasses, recut those threads as best I can, buy a new collet, and get her going. Or, buy the die for the threads, should be about 1/2 28? I know it is a fine thread, the die will be expensive, or take it to a machine shop and ask them to do it. But get the collet first so they can try it. The new armature is expensive, I replaced one once. I bent the armature.

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With 3 or 4 flathead screws thru the table into the faceplate of the router.

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I wrote a long response to your question, which apparantly has been lost in the web somewhere.
Try to make sure the detachable power cord is properly connected, and twisted 1/4 turn clockwise to lock in place.
Make sure the toggle switch is working freely.
Make sure the collet lock or spindle lock is not engaged.
If that doesn't help, please write back and I'll try to re write a troubleshooting guide for you.
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could be brushes stuck, the tubes might have been smashed a little not allowing them to contact the armature or other major electrical problems, Check for continuity thru the brush tubes and see what you get.

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How to open the case in order to replace the bearings

This is a serious disassembly and re-assembly.

Not only do you need to remove the yellow plastic cover end, but also disassemble the collet end. Depending on which version 618 you have it may have screws on the collet end or just a large nut. Sometimes you can't see the screws because they are plugged or covered with wood dust. The bearing is press-fit on the shaft on at least one end and requires an arbor press and special pressing sleeve. So you can only get so far on one of the 618 models then you have to use the arbor press to finish disassembly. The outside of the bearing sits in a very very close fit bore in the aluminum housing, which often becomes very difficult to disassemble without heating the aluminum housing. One bearing (top) must be pressed off the shaft and the replacement bearing precisely positioned where the old one was, so you need to measure with an inside snap gage, a dial caliper tail or depth micrometer to assure proper re-positioning. If you don't get it right then the motor shroud will rub the housing and the shaft won't sit right in the lower bearing.

You also need to replace the brushes while you have it apart. Between the labor, brushes and bearings cost you are better off taking it to a DeWalt service center - but even so, the cost to replace the router would usually be less than the service cost if it is out of warranty! Be very careful to make sure if you or anyone does do this job that the replacement bearings are properly rated for high speed - otherwise you'll be doing the job again in a few months of use.

Feb 28, 2009 | Dewalt DW618 Router

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