Bosch 0 601 617 061, 1617, 1617EVS, 1617EVSPK, 1617PK Operating/safety Instructions Manual

IMPORTANT: IMPORTANT : IMPORTANTE:

Read Before Using Lire avant usage Leer antes de usar

Operating/Safety Instructions
Consignes de fonctionnement/sécurité

Instrucciones de funcionamiento y seguridad

1617
1617EVS
1617PK
1617EVSPK
1618
1618EVS
0 601 617 061

For English Version Version française Versión en español

See page 2

Voir page 24 Ver la página 46

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BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 1

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

-2-

Work Area

Keep your work area clean and well lit.

Cluttered benches and dark areas invite
accidents.

Do not operate power tools in explosive
atmospheres, such as in the presence of
flammable liquids, gases, or dust.

Power
tools create sparks which may ignite the dust
or fumes.

Keep by-standers, children, and visitors
away while operating a power tool.

Distractions can cause you to lose control.

Electrical Safety

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 the plug in any way. Double

Insulation xxxx eliminates the need for the
three wire grounded power cord and
grounded power supply system.

Before
plugging in the tool, be certain the outlet
voltage supplied is within the voltage marked
on the nameplate. Do not use “AC only”
rated tools with a DC power supply.

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. If
operating the power tool in damp locations is
unavoidable, a Ground Fault Circuit
Interrupter must be used to supply the power
to your tool. Electrician’s rubber gloves and
footwear will further enhance your personal
safety.

Don't expose power tools to rain or wet
conditions.

Water entering a power tool will

increase the risk of electric shock.

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.

When operating a power tool outside, use
an outdoor extension cord marked "W-A"
or "W."

These cords are rated for outdoor
use and reduce the risk of electric shock.
Refer to “Recommended sizes of Extension
Cords” in the Accessory section of this
manual.

Personal Safety

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
operating power tools may result in serious
personal injury.

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.
Keep handles dry, clean and free from oil
and grease.

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.

Remove adjusting keys or wrenches
before turning the tool “ON”.

A wrench or
a key that is left attached to a rotating part of
the tool may result in personal injury.

Do not overreach. Keep proper footing
and balance at all times.

Proper footing and
balance enables better control of the tool in
unexpected situations.

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

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.

!

WARNING

Power Tool Safety Rules

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-3-

Safety Rules for Routers

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.

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.

Disconnect the plug from the power
source before making any adjustments,
changing accessories, or storing the tool.

Such preventive safety measures reduce the
risk of starting the tool accidentally.

Store idle tools out of reach of children
and other untrained persons.

Tools are

dangerous in the hands of untrained users.

Maintain tools with care. Keep cutting
tools sharp and clean.

Properly maintained
tools, with sharp cutting edges are less likely
to bind and are easier to control. Any
alteration or modification is a misuse and
may result in a dangerous condition.

Check for misalignment or binding 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. Develop
a periodic maintenance schedule for your
tool.

Use only accessories that are
recommended by the manufacturer for
your model.

Accessories that may be
suitable for one tool, may become hazardous
when used on another tool.

Service

Tool service must be performed only by
qualified repair personnel.

Service or
maintenance performed by unqualified
personnel could result in a risk of injury. For
example: internal wires may be misplaced or
pinched, safety guard return springs may be
improperly mounted.

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. Certain cleaning
agents such as gasoline, carbon
tetrachloride, ammonia, etc. may damage
plastic parts.

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 the tool "live"
and shock the operator.

If cutting into
existing walls or other blind areas where
electrical wiring may exist is unavoidable,
disconnect all fuses or circuit breakers
feeding this worksite.

Always make sure the work surface is
free from nails and other foreign objects.

Cutting into a nail can cause the bit and the
tool to jump and damage the bit.

Never hold the workpiece in one hand and
the tool in the other hand when in use.
Never place hands near or below cutting
surface.

Clamping the material and guiding

the tool with both hands is safer.

Never lay workpiece on top of hard
surfaces, like concrete, stone, etc...

Protruding cutting bit may cause tool to jump.

Always wear safety goggles and dust
mask. Use only in well ventilated area.

Using personal safety devices and working in
safe environment reduces risk of injury.

After changing the bits or making any
adjustments, make sure the collet nut and
any other adjustment devices are
securely tightened.

Loose adjustment
device can unexpectedly shift, causing loss
of control, loose rotating components will be
violently thrown.

Never start the tool when the bit is
engaged in the material.

The bit cutting
edge may grab the material causing loss of
control of the cutter.

Always hold the tool with two hands
during start-up

. The reaction torque of the

motor can cause the tool to twist.

The direction of feeding the bit into the
material is very important and it relates to
the direction of bit rotation. When viewing
the tool from the top, the bit rotates

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 3

clockwise. Feed direction of cutting must
be counter-clockwise.

NOTE: inside and
outside cuts will require different feed
direction, refer to section on feeding the
router. Feeding the tool in the wrong
direction, causes the cutting edge of the bit
to climb out of the work and pull the tool in
the direction of this feed.

Never use dull or damaged bits. Sharp
bits must be handled with care.

Damaged
bits can snap during use. Dull bits require
more force to push the tool, possibly causing
the bit to break.

Never touch the bit during or immediately
after the use.

After use the bit is too hot to

be touched by bare hands.

Never lay the tool down until the motor
has come to a complete standstill.

The
spinning bit can grab the surface and pull the
tool out of your control.

Never use bits that have a cutting
diameter greater than the opening in the
base.

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 paints,

• 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 specially
designed to filter out microscopic particles.

-4-

!

WARNING

Read and understand the tool manual and
these instructions for the use of this table
with your router.

Failure to follow all
instructions listed below may result in serious
personal injury.

Unplug tool before setting up in table,
making adjustments or changing bits.

Accidental start-up of the tool can cause
injury.

Fully assemble and tighten all the
fasteners required for this table and
mounting the router.

Also remember to
occasionally check the stand and make sure
it is still tight. A loose stand is unstable and
may shift in use and cause serious injury.

Before operating make sure the entire unit
is placed on a solid, flat, level surface.

Serious injury could occur if tool is unstable
and tips.

Never stand on the table or use as ladder
or scaffolding.

Serious injury could occur if
the table is tipped or the cutting tool is
accidentally contacted. Do not store
materials on or near the table such that it is

necessary to stand on the table or its stand
to reach them.

Never use dull or damaged bits. Sharp
bits must be handled with care.

Damaged
bits can snap during use. Dull bits require
more force to push the workpiece, possibly
causing the bit to break.

Match the appropriate bit and its speed to
your application. Do not use bits that
have a cutting diameter that exceeds the
capacity of the tool.

Overloading the tool

can lead to personal injury or tool failure.

Never start the tool when the bit is
engaged in the material.

The bit cutting
edge may grab the material causing loss of
control of the workpiece.

Router bits are intended for wood, wood
products and plastic only. Be sure the
workpiece does not contain nails, etc.
before routing.

Cutting a nail or the like will
cause the carbides to be dislodged, fly
toward the operator side, and possibly strike
you or bystanders.

Safety Rules for Router Table

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 4

Feed the workpiece against the rotation of
the bit. The bit rotates counter-clockwise
as viewed from the top of table.

Feeding
the work in the wrong direction will cause the
workpiece to "climb" up on the bit and may
lead to loss of control during operation.

N

ever place hands near the spinning bit.
Use push sticks, vertical and horizontally
mounted feather boards (spring sticks)
and other jigs to hold down the workpiece
and keep your hands away from the
spinning bit.

Router cuts are blind cuts but
the bit still protrudes through the table and
you must be aware of the position of your
hands relative to the spinning bit.

We do not recommend cutting material
that is warped, wobbly or otherwise
unstable. If this situation is unavoidable
always cut the material with the concave
side against the table.

Cutting the material
with the concave side up or away from table
may cause the warped or wobbly material to
roll; causing you to lose control, kickback and
serious personal injury may result.

Use the adjustable fence in straight
cutting applications.

When routing along

an entire edge of the work, the fence, fence
faces, and adjustable outfeed fence support
shims will help maintain stability.

When the table is used without the fence,
piloted bits (or "bearing bits") must be
used.

Piloted bits are used when routing

i

nternal and external contours on a
workpiece. The bearing of the piloted bit
assists in maintaining control of the
workpiece. Whenever possible, the starter
pin should also be used.

After changing the bits or making any
adjustments, make sure the collet nut and
any other adjustment devices are
securely tightened.

Loose adjustment
device can unexpectedly shift, causing loss
of control, loose rotating components will be
violently thrown.

Never touch the bit during or immediately
after the use.

Contact with a spinning bit will
cause injury and after use the bit is too hot to
be touched by bare hands.

Use only Bosch replacement parts. Any
others may create a hazard.

-5-

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 5

-6-

IMPORTANT: Some of the following symbols may be used on your tool. Please study them
and learn their meaning. Proper interpretation of these symbols will allow you to operate the
tool better and safer.

Symbol Name Designation/Explanation

V Volts Voltage (potential)

A Amperes Current

Hz Hertz Frequency (cycles per second)

W Watt Power

kg Kilograms Weight

min Minutes Time

s Seconds Time

Diameter Size of drill bits, grinding wheels, etc.

n

0

No load speed Rotational speed, at no load

.../min Revolutions or reciprocation per minute Revolutions, strokes, surface speed,

orbits etc. per minute

0 Off position Zero speed, zero torque...

1, 2, 3, ... Selector settings Speed, torque or position settings.

I, II, III, Higher number means greater speed

Infinitely variable selector with off Speed is increasing from 0 setting

Arrow Action in the direction of arrow

Alternating current Type or a characteristic of current

Direct current Type or a characteristic of current

Alternating or direct current Type or a characteristic of current

Class II construction Designates Double Insulated

Construction tools.

Earthing terminal Grounding terminal

Warning symbol Alerts user to warning messages

Ni-Cad RBRC seal Designates Ni-Cad battery recycling

program

Symbols

A

0

A

A

0

A

This symbol designates
that this tool is listed by
Underwriters Laboratories.

This symbol designates
that this tool is listed by
the Canadian Standards
Association.

This symbol designates
that this tool is listed to
Canadian Standards by
Underwriters Laboratories.

This symbol

designates
that
this tool
complies
to NOM
Mexican
Standards.

This symbol designates that
this tool is listed by
Underwriters Laboratories,
and listed to Canadian
Standards by Underwriters
Laboratories.

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 6

-7-

Functional Description and Specifications

Disconnect the plug from the power source before making any
a

ssembly, adjustments or changing accessories

.

Such preventive safety

m

easures reduce the risk of starting the tool accidentally.

!

WARNING

FIG. 1

SPEED CONTROL DIAL

Models 1617EVS

& 1618EVS only

SUB-BASE

TRIGGER

SWITCH

"LOCK-ON"

BUTTON

D-HANDLE

ROUND

HANDLE

BASE CLAMP LEVER

CHIP DEFLECTOR

MOTOR HOUSING

ROCKER ON\OFF

SWITCH

POWER ON/OFF

SWITCH

TEMPLET GUIDE

QUICK CHANGE LEVER

MOTOR ALIGNMENT

ARROW

FIG. 2

AIR VENTS

AIR VENTS

REVERSIBLE

HANDLE

BIT ROTATION ARROW

BIT ROTATION ARROW

Routers

BASE TYPE S

BASE TYPE D

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 7

-8-

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FIG. 3

SPEED CONTROL DIAL

Model 1617EVSP only

SUB-BASE

PLUNGE HANDLE

CHIP DEFLECTOR

MOTOR HOUSING

ROCKER ON\OFF SWITCH

MOTOR

ALIGNMENT ARROW

AIR VENTS

BIT ROTATION ARROW

BASE TYPE P

Model number 1617 & 1618 1617EVS & 1618EVS 0 601 617 061
Voltage rating 120V 50 - 60Hz 120V 50 - 60Hz 220V 50 - 60Hz
Amperage rating 11A 12A 6A
No load speed n025,000/min n08,000-25,000/min n025,000/min
Collet capacities 1/4", 3/8", 1/2", 8mm 1/4”, 3/8”, 1/2”, 8mm 1/4”, 3/8”, 1/2”, 8mm

RA1161 fixed-base shop router base marked type "S" is designed for use with these router motors:

1617 router motor (16171)
1617EVS router motor (16176)
0 601 617 061 router motor (0 601 617 161)
1618 router motor (16181)
1618EVS router motor (16186)

RA1162 D-handle router base marked type "D" is designed only for use with these router motors:

1618 router motor (16181)
1618EVS router motor (16186)

RA1166 plunge router base marked type "P" is designed for use with these router motors:

1617 router motor (16171)
1617EVS router motor (16176)
0 601 617 061 router motor (0 601 617 161)
1618 router motor (16181)
1618EVS router motor (16186)

PLUNGE LOCK

LEVER

DEPTH ROD

DEPTH ROD KNOB

DEPTH STOP TURRET

DEPTH INDICATOR

DEPTH ROD FINE

ADJUSMENT KNOB

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 8

-9-

Assembly

A wide assortment of router bits with different
profiles is available separately. Use 1/2"
shank whenever possible, and only use good
quality bits.

To prevent personal injury,

always remove the plug
from power source before removing or
installing bits or accessories.

INSTALLING A ROUTER BIT

Place router upside down or lay router on its
side with the base resting on the bench.
Another option is to remove the motor from
the base before installing the bit.

1. Remove the chip shield (or flip up if plunge

base is attached.

2. Hold the armature shaft in place with the

shaft wrench (Fig. 4)

3. Next, use the collet wrench to loosen the

collet chuck assembly in counter­clockwise direction (viewed from under the
router).

4. Insert the shank of the router bit into the

collet chuck assembly as far as it will go,
then back the shank out until the cutters
are approximately 1/8" to 1/4" away from
the collet nut face.

5.

With the router bit inserted and the shaft
wrench holding the armature shaft, use the
collet wrench to firmly tighten the collet
chuck assembly in a clockwise direction
(viewed from under the router). To ensure
proper gripping of the router bit and
minimize run-out, the shank of the router
bit must be inserted at least 5/8".

When the templet guide

has been removed from
base, do not use router bits greater than

2" in diameter as they will not fit through
the sub-base.

Cutter diameter must be at
least 1/4” smaller than

opening for the bit and cutter.

To prevent damage to
tool, do not tighten collet

without a bit.

NOTE:

The bit shank and chuck should be
clean and free of dust, wood, residue and
grease before assembling.

REMOVING THE ROUTER BIT

1. Use the shaft and collet chuck wrenches

as described earlier, and turn the collet
chuck assembly in a counter-clockwise
direction.

2. Once the collet chuck assembly is

loosened continue to turn the collet chuck
assembly until it pulls the collet free from
its taper, and the router bit can be
removed.

NOTE: The collet chuck is self-extracting; it
is NOT necessary to strike the collet chuck to
free the router bit.

!

WARNING

!

CAUTION

SHAFT

WRENCH

COLLET

WRENCH

FIG. 4

COLLET CHUCK CARE

With the router bit removed, continue to turn
the collet chuck counter-clockwise until it is
free of the shaft. To assure a firm grip,
occasionally blow out the collet chuck with
compressed air, and clean the taper in the
armature assembly shaft with a tissue or fine
brush. The collet chuck is made up of two
component parts as illustrated (Fig. 5); check
to see that the collet is properly seated in the
collet chuck nut and lightly thread the collet
chuck back onto the armature shaft. Replace
worn or damaged collet chucks immediately.

COLLET

COLLET

NUT

FIG. 5

COLLET

CHUCK

!

WARNING

!

WARNING

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 9

REMOVING MOTOR FROM BASE
To remove motor from non-plunge bases:
(Fig. 6)

1. Hold router in horizontal position, open

b

ase clamp lever, depress coarse
adjustment lever, and pull motor upwards
until it stops.

2. Turn motor counter-clockwise, and gently
pull it free of base.

To remove motor from plunge base: (Fig. 7)

1. Hold router in horizontal position, open
base clamp lever, and pull motor upwards
until it stops.

2. Turn motor counter-clockwise, and gently
pull it free of base.

INSTALLING MOTOR IN BASE

The motor can be installed with the switch
positioned on the right or left of the base from
the operator's side (and the cord facing the
opposite side of the router). Install the motor
so that the switch is in the location you find to
be the most easily accessible from the
handles. The switch should be easier to turn
"OFF" than "ON" in case of an emergency.

To install motor in non-plunge base:

1. Release the base clamp lever.

2. Line up the arrow on the base with arrow
on the motor. (Fig. 8)

• To position switch on the right side of the

base, line up the base’s arrow with
motor housing’s arrow that is below the
cord.

• To position switch on the left, line up the

base’s arrow with motor housing’s arrow
that is below the switch.

3.While pressing the coarse adjustment
lever, slide motor into base until resistance
in felt. (The base’s guide pin is now
engaged into slot on motor.)

4. Continue to press coarse adjustment lever,
and turn the motor clockwise until it stops.

5. Push the motor into the base until it
reaches the approximate desired depth.

6. Release the coarse adjustment lever and
slide the motor forward or back as needed
until the coarse adjustment system’s
“catch” springs into the coarse adjustment
detent notch.

7.

Set final height position as described
below in “Operating Instructions”.

To install motor in plunge base:

1. Release the base clamp lever.

2. Line up the arrow on the base with arrow
on the motor. (Fig. 8)

• To position switch on the right side of the

base, line up the base’s arrow with
a

rrow on the motor housing that is

below the cord.

-10-

ALIGNMENT

ARROWS

COARSE

ADJUSTMENT

NOTCHES

MOTOR

BASE

FIG. 8

BASE

CLAMP

LEVER

FIG. 6

COARSE

ADJUSTMENT

LEVER

BASE

CLAMP

LEVER

FIG. 7

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 10

CHIP DEFLECTOR

Always wear eye

protection. The chip
deflector is not intended as a safety
guard.

The chip deflectors help keep dust and chips
out of your face, it will not stop objects larger
than dust thrown from the bit.

To remove chip shield from bases, press
inward on tabs until it releases from base and
remove. To attach, place deflector into
position as shown in (Fig. 10). Then flex
sides of deflector while pushing until it snaps
into place. The plunge base’s chip shield can
also be flipped out.

2

1

0

IN

50

40

30

20

10

0

M

M

INSTALLING TEMPLET GUIDE ADAPTER

Place templet guide adapter over the holes in
the center of the sub-base, and align the two
threaded holes in the bottom of adapter with
the countersunk holes in sub-base. Fasten
adapter with the screws provided. Note that
the adapter is reversible, so the release lever
may be positioned as desired. (Fig. 9)

-11-

TEMPLET GUIDE

ADAPTER

MOUNTING SCREWS

FIG. 9

FIG. 10

!

WARNING

• To position switch on the left, line up the
base’s arrow with arrow on the motor
housing that is below the switch.

3. Slide motor into base until resistance in
f

elt. (The base’s guide pin is now engaged

into slot on motor.)

4. Turn the motor clockwise until it stops.

5. Push the motor into the base as far as it
will go.

6. Fasten the base clamp lever.

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 11

Bosch routers are designed for speed,
accuracy and convenience in performing
cabinet work, routing, fluting, beading, cove­cutting, dove tails, etc. They will enable you
to accomplish inlay work, decorative edges
and many types of special carving.

DEPTH ADJUSTMENT

WITH FIXED BASE

Router’s RA1161 fixed base are equipped
with a true micrometer type fine adjustment
mechanism, which can be used in any
position and provides precise adjustment of
the router bit position for unmatched
accuracy. When the tool is lowered to the
approximate position desired, this device
may be adjusted to precisely set the final bit
position.

Your router also features three horizontal
notches on both sides of the motor housing
for coarse adjustments. The notches are
spaced 1/2" apart which allows you to quickly
lower or raise the tool depth in three 1/2"
increments. (Approximately 12.7 mm), by
simply depressing the coarse adjustment
release lever.

TO ADJUST DEPTH

NOTE:

All depth adjustments must be made

with the base clamp lever released.

1. Hold the tool in a horizontal position with
the base clamp lever facing you.

2. Open the base clamp lever to release the
motor.

3. COARSE ADJUSTMENT:

To make a large depth adjustment, depress
coarse adjustment release lever and raise or
lower to desired depth. There are three
notches in the motor housing which are
spaced 1/2" to facilitate this adjustment.

4. FINE DEPTH ADJUSTMENT:

To use the fine adjustment feature, turn the
fine adjustment knob clockwise to lower the
router bit or counter-clockwise to raise it.

NOTE: Be sure coarse adjustment lever is
engaged in one of the coarse adjustment
notches before making a fine adjustment.

To allow precise settings, the indicator ring is
graduated in English and Metric increments.
(Note: one full turn of fine adjustment knob =
1/16" or approximately 1.5 mm. The fine
adjustment mechanism has a total
adjustment range of 7/8" (23 mm). Each cast
indicator mark next to coarse adjustment
lever is equal to 1/8"

To prevent damage to tool, avoid wedging
the coarse adjustment lever against the
upper A or lower B portion of the housing as
shown in figure 11.

5.

After making depth adjustments, re-clamp
the motor.

The indicator ring may be reset to zero
without moving the fine adjustment knob, to
allow the user to begin the adjustment from
any reference point desired.

-12-

Operating Instructions

A

B

FINE ADJUSTMENT DIAL

BASE CLAMP LEVER

COARSE

ADJUSTMENT

LEVER

INDICATOR RING

FIG. 11

CAST INDICATOR MARKS

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 12

-13-

When the router is installed in a router table,
it can be adjusted with a 1/8” hex wrench, not
included with all models. (See page 21).

The RA1002 Fine Adjustment Control
Extension, an optional accessory for the non­plunge bases, allows fine adjustment from
b

eyond the top of the motor housing. To
install, simply press the RA1002 into the end
of the base’s own fine adjustment knob.
(Fig. 12)

TO CLAMP MOTOR

When final coarse and fine adjustments have
been made, fasten the base clamp lever to
secure adjustments. (If additional clamping
force is desired: using a 10 mm wrench,
rotate clamp nut clockwise SLIGHTLY (1/8
turn or less), then test clamp. Do not over­tighten.)

DEEP CUTS

For deeper cuts, make several progressively
deeper cuts by starting at one depth and

then make several subsequent passes,
increasing the cutting depth with each pass.

To be certain that your depth settings are as
desired, you may want to make test cuts in
scrap material before beginning work.

FIG. 12

DEPTH ADJUSTMENT WITH PLUNGE

BASE PLUNGING ACTION

The plunge feature simplifies depth
adjustments and will allow the cutting bit to
easily and accurately enter the workpiece. To
lower, push plunge lock lever to the left, apply
downward pressure until you reach desired
depth, and release pressure on lever to lock
(Fig. 13). The plunge lock lever is spring
loaded and returns automatically to the locked
position. To raise the router, push plunge lock
lever to the left, release pressure on router and
the router will automatically retract the bit from
the workpiece. It is advisable to retract the bit
whenever it is not engaged in workpiece.

DEPTH ROD AND TURRET

The depth rod and the depth stop turret are
used to control cutting depth as follows;

1. With the bit installed, gently lower the motor

until the tip of the router bit just contacts the
level surface the router is sitting on. This is
the “zero” position, from which further depth
adjustments can be accurately made.

2. To set a desired depth of cut, rotate depth

stop turret until the lowest step is aligned
with the depth rod. Loosen depth indicator
knob and lower the depth rod until it
contacts the lowest step of the turret. Slide
the depth indicator until the red line indicates
zero on the depth scale, indicating the point

at which the bit just contacts the work
(Fig. 14).

3. To set a desired cutting depth, slide the
depth rod up until the red depth indicator line
attains the desired cutting depth, and secure
the rod in position by firmly tightening the
depth indicator knob.

4.

The desired depth of cut may now be
achieved by plunging the router until the
depth rod contacts the selected stop on the
turret.

FIG. 13

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 13

DEEP CUTS

For deeper cuts, make several progressively
deeper cuts by starting with the highest step
on the depth turret, and after each cut, rotate
the depth turret to progressively lower steps
as desired, until the final depth (lowest step
or flat) is reached. Steps progress by 1/8”
increments.

To be certain that your depth settings are as
desired, you may want to make test cuts in
scrap material before beginning work.

FINE ADJUSTMENT

The RA1166 plunge base is equipped with a
fine adjustment system that allows you to
micro adjust the plunge depth of the router bit
for superior routing accuracy.

Each complete revolution of the fine
adjustment stop adjusts the plunging depth
by 1/32”, and each of the four indicator marks
on the knob represents 1/128”. One of the
four tick marks is larger than the other to
indicate a complete revolution. A reference
indicator line is built in to the depth rod.

To use the fine adjustment knob, once the
depth rod and turret have been set, check
the final depth setting and fine-adjust as
follows:

To micro-increase the plunge depth, raise the
fine adjustment stop by turning it counter­clockwise by the desired amount.

To micro-reduce the plunge depth, lower the
fine adjustment stop by turning it clockwise
by the desired amount.

Notes:

• When micro-adjusting the plunge depth, it
is more convenient to move the fine
adjustment stop up than down. Before
setting the depth rod and turret, make sure
the fine adjustment stop has been turned
several revolutions down from its top
position so that it can be adjusted upward.

• The fine adjustment stop cannot be use to
reduce the plunge depth when the depth
rod is already touching the depth stop
turret. The router must be raised before
such an adjustment can be made.

•

Also available is an alternative turret that
has an adjustable step which uses an M4
screw for the adjustable step. The
adjustable step makes it possible to make
multiple-pass applications without having
to make a fine depth adjustment even
when the total cutting depth is not a
multiple of 1/8".

-14-

2

1

0

I

N

5

0

4

0

3

0

2

0

1

0

0

MM

F

IG. 14

DEPTH INDICATOR

KNOB

DEPTH

INDICATOR

DEPTH ROD

DEPTH STOP

TURRET

DEPTH ROD FINE

ADJUSMENT KNOB

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 14

-15-

ROCKER “ON/OFF” SWITCH

Your tool can be turned “ON” or “OFF” by the
rocker switch located on the motor housing.
One side of the switch is marked “I” for “ON“,
and the other side of switch is marked “O” for
“OFF“. Also the edge of switch displays red
when switch is in the “ON“ position.

TO TURN THE TOOL “ON”: Push the side
of the switch marked “I”.

TO TURN THE TOOL “OFF”: Push the side
of the switch marked “O”.

Always hold the router off the work when
turning the switch on or off. Contact the work
with the router after the router has reached
full speed, and remove it from the work
before turning the switch off. Operating in this
manner will prolong switch and motor life and
will greatly increase the quality of your work
(Fig. 1).

ROCKER POWER "ON-OFF" WITH

TRIGGER SWITCH AND "LOCK-

ON"BUTTON

(Models 1618 & 1618EVS only)

The power is switched "ON" by the rocker
switch located on the top of the motor
housing as described above. Now your tool
can be turned "ON" or "OFF" by squeezing or
releasing the trigger. Your tool is also
equipped with “Lock-ON” button located just
above the trigger that allows continuous
operation without holding the trigger (Fig. 2).

TO LOCK SWITCH ON: Squeeze trigger,
depress button and release trigger.

TO UNLOCK THE SWITCH: Squeeze trigger
and release it without depressing the “Lock­ON” button.

If the “Lock-ON” button is
continuously being

depressed, the trigger cannot be released.

On models 1617 & 1618 hold the tool with
both hands while starting the tool, since
torque from the motor can cause the tool to
twist.

SOFT START FEATURE

(Models 1617EVS & 1618EVS only)

Electronic feedback control minimizes torque
twist customary in larger routers by limiting
the speed at which motor starts.

ELECTRONIC VARIABLE

SPEED CONTROL

(Models 1617EVS & 1618EVS only)

The electronic speed control feature allows
motor speed to be matched to cutter size and
material hardness for improved finish,
extended bit life, and higher performance.
Speed changes are achieved by rotating
Control Dial RIGHT to increase speed, LEFT
to decrease as indicated on housing (Fig. 1).
Speed may be changed while tool is on. The
reference numbers on the dial facilitate re­setting control to desired speed.

The speed chart indicates the relationship
between settings and application, exact
settings are determined by operator
experience and preference. The bit
manufacturer may also have a speed
recommendation.

CONSTANT RESPONSE™ CIRCUITRY

(Models 1617EVS & 1618EVS only)

The router's Constant Response™ Circuitry
monitors and adjusts power to maintain the
desired RPM for consistent performance and
control.

!

WARNING

DIAL

SETTING RPM APPLICATION

1 8,000
2 13,500
3 16,500

4 20,000
5 21,500
6 25,000

}
}

Nonferrous metals,
larger diameter bits,
and cutters

Softwoods, plastics,
counter tops, smaller
diameter bits, and
cutters

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 15

FEEDING THE ROUTER

As seen from the top of the router, the bit
turns clockwise and the cutting edges face
accordingly. Therefore, the most efficient cut
is made by feeding the router so that the bit
turns into the work, not away. Figure 15
shows proper feed for various cuts. How fast
y

ou feed depends on the hardness of the
material and the size of the cut. For some
materials, it is best to make several cuts of
increasing depth.

If the router is hard to control, heats up, runs
very slowly or leaves an imperfect cut,
consider these causes:

1. Wrong direction of feed — hard to control.

2. Feeding too fast — overloads motor.

3. Dull bit — overloads motor.

4. Cut is too large for one pass — overloads

motor.

5. Feeding too slow — leaves friction burns

on work.

Feed smoothly and steadily (do not force).
You will soon learn how the router sounds
and feels when it is working best.

RATE OF FEED

When routing or doing related work in wood
and plastics, the best finishes will result if the
depth of cut and feed rate are regulated to
keep the motor operating at high speed.
Feed the router at a moderate rate. Soft
materials require a faster feed rate than hard
materials.

The router may stall if improperly used or
overloaded. Reduce the feed rate to prevent
possible damage to the tool. Always be sure
the collet chuck is tightened securely before
use. Always use router bits with the shortest
cutting length necessary to produce the
desired cut. This will minimize router bit run­out and chatter.

-16-

GUIDING THE ROUTER

The router can be guided through the work in
any of several ways. The method you use
depends, of course, on the demands of the
particular job and on convenience.

For routing operations such as grooving or
dadoing, it is often necessary to guide the
tool in a line parallel to a straight edge. One
method of obtaining a straight cut is to
securely clamp a board or other straightedge
to the work surface, and guide the edge of
the router sub-base along this path (Fig. 16).

FIG. 15

FIG. 16

BIT

WORK

DIRECTION OF
ROUTER FEED

START

HERE

BOARD GUIDE

SECURELY CLAMP

BOARD GUIDE

FEED

DIRECTION

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 16

CENTERING THE SUB-BASE AND

TEMPLET GUIDES

Your router features the Bosch “Precision
Centering Design”. Its sub-base is precisely
centered at the factory. This positions the bit
at the center of the sub-base and optional
templet guides. Precision centering allows you
t

o closely follow jigs such as straight guides,
templets, and dovetail fixtures without
worrying about bit walk-off from the intended
cut line for any reason, including the
orientation of the router’s handles.
In the event the sub-base screws are
loosened or removed, such when preparing
the router for use in a router table, here's how
to re-center the sub-base when reattaching it:

To quickly re-center the sub-base, attach the
sub-base using the set of flathead screws
(included) and the countersunk screw holes in
the sub-base. (Flathead screws have the
tapered heads.) The flathead screws and
countersunk holes will pull the sub-base into a
position that is very close to centered.

OR — To most precisely re-center the sub­base, attach the sub-base using the optional
Bosch centering cone, an optional Bosch
templet guide, and the set of pan-head screws
(included). (Pan-head screws have rounded
tops.) Follow steps 1-8.

1. Position the sub-base so that its pan-head
screw holes are over the matching set of
threaded holes in the base.

2. Insert the pan-head screws, not the flathead
screws, through the sub-base and tighten
them until they are snug, but still allow the
s

ub-base to move.

3. Insert templet guide (optional accessory)
the installed template guide adapter as
described elsewhere in this manual.

4. Slide centering cone (optional accessory)
through templet guide and into collet. Use
narrow end of cone when inserting into 1/4”
collet, wider end of cone when inserting into
1/2” collet.

5. Tighten collet nut with fingers to put slight
grip on centering cone.

6. Lightly press centering cone into templet
guide to center guide and sub-base.

7. Tighten the pan-head screws.

8. Remove centering cone. The precision
centering of the templet guide and sub-base
is complete.

Cutter diameter must be at
least 1/4” smaller than

opening for the bit and cutter.

-17-

CENTERING CONE

(optional accessory)

FIG. 17

PLUNGE BASE

FIG. 18

OTHER BASES

A = M4 COUNTERSUNK SCREW
HOLES

B = M4 PAN-HEAD SCREW HOLES
C = TEMPLET GUIDE ADAPTER

SCREW HOLES

D = HOLES FOR ATTACHING

ROUTER TO ROUTER TABLE
MOUNTING PLATE
(Under sub-base on
non-plunge bases)

!

WARNING

D D

B

A

B

A

B

A

C

C

D

CENTERING CONE

(optional accessory)

TEMPLET GUIDE

(optional accessory)

SUB-BASE

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 17

-18-

TEMPLET GUIDES

The router is equipped with an exclusive
quick-change templet guide adapter, which
firmly grips the guides with a spring-loaded
ring. To insert or change the templet guide,
retract the templet guide release lever. Align
the cutaways on the templet guide with the
t

abs on the bottom of the templet guide
adapter. Insert the templet guide and release
the lever to grip the templet guide in place
(Fig. 19).

Templet guides are used with a number of
special accessories, such as hinge templets,
which are listed in your BOSCH catalog. In
addition, special templets are easily prepared
for cutting repeated patterns, special
designs, inlays, and other applications. A
templet pattern may be made of plywood,
hardboard, metal or even plastic, and the
design can be cut with a router, jigsaw, or
other suitable cutting tool. Remember that
the pattern will have to be made to
compensate for the distance between the
router bit and the templet guide (the “offset”),
as the final workpiece will differ in size from
the templet pattern by that amount, due to
the bit position (Fig. 20).

Also available as an optional accessory is an
additional adapter, the RA1100, that allows
use of conventional threaded templet guides
with the Bosch quick-release system.

TEMPLET GUIDE

(optional accessory)

TEMPLET GUIDE

ADAPTER

TEMPLET GUIDE
RELEASE LEVER

FIG. 19

COLLET CHUCK

WORKPIECE

ROUTER BIT

OFFSET

TEMPLET

GUIDE

TEMPLET
PATTERN

FIG. 20

ROUTER

SUB-BASE

ROUTER DUST COLLECTION

There are three optional dust extraction hood
accessories. Each dust extraction hood is
sized to accept 35mm vacuum hoses. Each
accessory pack includes the VAC002
adapter that will connect the hood to 1-1/4”
and 1-1/2” vacuum hoses. An adapter to
connect the hood to 2-1/2" hoses is also
available separately.

ROUTER DUST COLLECTION FOR

PLUNGE BASE

This dust extraction hood is designed for use
the plunge base (RA1166) when routing is
done in the middle of the workpiece, such as
when creating slots or routing patterns for
inlays. If you have a shop vacuum system,
you can attach the dust extraction hood for
improved visibility, accuracy and utility,
particularly in freehand routing.

To attach, position as shown and secure
adapter to base with the thumbscrews
provided (Fig. 21).

The dust extraction hood can also be
installed with the hose outlet facing the front
of the tool. If the templet guide adapter is
installed, it will need to be reversed or
removed to allow the release lever to fit
under the dust hood.

FIG. 21

DUST EXTRACTION HOOD

(Optional Accessory)

M4 THUMB

SCREWS

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 18

-19-

DUST EXTRACTION HOOD FOR

BACKSIDE OF FIXED BASE

Read and understand these
instructions and tool

manual for use of these accessories.

Do not reach in area of the bit while the
r

outer is ON or plugged in.

To avoid entangling hoses,

do not use this dust
extraction hood at the same time as any
other dust extraction hood.

This dust extraction hood is designed for use
with Bosch routers 1617, 1617EVS, 1618,
1618EVS and their fixed bases when the
routing is done in the middle of the workpiece,
such as when creating slots or routing out
patterns for inlays.

To attach the hood to the router base, slide
the hood into the backside of the router base
around the router’s depth adjustment rod with
the hood’s rounded corners facing up (Fig. 1
& 2). Securely tighten the two knurled
thumbscrews.

The dust extraction hood itself is sized to
accept 35mm vacuum hoses. Also included is
the VAC002 adapter that will connect the
hood to 1-1/4’’ and 1-1/2’’ vacuum hoses.

An adapter to connect the hood to 2-1/2"
hoses is also available, (optional accessory
VAC 020).

USING THE HOOD FOR BACKSIDE OF

FIXED BASE

For maximum dust collection effectiveness,
make sure the router’s chip shield is in place.

!

WARNING

!

CAUTION

DUST

EXTRACTION

HOOD

ROUTER

BASE

M5 SCREW

FIG. 22

FIG. 23

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 19

-20-

EDGEFORMING DUST

EXTRACTION HOOD

Do not reach in area of the

bit while the router is ON
or plugged in. To avoid entangling hoses,
do not use this dust extraction hood at
the same time as any other dust
e

xtraction hood.

This dust extraction hood (optional
accessory) is used for dust collection when
edge-forming (Fig. 24).

ATTACHING DUST EXTRACTION HOOD

You can attach the edge-forming hood in
several places according to your needs or
preferences. This hood is attached using two
of the screw holes on the router base that
are used to attach the router’s sub-base.
Choose the desired location for the hood.
Loosen and take out the two screws from the
router base and attach the dust extraction
hood — over the router’s sub-base — using
the screws provided with the hood. Securely
tighten the screws. (Figures 25 & 26).

DUST

EXTRACTION

HOOD

ROUTER

SUB-BASE

WORKPIECE

EDGE

!

WARNING

M4 x 16mm

SCREW

M4 x 16mm

SCREW

M4 x 16mm

SCREW

SUB-BASE

DUST

EXTRACTION

HOOD

M4 x 16mm

SCREW

FIG. 24

DUST

EXTRACTION

HOOD

FIG. 25

PLUNGE BASE

FIG. 26

OTHER BASES

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 20

-21-

DELUXE ROUTER GUIDE

(Not included, available as accessory)

The Bosch deluxe router guide is an optional
accessory that will guide the router parallel to
a straight edge or allow you to create circles
and arcs.

The deluxe router guide is supplied with two
rods and screws to fasten the guide (Fig. 27).
In addition, it features a fine adjustment knob
and indicator for accurately positioning the
edge guide relative to the bit. With the guide
installed and adjusted, the router should be

fed normally, keeping the guide in contact
with the edge of the workpiece at all times.
The deluxe router guide may also be
positioned directly under the router base for
operations where a cut is needed close to or
at the edge of the work.

The deluxe router guide includes a dust
extraction hood and the VAC002 vacuum
hose adapter.

For complete instructions on installation and
operation, please refer to the instructions
which are included with this accessory.

FIG. 27

DESIRED

WIDTH

CUT

BASE

WORKPIECE

ROUTER

GUIDE

RODS

M6 WING

SCREW

M6 WING SCREW

FINE

ADJUSTMENT

KNOB

FINE

ADJUSTMENT

INDICATOR

FEED

DIRECTION

USE IN ROUTER TABLE

Your router can also be used in a router table.
The RA1161 fixed base is designed to allow
easy depth adjustment in a table. The RA1162
"D" D-Handle base will not fit in most router
tables.

The RA1166 Plunge Base is
not recommended for use

in a router table.

Damage to plunge router

base may occur.
To eliminate the hassle of installing your

router’s own base on the router table and later
having to convert it back for non-table use,
Bosch offers the optional RA1165 Undertable
Router Base (Fig. 28). The RA1165 base is
designed to be permanently attached your
router table, leaving your other router bases
ready for non-table use. The motor can be
quickly moved from base to base — without
any tools!

!

CAUTION

Shown after

subbase has

been removed

Hole for Hex

Wrench

Quick-release
clamp lever
and depth
adjustment
controls should
face the front of the router table

Mounting

Plate

10-24 Screw

FIG. 28

Hex

Wrench

BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 21