Milwaukee 5615 User Manual
OPERATOR'S MANUAL
MANUEL de L'UTILISATEUR
MANUAL del OPERADOR
Catalog No.
No de Cat.
Catálogo No.
5615 & 5619 Series
5615 & 5619 Série
5615 & 5619 Serie
FPO
HEAVY-DUTY ROUTERS
TOUPIES EXTRA-ROBUSTES
BURILADORAS PARA SERVICIO PESADO
TO REDUCE THE RISK OF INJURY, USER MUST READ AND UNDERSTAND
OPERATOR'S MANUAL.
AFIN DE RÉDUIRE LE RISQUE DE BLESSURES, L'UTILISATEUR DOIT LIRE ET
BIEN COMPRENDRE LE MANUEL DE L'UTILISATEUR.
PARA REDUCIR EL RIESGO DE LESIONES, EL USUARIO DEBE LEER Y
ENTENDER EL MANUAL DEL OPERADOR.
GENERAL SAFETY RULES
READ AND UNDERSTAND ALL INSTRUCTIONS
Failure to follow all instructions listed below, may result in
electric shock, fire and/or serious personal injury.
SAVE THESE INSTRUCTIONS
WORK AREA
1. Keep your work area clean and
well lit. Cluttered benches and dark
areas invite accidents.
2. Do not operate power tools in ex-
plosive atmospheres, such as in
the presence of flammable liquids, gases, or dust. Power tools
create sparks which may ignite the dust
or fumes.
3. Keep bystanders, children, and
visitors away while operating a
power tool. Distractions can cause
you to lose control. Protect others in
the work area from debris such as
chips and sparks. Provide barriers or
shields as needed.
ELECTRICAL SAFETY
4. 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 adaptor plugs. Check with
a qualified electrician if you are in
doubt as to whether the outlet is
properly grounded. If the tools
should electrically malfunction or break
down, grounding provides a low resistance path to carry electricity away
from the user.
5. Double Insulated tools are
equipped with a polarized plug
(one blade is wider than the other).
This plug will fit in a polarized outlet only one way. If the plug does
not fit fully in the outlet, reverse
the plug. If it still does not fit, contact a qualified electrician to install
a polarized outlet. Do not change
WARNING!
the plug in any way. Double insulation eliminates the need for the
three wire grounded power cord and
grounded power supply system.
6. 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.
7. Do not expose power tools to rain
or wet conditions. Water entering a
power tool will increase the risk of electric shock.
8. Do not abuse the cord. Never use
the cord to carry the tools or pull
the plug from an outlet. Keep cord
away from heat, oil, sharp edges
or moving parts. Replace damaged
cords immediately. Damaged cords
increase the risk of electric shock.
9. When operating a power tool out-
side, use an outdoor extension
cord marked W-A or W. These
cords are rated for outdoor use and
reduce the risk of electric shock.
PERSONAL SAFETY
10. 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 op-
erating power tools may result in serious personal injury.
11. 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.
12. Avoid accidental starting. Be sure
switch is off before plugging in.
Carrying tools with your finger on the
switch or plugging in tools with the
switch on invites accidents.
13. Remove adjusting keys or
wrenches before turning the tool
on. A wrench or a key that is left at-
tached to a rotating part of the tool may
result in personal injury.
14. Do not overreach. Keep proper
footing and balance at all times.
Proper footing and balance enables
better control of the tool in unexpected
situations.
15. 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
16. Use clamps or other practical way
to secure and support the
workpiece to a stable platform.
Holding the work by hand or against
your body is unstable and may lead to
loss of control.
17. Do not force tool. Use the correct
tool for your application. The correct tool will do the job better and safer
at the rate for which it is designed.
18. 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.
19. Disconnect the plug from the
power source before making any
adjustments, changing accessories, or storing the tool. Such pre-
ventive safety measures reduce the
risk of starting the tool accidentally.
20. Store idle tools out of reach of chil-
dren and other untrained persons.
Tools are dangerous in the hands of
untrained users.
21. Maintain tools with care. Keep cut-
ting tools sharp and clean. Properly
maintained tools with sharp cutting edge
are less likely to bind and are easier to
control. Do not use a damaged tool.
Tag damaged tools Do not use until
repaired.
22. Check for misalignment or bind-
ing of moving parts, breakage of
parts, and any other condition that
may affect the tools operation. If
damaged, have the tool serviced
before using. Many accidents are
caused by poorly maintained tools.
23. Use only accessories that are rec-
ommended by the manufacturer
for your model. Accessories that may
be suitable for one tool, may become
hazardous when used on another tool.
SERVICE
24. Tool service must be performed
only by qualified repair personnel.
Service or maintenance performed by
unqualified personnel could result in a
risk of injury.
25. 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 Maintenance Instructions may create a risk of electric shock or injury.
2 3
GROUNDING
EXTENSION CORDS
WARNING!
Improperly connecting the
grounding wire can result in the
risk of electric shock. Check
with a qualified electrician if you
are in doubt as to whether the
outlet is properly grounded. Do
not modify the plug provided
with the tool. Never remove the
grounding prong from the plug.
Do not use the tool if the cord or
plug is damaged. If damaged,
have it repaired by a MILWAUKEE
service facility before use. If the
plug will not fit the outlet, have a
proper outlet installed by a qualified electrician.
Grounded Tools:
Tools with Three Prong Plugs
Tools marked Grounding Required have
a three wire cord and three prong grounding plug. The plug must be connected to a
properly grounded outlet (See Figure A). If
the tool should electrically malfunction or
break down, grounding provides a low resistance path to carry electricity away from
the user, reducing the risk of electric shock.
The grounding prong in the plug is connected through the green wire inside the
cord to the grounding system in the tool.
The green wire in the cord must be the
only wire connected to the tool's grounding system and must never be attached to
an electrically live terminal.
Your tool must be plugged into an appropriate outlet, properly installed and
grounded in accordance with all codes and
ordinances. The plug and outlet should look
like those in Figure A.
Double Insulated Tools:
Tools with Two Prong Plugs
Tools marked Double Insulated do not require grounding. They have a special
double insulation system which satisfies
OSHA requirements and complies with the
applicable standards of Underwriters Laboratories, Inc., the Canadian Standard Association and the National Electrical Code.
Double Insulated tools may be used in either of the 120 volt outlets shown in
Figures B and C.
Grounded tools require a three wire extension cord. Double insulated tools can
use either a two or three wire extension
cord. As the distance from the supply outlet increases, you must use a heavier
gauge extension cord. Using extension
cords with inadequately sized wire causes
a serious drop in voltage, resulting in loss
of power and possible tool damage. Refer
to the table shown to determine the required minimum wire size.
The smaller the gauge number of the wire,
the greater the capacity of the cord. For
example, a 14 gauge cord can carry a
higher current than a 16 gauge cord. When
using more than one extension cord to make
up the total length, be sure each cord contains at least the minimum wire size required. If you are using one extension cord
for more than one tool, add the nameplate
amperes and use the sum to determine the
required minimum wire size.
Guidelines for Using Extension Cords
If you are using an extension cord out-
doors, be sure it is marked with the
suffix W-A (W in Canada) to indicate that it is acceptable for outdoor
use.
Be sure your extension cord is prop-
erly wired and in good electrical
condition. Always replace a damaged
extension cord or have it repaired by a
qualified person before using it.
Protect your extension cords from
sharp objects, excessive heat and
damp or wet areas.
Recommended Minimum Wire
Gauge for Extension Cords*
Nameplate
Amperes
0 - 2.0
2.1 - 3.4
3.5 - 5.0
5.1 - 7.0
7.1 - 12.0
12.1 - 16.0
16.1 - 20.0
* Based on limiting the line voltage drop to
five volts at 150% of the rated amperes.
Extension Cord Length
25'
18
18
18
18
16
14
12
READ AND SAVE ALL INSTRUCTIONS FOR FUTURE USE.
50'
18
18
18
16
14
12
10
75'
18
18
16
14
12
10
100'
150'
18
16
16
14
14
12
12
12
10
--
--
--
--
--
--
Fig. A
Fig. B
4 5
Fig. C
Symbology
Double Insulated
Canadian Standards
Association
Underwriters
Laboratories, Inc.
Volts Alternating Current
No Load Revolutions
per Minute (RPM)
Amperes
SPECIFIC SAFETY RULES - ROUTERS
FUNCTIONAL DESCRIPTION
1. 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 live
wire will make exposed metal parts of tool live and shock the operator.
2. Maintain labels and nameplates. These carry important information. If
unreadable or missing, contact a MILWAUKEE service facility for a free replacement.
3. Always wear safety goggles and dust mask. Use only in a well ventilated
area. Using personal safety devices and in a safe environment reduce the risk for
injury.
4. WARNING! Some dust created by power sanding, sawing, grinding, drilling, and other
construction activities contains chemicals known to cause cancer, birth defects or
other reproductive harm. Some examples of these chemicals are:
lead from lead-based paint
crystalline silica from bricks and cement and other masonry products, and
arsenic and chromium from chemically-treated lumber.
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 specifically
designed to filter out microscopic particles.
5. Some woods contain preservatives that can be toxic. Take extra care to
prevent inhalation and skin contact when working with these materials. Request, and
follow, any safety information available from your material supplier.
6. Always make sure the workpiece is free from nails, screws and other
foreign objects. Keep the working edge away from the clamping surface.
Cutting these objects can cause loss of control of the tool and damage to the bit.
7. Never hold the workpiece in one hand and the tool in the other hand when
using the tool. Never place hands near or below cutting surface. Clamping
the material and guiding the tool with both hands is safer.
8. Never use dull or damaged bits. Sharp bits must be handled with care.
Damaged bits can break during use. Dull bits require more force to push the tool,
which could cause the bit to break. Damaged bits can throw carbide pieces and burn
the workpiece.
9. After changing the bit or making any adjustments, make sure the collet nut
and any other adjustment devices are securely tightened. Loose adjustment
devices can unexpectedly shift, causing loss of control. Loose rotating components
will be violently thrown. Watch for vibration or wobbling that could indicate an improperly installed bit.
10. Maintain firm grip on router when starting motor to resist starting torque.
11. Always keep the power supply cord away from moving parts on the tool.
Keep the cord away from the direction of the cut.
12. Never start the tool when the bit is in contact with the material. The bit cutting
edge may grab the material causing loss of control of the tool.
13. Never lay the tool down until the bit has come to a complete stop. The
spinning bit can grab the surface and pull the tool out of your control.
14. Never touch the bit during or immediately after use. After use the bit may be
hot enough to burn bare skin.
Cat. No. 5615 Series
1
2
3
1. Depth adjustment screw
2. Motor release button
3. Locking lever
4. Scale
5. Depth adjustment knob
6. On/Off switch
7. Motor
8. Cord
9. Body grip
10. Strap
11. Handle
12. Collet assembly
13. Sub-Base
14. Base
15. Lock button
16. Trigger
17. D-handle
Motor/Base
Cat. No
5615-20
5619-20
.
5
4
11
14
Specifications
Motor Only
Cat. No.
5615-29
5619-29
13
Volts
AC
120
120
6
12
Cat. No. 5619 Series
No Load
Amps
RPM
24,000
11
24,000
11
7
8
9
10
11
8
15
16
17
8
6 7
TOOL ASSEMBLY
Collets
The collet must be attached to the collet
nut before it is put into the collet shaft. Be
sure that the size of the collet matches the
size of the bit shank being used. If the
wrong size bit shank is used, the collet
may break. For attaching or detaching the
collet nut to the collet, follow the illustrated
instructions on this page.
Attaching Collet to Collet Nut
FPO
To assemble, place the narrow end of the
collet on an even surface. Take the nut
and place it over the collet (Fig. 1).
Fig. 1
Position nut squarely over collet with the
smaller opening of the nut facing up (Fig. 2).
Fig. 2
Snap nut and collet together by firmly applying downward pressure into assembly
with palm of hand (Fig. 3).
Fig. 3
To remove collet from nut, hold nut firmly
with one hand and press the collet to one
side with the other hand (Fig. 4).
Fig. 4
WARNING!
To reduce the risk of injury,
always unplug tool before attaching or removing accessories
or making adjustments.
If hand is not securely on motor,
pressing the motor release button will cause the motor housing
to drop down, which may cause
personal injury or damage to the
tool or workpiece.
Removing Motor from Base (Fig. 5)
Fig. 5
1. Unplug tool. Release locking lever to
fully open position.
2. Firmly grasp motor. Press and hold
motor release button and pull out
motor from base.
Placing Motor into Base (Fig. 6)
Fig. 6
1. Unplug tool. Make sure locking lever is
fully open.
2. Align depth screw on the motor with
hole on base.
3. Press and hold motor release button
and lower motor into base to desired
depth.
4. Release motor release button and
push-in locking lever to fully closed
position.
WARNING!
To reduce the risk of injury, wear
safety goggles or glasses with
side shields.
To reduce the risk of injury,
always unplug tool before attaching or removing accessories or
making adjustments.
Use only specifically recommended accessories. Others may
be hazardous.
Installing the Bit
It is not necessary to remove the motor
from the base to install a collet assembly
or a bit. If removal of the base is desired,
see previous section. Always wipe wood
chips, dust or other foreign materials from
the collet shaft and collet assembly before
assembling.
Insert the collet assembly into the collet
shaft. Insert the bit shank into the collet as
follows:
1. Insert the bit shank into the collet as
far as it will go.
2. Back the bit shank out slightly to avoid
bottoming out.
3. Be sure there is a minimum of 1/16"
between the bottom of the collet assembly and the radius to the cutting
portion of the bit (Fig. 7).
4. Be sure that the collet is not clamped
to a fluted section on the bit shank.
The collet should be clamped to a solid
part on the bit shank.
Fig. 7
Collet nut
Minimum
1/16"
To tighten the bit in the collet assembly, use
two wrenches (Fig. 8).
Fig. 8
NOTE: Never tighten a collet assembly with-
out inserting a bit shank of the proper size.
This may damage the collet.
Removing the Bit
1. Loosen the collet nut from the collet
shaft using two wrenches.
2. Once loose, unscrew the collet nut by
hand until it feels tight again.
3. Return to using the wrenches until the
bit shank can be pulled out.
Collet
Bit shank
8 9
Installing/Removing Edge Guide
(Fig. 9)
To install an edge guide, loosen the two
rod screws. Insert the edge guide rods
into the rod holes and tighten the rod
screws.
Fig. 9
Rod screws
Installing/Removing Sub-base (Fig. 10)
Remove the sub-base screws. Place a subbase onto the tool. Replace sub-base
screws.
Fig. 10
Sub-base screws
Rod holes
Installing Templet Guide
To install a templet guide, insert guide into
the center hole of router base and secure
according to templet guide instructions.
NOTE: The sub-base provided with this
tool does not accept templet guides. An
accessory sub-base is avaivable that
accepts 1-3/16" threaded inserts.
OPERATION
WARNING!
Unplug the tool before changing
accessories or making adjustments.
Never make adjustments while
the router is running.
Adjusting the Depth of Cut
The tool depth can be adjusted by using
the depth adjustment knob or a 3/8" socket
wrench.
When using the depth adjustment knob, fully
open the locking lever and rotate knob to
the desired depth of cut. One revolution of
the depth adjustment knob is equal to 0.2".
For fine adjustments less than 5/32", use
the independent scale on the depth adjustment knob.
For deeper cuts:
1. Align the "0" on the scale with the arrow on the tool.
2. Rotate depth adjustment knob clockwise to desired depth measurement.
For shallower cuts:
1. Align the desired depth measurement
with the arrow on the tool.
2. Rotate depth adjustment knob counterclockwise to "0."
Push-in locking lever to fully closed position when finished adjusting.
When using a socket wrench, place the
router on a flat surface and fully open the
locking lever. Insert a 3/8" socket wrench
into the hole on the base and turn to desired depth (Fig. 11). Push-in locking lever
to fully closed position.
Fig. 11
Holding the Tool
For Body Grip Base (Fig. 12):
You can hold this tool using the body grip
and handle or both handles. The body grip
features an adjustable strap, which can
be attached in two different positions for
maximum control and comfort.
Fig. 12
10 11
Alternate
strap positions
For D-handle Base (Fig. 13):
Grip the D-handle with one hand and place
the other on the handle.
Fig. 13
Alternate handle positions
For both bases:
One handle on both bases may be adjusted
to three different positions for maximum
control and comfort.
NOTE: Use both hands at all times.
WARNING!
To reduce the risk of injury, wear
safety goggles or glasses with
side shields.
To reduce the risk of injury, keep
hands, body and cord away from
the bit and all moving parts.
Before plugging the tool into a
power outlet, make sure the on/
off switch is in the "O" position.
Starting and Stopping Router Motor
For Body Grip Base:
1. To start the motor, grasp the tool firmly
and push the On/Off switch to the "I"
position.
2. To stop the motor, push the on/off
switch to the "O" position and place
the router so the bit is away from you.
Hold the tool until the bit stops turning.
For D-handle Base:
1. Push the On/Off switch to the "I" position.
2. To start the motor, grasp the tool firmly
and pull the trigger.
3. To stop the motor, release the trigger.
Locking the D-handle Base Trigger
(Fig. 14)
The lock button holds the trigger in the ON
position for continuous use.
Fig. 14
1.To lock the trigger, hold-in the lock
button while pulling the trigger. Release
the trigger.
2. To unlock the trigger, pull the trigger
and release. The lock button will pop
out.
Lock button
WARNING!
To reduce the risk of injury,
always wear eye protection.
To reduce the risk of explosion,
electric shock and property
damage, always check the work
area for hidden pipes and wires
before routing.
Making the Cut
The speed and depth of cut will depend
largely on the type of material being worked.
Keep the cutting pressure constant but do
not use excessive force on the router so
the motor speed slows excessively. It may
be necessary on exceptionally hard woods
or problem materials to make more than
one pass to get the desired depth of cut.
Before beginning the cut on the actual
workpiece, it is advisable to take a sample
cut on a scrap piece of lumber. This will
show you exactly how the cut will look as
well as enable you to check dimensions.
Always be sure the workpiece is secure
before routing. When routing edges, the
router should be held firmly down and
against the work using handles.
Since the cutter rotates clockwise, more
efficient cutting will be obtained if the router
is moved from left to right as you stand
facing the work. The arrows on the base
of the tool indicate the direction of bit rotation. When working on the outside of an
edge, move router in a counterclockwise
direction (Fig. 15).
Fig. 15
Work
Router feed
Top view
Bit rotation
When working on an inside edge, move
the router in a clockwise direction (Fig. 16).
Fig. 16
Direction
of feed
Moving the router in the opposite direction
is known as "climb cutting."
WARNING!
To reduce the risk of injury, avoid
"climb cutting." Climb cutting increases the potential for loss of
control of the tool and damage to
the workpiece. If climb cutting
can not be avoided, use extreme
caution.
12 13
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