Bosch 1608LX User Manual
Before use - Read this instruction manual.
Lisez attentivement la présente notice avant l'emploi.
Lea estas instrucciones de manejo antes de la utilización del aparato.
BM 2610909755 7/01 7/26/01, 12:03 PM1
Fig. 1
1
2
3
8
9
BM 2610909755 7/01 7/26/01, 12:03 PM2
4
5
6
7
(Model 1608LX Pictured)
(Modèle 1608LX illustré)
(Modelo 1608LX ilustrado)
2
Product Data - Trim Router
Base dimensions 3.7" x 2.8" (95mm x 71mm)
Collet capacity 1/4" max.
Bit diameter 1" max.
(NOTE: This tool is designed for use with alternating current (AC) only.)
Accessory Listing
*STANDARD EQUIPMENT—ALL MODELS
1608M 1608 1608LX 1608T 1608U 1609A 1609AK
Steel Case * *
650 Watt Trim Motor * * * * * * * *
Wrench 2pcs 2pcs 2pcs 2pcs 2pcs 1pc 2pcs 2pcs
Trimmer Base * * * *
Laminate Trim Guide *
Deluxe Laminate * *
Trim Guide
Tilt Base * * *
Offset Base * * *
Underscribe Base * *
4mm Hex Key * * * *
3mm Hex Key * *
1/4 Collet * * * * * * *
Collet Nut * * * * * * *
Carbide Tipped Bit * *
Toothed Belt Pulley * * *
1609AKX
Trim Router Components
1. Ventilation openings
2. Wrench slot
3. Slide "ON/OFF" switch
4. Motor clamping ring
5. Collet nut
6. Base assembly
7. Sub-base
8. Clamping ring screw
9. Trim guide assembly
10. Locking knob - depth of cut
(NOTE: components not illustrated on page 2 are illustrated elsewhere in this manual)
11. Adjusting screw - depth of cut
12. Adjusting knob - trim guide
13. Locking screw - trim guide
14. Combination Wrench
15. Toothed Belt Pulley
16. Offset Base Assembly
17. Toothed Belt
18. Depth Locking Screw
19. Slotted Adjusting Gear
20. Wing Nuts
BM 2610909755 7/01 7/26/01, 12:03 PM3
3
WARNING! “READ ALL INSTRUCTIONS”.
Failure to follow the SAFETY RULES identified by the BULLET (•) symbols listed BELOW and other safety precautions, may result
in serious personal injury. Keep these operating
instructions with this product.
GENERAL SAFETY RULES
for all Power Tools
Work Area
• KEEP WORK AREAS CLEAN. Cluttered
areas and benches invite accidents.
• AVOID DANGEROUS ENVIRONMENT.
Don’t use power tools in damp or wet locations.
Do not expose power tools to rain. Keep work
area well lit.
• AVOID GASEOUS AREAS. Do not operate
portable electric tools in explosive atmospheres
in presence of flammable liquids or gases. Motors in these tools normally spark, and the sparks
might ignite fumes.
• KEEP CHILDREN AWAY. Do not let visitors contact tool or extension cord. All visitors
should be kept away from work areas.
Personal Safety
• GUARD AGAINST ELECTRIC SHOCK.
Prevent body contact with grounded surfaces
such as pipes, radiators, ranges and refrigerator
enclosures. Rubber gloves and non-skid footwear are recommended when working outdoors,
where damp or wet ground may be encountered.
A Ground Fault Circuit Interrupter protected
power line must be used for these conditions.
• DRESS PROPERLY. Do not wear loose
clothing or jewelry. They can be caught in
moving parts. Wear protective hair covering to
contain long hair.
• USE SAFETY EQUIPMENT. WEAR
SAFETY GOGGLES or glasses with side
shields. Wear hearing protection during extended use of power tools and dust mask for
dusty operations.
• STAY ALERT. USE COMMON SENSE.
Watch what you are doing. Do not operate tool
when you are tired or under influence of drugs.
• REMOVE ADJUSTING KEYS AND
WRENCHES. Form habit of checking to see
that keys and adjusting wrenches are removed
from tool before turning it on.
• AVOID ACCIDENTAL STARTING. Don’t
carry plugged in tool with finger on switch. Be
sure the switch is OFF before being plugged in.
• DON’T OVERREACH. Keep proper footing and balance at all times.
• BEFORE CONNECTING THE TOOL to a
power supply (receptacle, outlet, etc.) be sure
the voltage supplied is the same as that specified on the tool’s nameplate. A power supply
with voltage greater than that specified for the
tool can result in serious injury to the user—as
well as damage to the tool. If in doubt, DO NOT
PLUG IN THE TOOL. Using a power supply
with voltage less than the nameplate rating is
harmful to the motor.
“Volts AC” designated tools are for Alternating
Current 50-60 Hz only. “Volts DC” designated
tools are for Direct Current. Do not use AC
designated tools with DC power supply. Do not
use electronic speed controlled tools with DC
power supply.
Tool Use and Care
• DON’T FORCE TOOL. It will do the job
better and safer at the rate for which it was
designed.
• USE RIGHT TOOL. Don’t force small tool
or attachment to do the job of a heavy-duty tool.
Don’t use tool for purpose not intended—for
example; don’t use a circular saw for cutting
tree limbs or logs.
• SECURE WORK. Use clamps or a vise to
hold work. It’s safer than using your hand and
it frees both hands to operate the tool.
• DON’T ABUSE CORD. Never carry tool by
cord or yank it to disconnect from receptacle.
Keep cord from heat, oil, and sharp edges.
Always keep cord away from the spinning blade,
bits or any other moving part while the tool is in
use.
• OUTDOOR USE EXTENSION CORDS.
When tool is used outdoors, use only extension
cords suitable for use outdoors and marked with
suffix W-A (for UL), or W (for CSA). Refer to
section “Extension Cords”, for proper cord use.
• DISCONNECT TOOLS. When not in use,
before servicing, or when changing blades, bits,
cutters, etc.
• STORE IDLE TOOLS. When not in use,
tools should be stored in dry, high or locked up
place - out of the reach of children.
• DO NOT ALTER OR MISUSE TOOL. These
tools are precision built. Any alterations or
modifications not specified is misuse and may
result in a dangerous condition.
• THE USE OF ANY ACCESSORIES not
specified in this manual may create a hazard.
• MAINTAIN TOOLS WITH CARE. Keep
tools sharp and clean for better and safer performance. Follow instructions for lubricating and
changing accessories. Inspect tool cords peri-
odically and if damaged, have repaired by au-
4
BM 2610909755 7/01 7/26/01, 12:03 PM4
thorized service facility. Inspect extension cords
periodically and replace if damaged. Keep
handles dry, clean and free from oil and grease.
• CHECK DAMAGED PARTS. Before further use of the tool, a guard or other part that is
damaged should be carefully checked to determine that it will operate properly and perform
its intended function. Check for alignment of
moving parts, binding of moving parts, breakage of parts, mounting, and any other conditions that may affect its operation. A guard or
other part that is damaged should be promptly
and properly repaired or replaced. Have defective switches replaced. Do not use tool if switch
does not turn it on or off.
• ALL REPAIRS, ELECTRICAL OR MECHANICAL, should be attempted only by
trained repairmen. Contact the nearest Bosch
Factory Service Center, or Bosch Authorized
Service Center or other competent repair center. Use only Bosch replacement parts, any
other may create a hazard
Safety Rules for Trim Router
• Always wear safety goggles. If trimmer has a
removable chip deflector, keep it in place when
routing.
• Never use dull or damaged bits. Handle bits
with care.
• Always make sure the workpiece is free from
nails and other foreign objects which can cause
the bit and trimmer to jump and damage the bit.
• Be sure that the bit is installed according to
the procedure described in this manual. Check
all settings and adjustments before making a
cut. An incorrectly installed bit or loose setting
could cause an accident or injury. Always disconnect the power cord before making adjustments or changing bits.
• Do not make adjustments while the tool is
running.
• Never hold the workpiece in one hand and the
trimmer in other when in use. Always clamp the
material and hold the trimmer securely with
both hands.
• Never start the trimmer when the bit is engaged in the material. The bit’s cutting edge
may grab the material causing the trimmer to
get out of control. Always hold the trimmer
with two hands during start-up. The reaction
torque of the motor can cause the trimmer to
twist.
• When turning the trimmer "ON", be aware
that the bit is protruding below the base. Keep
hands away from this area.
• Do not cut or rout into existing walls, around
any fixture or in a blind area which may have
electrical wiring, as the bit could conduct electricity to the tool, creating a hazard for the
operator.
• The trimmer should always be used with its
base flat on the material being cut. For better
control and accuracy of cut, guide the trimmer
with both hands. Use hand positions most comfortable and giving best control for your job.
• Never use bits that have a cutting diameter
greater than the opening in the base.
• The direction of feeding the trimmer into
the material is very important and it relates to
the direction of bit rotation. When viewing the
trimmer from the top, the bit rotates clockwise.
When the trimmer is located between your body
and the material, the feed direction must be to
the right. If the material is located between your
body and the trimmer, then the feed direction
must be to the left. Feeding the trimmer in the
wrong direction causes the cutting edge of the
bit to climb out of the work and pull the trimmer
in the direction of this feed.
• Never touch the bit or other moving part
during use. After use the bit is too hot to be
touched by bare hands.
• Be sure that the bit has come to a complete
stop before you put the trimmer down. This will
reduce the chance of unintentional contact with
the bit.
• When using the tool for laminate trimming,
keep the laminate overhang small. Do no allow
too much laminate to overhang when cutting
the laminate parts to size. When the overhang is
too great, it makes the trimmer more diffi
control. If the laminate overhangs the
workpiece by more than 2", use an overhang
bit to reduce the amount of material before
actually trimming the laminate to desired size.
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 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
5
cult to
BM 2610909755 7/01 7/26/01, 12:03 PM5
in a well ventilated area, and work with ap-
proved safety equipment, such as those dust
masks that are specially designed to filter out
microscopic particles.
Double Insulated Tools
• Double Insulation is a design concept used
in electric power tools which eliminates the
need for the three wire grounded power cord
and grounded power supply system. It is a
recognized and approved system by
Underwriter’s Laboratories, CSA and Federal
OSHA authorities.
IMPORTANT: Servicing of a tool with double
insulation requires care and knowledge of the
system and should be performed only by a
qualified service technician. WHEN SERVICE
IS REQUIRED USE ONLY IDENTICAL REPLACEMENT PARTS.
POLARIZED PLUGS: If your tool is 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 the
proper outlet. To reduce the risk of electric
shock do not change the plug in any way.
Extension Cords
• Replace damaged cords immediately. Use of
damaged cords can shock, burn or electrocute.
•If an extension cord is necessary, a cord
with adequate size conductors should be used
to prevent excessive voltage drop, loss of power
or overheating. The table below shows the
correct size to use, depending on cord length
and amperage rating on the tool’s nameplate.
If in doubt, use the next heavier gauge. Always
use U.L. and CSA listed extension cords.
Ampere Rating (shown on nameplate)
Note: The smaller the gauge number, the larger
0- 2.1- 3.5- 5.1- 7.1- 12.1-
2.0 3.4 5.0 7.0 12.0 16.0
25' 18 18 18 18 16 14
50' 18 18 16 16 14 12
75' 18 18 16 14 12 10
100' 18 16 14 12 10
Cord Length
150' 16 14 12 12 Wire Gauge
the wire is in the cord.
"SAVE THESE INSTRUCTIONS"
Operating the Tool
This tool is switched "ON" by the slide switch
located on the front of the motor housing.
TO TURN THE TOOL "ON" slide the switch
button to the right or "I" position.
TO TURN THE TOOL "OFF" slide the switch
button to the left or "0" position.
WARNING! Hold the tool with both hands
while starting the tool, since torque from the
motor can cause the tool to twist.
WARNING! Always disconnect tool from the
power source before installing bits, accessories, or making any adjustments.
If the base is installed, you may remove it to
completely expose the collet assembly. The
motor may be placed on its side or flat top
surface when changing bits.
Insert the small end of one of the wrenches
provided into slot 2 in the motor. The wrench
is designed to turn and lock the armature, but
it may be necessary to turn the armature shaft
from the collet end to position the shaft in the
wrench. The wrench MUST be fully inserted
to the line stamped on the wrench before loosening or tightening the collet nut. Damage to
the armature shaft is possible if the wrench is
not fully inserted.
With the shaft firmly locked, turn collet nut 5
in a counterclockwise direction with the other
wrench provided. Insert the shank of the router
bit as far as it will go, back it out until the
cutters are 1/8" to 1/4" from the collet nut, and
firmly tighten the nut in a clockwise direction
to secure the bit. Remove both wrenches from
the tool and re-attach base or any accessories
before connecting tool to the power source.
Reverse the above procedure to remove the bit,
and if it does not slide out easily, tap the collet
nut sharply with the wrench to free it. NEVER
strike the bit.
6
Slide "ON/OFF" Switch
All Models Except Model 1609A
Inserting and Removing Bits
Fig. 2
Fig. 3
BM 2610909755 7/01 7/26/01, 12:03 PM6
Model 1609A Only
Insert the 4mm hex wrench supplied into the
hole in the top of the offset base to hold the
spindle in position, and loosen the collet in a
counterclockwise direction with one of the
combination wrenches supplied. Insert a laminate trim bit into the collet as far as it will go,
and back out slightly until the cutters are 1/8"
to 1/4" away from the collet. Holding the
spindle firmly with the 4mm hex wrench,
tighten the collet in a clockwise direction with
the combination wrench to firmly grip the bit.
Model 1609A Only
Remove collet and nut (if fitted) from motor
spindle as described earlier. Lock the armature
shaft with the combination wrench 14 fur-
nished, and screw the toothed pulley 15 in
Fig. 5
15
14
Fig. 4
Wrench
To remove bit, use the wrenches as described
above, and turn the collet in a counterclockwise direction until the bit can be pulled out.
Note that the collet is self-extracting; it is NOT
necessary to strike the collet to free the bit.
CAUTION! The minimum insertion of the bit
shank is 5/8" to ensure proper gripping and
minimize bit run-out.
Collet Care
With the router bit removed, continue to turn
the collet or collet nut counterclockwise until
it is free of the spindle and the collet can be
removed. To assure a firm grip, occasionally
blow out the collet with compressed air and
clean the taper in the spindle shaft with a tissue
or fine brush.
After cleaning, reinsert the collet and lightly
thread in place. To avoid damage, NEVER
tighten the collet or collet nut unless a bit is
inserted. Replace worn or damaged collets
immediately.
Assembling Motor to Base
All Models Except Model 1609A
Insert router motor into clamping ring 4. Rotate motor to the desired position, and tighten
clamping ring screw 8 with a screwdriver. Be
sure clamping ring holds motor firmly before
turning tool "ON ", but do not overtighten the
ring.
place with a screwdriver. Remove the combination wrench, and with the clamping ring
loosened, slide the offset base assembly 16
into place on the motor as far as it will go.
Fig. 6
16
17
As the base is installed, it is necessary to guide
the toothed belt 17 over the pulley by using a
screwdriver inserted through the U-shaped hole
in the sub-base. Position the motor in the base
in the most comfortable position to suit the
operator, and tighten the clamping ring firmly.
Do not overtighten.
Depth Adjustment
Model 1608, 1608LX Only
With the motor clamped in the base and the bit
installed, loosen knob 10 and raise or lower the
motor and cutter with adjusting screw 11 until
the desired amount of bit is exposed. Tighten
knob 10 and make a test cut in scrap material.
Fig. 7
11
10
Repeat this procedure until the desired depth
of cut is achieved.
BM 2610909755 7/01 7/26/01, 12:03 PM7
7
Laminate Trim Guide
Unpiloted laminate trim bits require the use of
a trim guide which may be fitted to models
1608, 1608LX, or 1609A. Mount the guide 9 to
Fig. 11
19
Fig. 8
the bottom of the base in either pair of holes
(1609A has one pair of holes) with the screws
provided, and be sure the bit clears the trim
guide by at least 1/16" (1.5 mm) to avoid
damage. The horizontal position of the guide
determines the amount of material removed by
the bit. To adjust, loosen screw 13 and turn
adjuster 12 to move the guide in or out. Tighten
screw 13, and make a trial cut to check the
Fig. 9
setting and readjust as necessary. For making
straight or bevel cuts, align the tip of the guide
with the cutting edge of the bit to produce the
desired amount of cutter exposure that will
trim the laminate flush or create the desired
bevel.
Refer to instruction sheet included with deluxe
trim guide (1608LX, 1609KX) for additional
adjustments required for that guide.
9
13
9
12
1608T
With the motor fastened tightly in the clamping ring and a bit installed, loosen the depth
locking screw 18 with a screwdriver approximately 1/4 turn. Raise or lower the base by
turning the slotted gear 19, and retighten screw
18 firmly when the desired adjustment is
Fig. 10
18
achieved. Do not overtighten.
Model 1608T has an angular adjustment range
of 75 degrees—45 degrees in one direction,
and 30 degrees in the other. To set the angle,
loosen the wing nuts 20 on either side of the
Fig. 12
20
base, tilt motor to the desired angle, and retighten the wing nuts. Be careful not to overtighten, or the base may be damaged.
When tilted, model 1608T will trim laminated
tops up to a vertical backsplash or on irregular
corners. Use a suitable self-piloted bit such as
Bosch, and guide the trimmer as shown in
Figure 13.
Fig. 13
Underscribe Trimmer—Model 1608U
The underscribe trimmer is designed to cut
plastic laminates when creating joints between
pieces of such material. Properly adjusted, the
router will produce very accurate seams between adjacent sections of the laminated surface.
To install the underscribe base insert the bit
into the collet as described earlier in this manual.
Slide the clamping ring of the base onto the
motor's lower bearing housing as far as it will
go, and carefully tighten the clamp ring screw.
Now adjust the bit until the tip just enters the
machined recess in the aluminum plate of the
underscribe guide. Your tool is now assembled,
and ready to make a test cut in some surplus
material before beginning work.
8
BM 2610909755 7/01 7/26/01, 12:03 PM8
To create a joint, contact cement should be
applied to the core material and the plastic
laminate, and one piece of laminate should be
fastened to the core with the other overlapping
it by about 3/4". The fixed piece must have a
clean, straight edge as it will serve as a guide
for the underscribe base to follow. The overlapping sheet of laminate will then pass over
the aluminum plate and be cut to the proper
length by the router bit. (See Figure 14). This
Fig. 14
accurate system makes it a perfect tool for
joining laminate on stile and rail constructions,
circular or curved edges, and many other surfaces. Because the cutter will generate chips, it
is necessary to keep the laminate pressed down
tightly near the seam to keep these chips from
getting into the joint—this is especially important on larger pieces of material. It is also
necessary to keep steady pressure on the tool so
that the guiding edge of the base remains in
contact with the fixed piece of laminate throughout the operation. (See Figure 15). This is
especially important at the beginning and end
of a cut.
Fig. 15
An eccentric adjuster is fitted to the aluminum
plate and if necessary, can be adjusted with the
pin wrench provided, after loosening the two
screws which mount the aluminum plate. To
make the joint tighter, turn the eccentric clockwise. For a looser joint, turn the eccentric
counterclockwise, as viewed from under the
base (see Figure 16). It is advisable to make
some test cuts on scrap material to determine if
adjustment is required before beginning work,
and to be certain that the screws are re-tightened after adjusting the eccentric. Once this is
done, no further adjustment should be required.
Fig. 16
Note that the base receives a preliminary adjustment at the factory, but will generally need
to be "fine tuned" by the user to produce a
perfect seam.
Offset Trimmer
Model 1609A
Offset trimmer 1609A is primarily used for
trimming laminate in confined areas such as
backsplashes, corners, or other locations inaccessible to the standard trim bases (see Fig 17).
Piloted bits may be used, or the laminate trim
guides may be fitted for use with unpiloted
bits. Note that the offset base is designed for
these specialized laminate trimming applications, and is not suitable for heavy stock removal or continuous service.
Using Self-Piloted Bits
Self-piloted bits have an integral round tip or
ball bearing which rides against the work surface above or below the cutters to control
horizontal cutting depth. When using these
bits, the trim guide is not required, and it is
only necessary to adjust the cutting depth to
allow the pilot to ride on the work surface.
When guiding against a laminated surface, use
wax or other lubricant and do not apply excess
pressure or the piloted end may mar the work.
Bearing pilots must be kept clean and free of
adhesive or other residue. Router bit bearings
are sealed and permanently lubricated, and
should be replaced when they no longer turn
freely to avoid damaging the work surface.
Templet Guides
Your Bosch trim router Model 1608 will accept optional Bosch templet guides for pattern
and other fixture work. To install a guide,
remove the sub-base 7, insert the desired templet guide into the sub-base recess, and reinstall the sub-base. (Templet guide screws are
not used - the sub-base holds the guide in
place). See your Bosch dealer for templet guides
and other accessories.
9
BM 2610909755 7/01 7/26/01, 12:03 PM9
Fig. 17
WARNING! Use of any accessory not speci-
fied in this manual or the BOSCH catalog for
use with this tool may create a hazard.
Trimming Tips
Your Bosch trim router is designed to trim
laminates, phenolics, or other materials which
have been bonded to a substrate and overhang
by about 1/8" (3 mm). It is also handy for light
edge forming, grooving, and sign making with
1/4" shank bits. Be sure the workpiece is secure, and clamp it in place if necessary. With
the tool properly assembled and adjusted, be
certain that the switch is in the “OFF” position,
and connect to the power source. Grasp the
motor housing firmly to resist starting torque,
and slide switch 3 to the “ON” position. With
the motor running at full speed, place the base
of the trimmer on the work surface and feed the
bit with a smooth steady motion into the material to be cut. The correct relationship between
the direction of bit or cutter rotation and router
feed is shown in Fig 18; feed in this direction
or chatter will result.
Fig. 18
WORK
CUTTER
DIRECTION
OF FEED
Support the router on the long edge of the base
whenever possible for maximum stability. At
the completion of the cut, slide switch to the
“OFF” position and allow the bit to come to a
complete stop before setting the tool down.
When using edge forming bits, it may be necessary to make the cut in more than one pass
with progressively deeper settings to avoid
overloading the motor. If the bit cuts freely
and the motor does not slow down, the cutting
depth is generally correct.
BM 2610909755 7/01 7/26/01, 12:03 PM10
10
Maintenance and Service
WARNING! Preventive maintenance per-
formed by unauthorized personnel may result
in misplacing of internal wires and components which could cause serious hazard. We
recommend that all tool service be performed
at a Bosch Factory Service Center.
Tool Lubrication
Your Bosch tool has been properly lubricated
and is ready for use. We recommend, that tools
with gears be regreased with a special gear
lubricant every time the brushes are changed.
Carbon Brushes
The brushes and commutator in your Bosch
tool have been engineered for many hours of
dependable service. To maintain peak efficiency of the motor, we recommend that every
two to six months the brushes be examined.
Only genuine Bosch replacement brushes specially designed for your tool should be used.
NOTES:
Bearings
After about 300-400 hours of operation, or at
every second brush change, the bearings should
be replaced at a Bosch Factory Service Center.
Bearings which become noisy (due to heavy
load or very abrasive material cutting) should
be replaced at once to avoid overheating and
motor failure.
Cleaning
WARNING! To avoid accidents, always disconnect the tool from the power supply before
cleaning or performing any maintenance. The
tool may be cleaned most effectively with
compressed air. Always wear safety goggles
when cleaning tools with compressed air.
Ventilation openings and switch levers must
be kept clean and free of foreign matter. Do not
attempt to clean by inserting pointed objects
through openings.
CAUTION! Certain cleaning agents and solvents damage plastic parts. Some of these are:
gasoline, carbon tetrachloride, chlorinated
cleaning solvents, ammonia and household
detergents that contain ammonia.
BM 2610909755 7/01 7/26/01, 12:03 PM11
11
Loading...