Bosch 1613, 1614, 1613EVS, 1614EVS Instruction Manual

0 (0)

1613

0 601 613 0 . .

1614 0 601 614 0 . .

RPM 23000 22000 19500 17000 14500 12000

1613EVS 0 601 613 7 . .

1614EVS 0 601 614 7 . .

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.

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Product Data - Plunge Router

Model number 1613 1613EVS. Identification number 0 601 613 0 . . 0 601 613 7 . Router bit capacity 1-5/8" dia. max. 1-5/8" dia. max. Collet capacity 1/4", 3/8", & 1/2" shanks 1/4", 3/8", & 1/2" shanks

Model number 1614 1614EVS. Identification number 0 601 614 0 . . 0 601 614 7 . Router bit capacity 1-5/8" dia. max. 1-5/8" dia. max. Collet capacity 1/4" shank 1/4" shank

NOTE: This tool is designed for use with alternating current (AC) only.)

Accessory Listing

1613 & 1613EVS 1614 & 1614EVS 1/4" Collet chuck* 1/4" Collet chuck* 3/8" Collet chuck 3/4" Collet wrench* 1/2" Collet chuck* Deluxe router guide 15/16" Collet wrench* Vacuum attachment Deluxe router guide Vacuum hose Vacuum attachment Hose/vacuum adaptor Vacuum hose Carrying case Hose/vacuum adaptor Carrying case

(* = standard equipment)

Router Components

1. Fine adjust knob 14. Chip deflector

2. Variable speed dial (1613EVS & 1614EVS) 15. Subbase

3. Depth indicator rod 16. Plunge lock/release lever

4. Depth indicator 17. Index marker

5. Depth indicator lock/release knob 18. Trigger switch

6. Templet guide lock/release lever 19. Vacuum attachment

7. Revolving depth turret 20. Vacuum hose

8. "Lock-ON" button 21. Retaining ring

9. Router guide adustment knob 22. Collet

10. Deluxe router guide 23. Collet nut

11. Spindle lock 24. Templet guide

12. Guide plate 25. Collet chuck assembly

13. Guide plate 26. Router bit

27. Template pattern

(NOTE: Router components not illustrated on page 2 are illustrated elsewhere in this manual)

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WARNING! “READ ALL INSTRUC-

TIONS”. 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. keys and adjusting wrenches are removed from

Form habit of checking to see that

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.

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• 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 periodically and if damaged, have repaired by authorized 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 Routers

• If router bit is protruding through the base, never lay the router down until the motor has come to a complete standstill.

• Never hold the workpiece in one hand and the router in other when in use. Always clamp the material and hold the router securely with both hands.

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

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

• The direction of feeding the router into the material is very important and it relates to the direction of bit rotation. When viewing the router from the top, the bit rotates clockwise. When the router 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 router, then the feed direction must be to the left. Feeding the router in the wrong direction causes the cutting edge of the bit to climb out of the work and pull the router in the direction of this feed.

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.

• Never start the router when the bit is engaged in the material. The bit’s cutting edge may grab the material causing the router to get out of control. Always hold the router with two hands during start-up. The reaction torque of the motor can cause the router to twist.

• Always make sure the workpiece is free from nails and other foreign objects which can cause the bit and router to jump and damage the bit.

• Always wear safety goggles. If router has a removable chip deflector, keep it in place when routing.

• Never touch the router bit or other moving part during use. After use the router bit is too hot to be touched by bare hands.

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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)

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

Note: The smaller the gauge number, the larger

the wire is in the cord.

"SAVE THESE INSTRUCTIONS"

Operating the Tool

Variable Speed with Dial Setting

(1613EVS & 1614EVS)

Your router is also equipped with a variable speed dial 2. The router bit speed can be preset from 12,000 to maximum nameplate RPM by rotating the dial to the desired setting. The dial may be set on or between any of six positions (1 = low through 6 = high). The "Lock-ON" button may also be used with any setting of the dial.

The following speeds generally apply, but precise settings are largely determined by experience with the material being cut. Momentary speed variation is normal when starting the router until the electronic regulator takes control.

Dial 1613EVS 1614EVS

Setting RPM RPM Material

1 12,000 12,000 nonferrous metals, 2 14,000 14,500 larger diameter router 3 16,000 17,000 bits and cutters.

4 18,000 19,500 Softwoods, plastics, 5 20,000 22,000 counter tops, smaller 6 22,000 23,000 diameter router bits

and cutters.

"Soft Start" Feature

(1613EVS & 1614EVS )

The router is equipped with the "soft start" feature which gradually increases the starting speed and torque, reducing the stress that occurs from a high torque start.

Trigger Switch with "Lock-ON"button

Your tool can be turned "ON" or "OFF" by squeezing or releasing the trigger. Your tool is also equipped with "Lock-ON" button, located on the left side of the trigger handle, that allows for continuous operation without holding the trigger.

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.

WARNING! If the "Lock-ON" button is con-

tinuously being depressed, the trigger cannot be released.

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Start the tool before applying to work and let the tool come to full speed before contacting the workpiece. Lift the tool from the work before releasing the switch. DO NOT turn the switch "ON" and "OFF" while the tool is under load; this will greatly decrease the switch life.

Router Bit Installation and Removal

WARNING! Always disconnect the tool

from the power supply before installing router bits, accessories or making any adjustments.

Installing a Router Bit

Turn the armature shaft to align the flats with the spindle lock 11, and press the spindle lock firmly down to engage it. Next, use the wrench supplied to loosen the collet chuck assembly. Insert the shank of the router bit into the collet chuck 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 chuck face. With the router bit inserted and the spindle lock fully engaged, tighten the collet chuck assembly firmly in a clockwise direction, (viewed from under the router), with the wrench supplied. To avoid damaging the collet chuck, never tighten the collet chuck unless a router bit of proper shank size is inserted into the collet.

To ensure proper gripping of the router bit and minimize run-out, the shank of the router bit should always be inserted at least 5/8".

CAUTION! 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.

CAUTION! Do not use router bits greater

than 1-5/8" in diameter as they will not fit through the base casting.

Removing the Router Bit

Use the spindle lock and wrench as described above, and turn the collet chuck assembly in a counter-clockwise direction. Once the collet chuck assembly is loosened, continue to turn the collet chuck 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 bit.

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 three component parts as illustrated; check to see that the retaining ring 21 is properly located around the collet 22 and seated in the inner groove of the collet chuck nut 23 and

lightly thread the collet chuck back onto the armature shaft. Replace worn or damaged collet chucks immediately.

Plunge Mechanism

To release the plunge mechanism, grasp the router handles firmly with both hands and press the plunge lock/release lever 16 with the thumb of the left hand. The motor may then be raised or lowered to the desired position. The plunge lock/release lever is spring-loaded, and will hold the router motor in position when pressure on the lock lever is released. When plunging, always apply uniform firm pressure to both handles to avoid cocking the motor on the posts.

Indicator Rod and Turret

The depth indicator rod 3 and the revolving depth turret 7 are used to control cutting depth as follows;

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. To set a desired depth of cut, rotate revolving depth turret until the lowest step is aligned with the depth indicator rod. Loosen depth indicator lock/release knob 5 and lower the depth indicator rod until it contacts the lowest step of the turret. Slide the depth indicator 4 until the red line indicates zero on the depth scale, indicating the point at which the bit just contacts the work.

To set a desired cutting depth, slide the depth indicator 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 lock/release knob. The desired depth of cut may now be achieved by plunging the router until the depth indicator rod contacts the selected stop on the revolving depth turret. To be certain that your depth settings are accurate, you may want to make test cuts in scrap material before beginning work. Once the desired final depth has been set on the lowest depth turret setting with the depth indicator rod, it is possible to make progressively deeper cuts by starting with a higher flat on the depth turret and after each cut, rotating the revolving

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depth turret to progressively lower stops as desired, until the final depth (lowest step or flat) is reached.

Fine adjustment

The router is equipped with a true micrometertype fine adjustment mechanism, which can be used in any plunge position and provides precise adjustment of the router bit position for unmatched accuracy. When the tool is plunged to the approximate position desired, this device may be adjusted to precisely set the final cutter position.

To use the fine adjustment, turn the fine adjust knob 1 clockwise to lower the router bit or counter-clockwise to raise it, as indicated by the arrow molded into the top of the knob. To allow precise settings, the indicator ring is graduated in English and Metric increments, and each line is equal to 1/10 mm or .004". The indicator ring may be reset to zero without moving the fine-adjust knob, to allow the user to begin the adjustment from any reference point desired.

The fine adjustment mechanism has a total adjustment range of 5/8", which is indicated by the two lines printed on back of the housing. Whenever the fine adjustment is used, be certain that the index marker 17 is positioned between these two lines to ensure that there will be enough travel in the desired direction after the router is plunged into position. Note that when the router is plunged to maximum depth or is fully retracted to the top of the posts, the fine adjustment mechanism will not move the motor further down or up, as the full extension of the travel has been reached at these points. Similarly, the fine adjustment cannot lower the bit when the depth indicator rod is tightened against the depth turret.

Direction of Feed

The router rotates in a clockwise direction, as viewed from the top of the router. The correct relationship between direction of router bit or cutter rotation and router feed is shown below. It is very important to move the router in the proper direction or router bit chatter and rough cutting will be the result. As an example, to rout a decorative edge on the front of a table top, you would move the router from left to right to perform the operation, or counter-clockwise

around the workpiece. If you were cutting an opening in the center of a panel, you would feed the router in a clockwise direction, so that the edge of the opening would be cut against the rotation of the router bit as described, and have a smooth finish. Whenever you are cutting completely around a workpiece, it is advisable to cut across the grain first, so any corner tearout may be smoothed by cutting with the grain on the second pass.

WORK

CUTTER

DIRECTION OF FEED

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 nut 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 run-out and chatter.

Templet Guides

The router is equipped with an exclusive quickchange templet guide mechanism, which firmly grips the guides with a spring-loaded ring built into the base. To insert or change the templet guide 24, retract the templet

guide lock/release lever 6. Align any two of the four cutaway tabs on the templet guide to the two cast-in bosses in the templet guide re-

24 23

cess of the base.

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Insert the templet guide and release the lock lever to grip the templet guide in place.

Templet guides are used with a number of special accessories, such as hinge templets and dovetail fixtures 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 24, as the final workpiece will differ in size from the templet pattern 27 by that amount, due to the cutter position.

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Deluxe Router Guide

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. It is best to keep the router in one position as it is moved along the guide, as this will produce the straightest cut.

The Bosch deluxe router guide is an accessory that will guide the router parallel to a straight edge or around a curved surface. The deluxe router guide is supplied with two rods and a series of wing nuts and screws to fasten the guide and adjust its position 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 under the router base for operations where a limited amount of bit exposure is desired.

The Bosch deluxe router guide includes a fine-adjustment mechanism for extra precision, and removable face plates for guiding the router along straight or curved surfaces. For proper operation, please refer to the instructions which are included with this accessory.

Chip Extraction

Your router may be fitted with optional chip extraction accessories, which are available from your Bosch dealer. Chip extraction is most effective on grooving, dadoing, and other flatsurface operations where flying chips can be controlled. It is less effective on edge forming or when template guides are used as the vacuum efficiency is greatly diminished in such circumstances.

WARNING! Use of any accessory not speci-

fied in this manual or the BOSCH catalog for use with this tool may create a hazard.

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.

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.

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