Bosch 1615, 1615EVS Instruction Manual
1615
0 601 615 0 . .
1615EVS
0 601 615 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 1615 1615EVS
Identification number 0 601 615 0 . . 0 601 615 7. .
Collet capacity 1/4", 3/8", 1/2" dia. 1/4", 3/8", 1/2" dia.
Router bit capacity 2-5/8" dia. max. 2-5/8" dia. max.
( NOTE: This tool is designed for use with Alternating Current (AC) only. )
Accessory Listing
1/2 “ Collet Chuck Assy *
3/8 “ Collet Chuck Assy
1/4 “ Collet Chuck Assy*
27 mm Collet Nut Wrench*
Templet Guide Adapter w/2 screws*
Deluxe Router Guide
Steel Case
Fine Adjustment Accessory* *
Vacuum adapter
Vacuum Hose
Hose/Vacuum adaptor
( * = standard equipment )
(* * = standard equipment 1615EVS only)
Router Components
1. Depth indicator rod 12. Trigger switch
2. Depth indicator scale 13. Plunge lock/release lever
3. Depth indicator lock/release knob 14. Cast boss
4. Router base 15. Retaining ring
5. Revolving depth turret 16. Collet
6. Stop nut 17. Collet nut
7. Collet chuck assembly 18. Templet guide adaptor
8. Subbase 19. Templet guide
9. Threaded guide rod 20. Bit
10. Spindle lock 21. Variable speed dial (1615EVS)
11. “Lock-ON” button 22. Fine adjustment accessory (1615EVS)
(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.
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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
150' 16 14 12 12 Wire Gauge
Cord Length
Note: The smaller the gauge number, the larger
the wire is in the cord.
"SAVE THESE INSTRUCTIONS"
Operating the Tool
Trigger Switch and “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
just above the trigger that allows 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.
WARNING! Hold the tool with both hands
while starting the tool, since torque from the
motor can cause the tool to twist.
Variable Speed with Dial Setting
(1615EVS)
Your router is also equipped with a variable
speed dial 21. 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 5 = 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 Setting Material
1-3 Hardwoods, soft plastics,
(12,000 to nonferrous metals,
15,000 RPM) larger diameter router
bits and cutters.
4-5 Softwoods, plastics,
(16,500 to counter tops, smaller
19,000 RPM) diameter router bits and
cutters.
"Soft Start" Feature (1615EVS)
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.
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 10, and push in with thumb to
hold the armature shaft firmly. Next, use the
27mm wrench supplied to loosen the collet
chuck assembly 7 in a counter-clockwise direction (viewed from under the router). Insert the
shank of the router bit into the collet chuck as
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far as it will go, and then back the shank out until
the cutters are approximately 1/8" to 1/4" away
from the collet nut face. With the bit inserted
and the spindle lock fully engaged, firmly tighten
the collet chuck assembly in a clockwise direction with the 27mm wrench. To avoid damage,
never tighten the collet chuck unless a bit of the
proper shank size is inserted.
and press the lever 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 lever is
released. When plunging, always apply uniform firm pressure to both handles to avoid
cocking the motor on the posts.
CAUTION! To minimize run-out and ensure
proper gripping, the bit should be inserted into
the collet as far as possible, and never less than
5/8".
CAUTION! Do not use router bits greater
than 2-5/8" in diameter as they will not fit
through the base casting.
Removing the Router Bit
To remove bit, use the spindle lock and wrench
as described above, and turn the collet chuck
assembly 7 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 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.
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 15 is properly located around the collet
16 and seated in the inner groove of the collet
chuck nut 17 and lightly
thread the collet chuck
back onto the armature
shaft. Replace worn or
damaged collet chucks
immediately.
15
16
7
17
Plunge Lock/Release Lever
To release the plunge lock/release lever 13
grasp the router handles firmly with both hands
Indicator Rod and
Revolving Depth Turret
The depth indicator rod 1 and the revolving
depth turret 5 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 depth turret until the
lowest step is aligned with the depth indicator
rod. Loosen depth indicator lock/release knob
3 and lower the depth indicator rod until it
contacts the lowest step of the turret. The reading of the red indicator line along the depth
indicator scale 2 now indicates the point at
which the bit just contacts the work, and is used
as a reference point to set the desired depth of
cut.
EXAMPLE: With the bit just contacting the
work surface, depth indicator rod 2 reads 3/4"
with the tip of the rod in contact with the turret.
To achieve a 1/2" depth of cut, loosen knob and
move the rod upward until the red line indicates
1 1/4", and tighten knob. Plunging the router
until the depth rodcontacts the depth turret will
now move the bit into the workpiece 1/2". To be
certain that your settings are accurate, you may
want to make test cuts in scrap material before
beginning work.
It is possible to make progressively deeper cuts
by starting with a higher flat on the depth turret
and rotating the turret to progressively lower
stops until the final cutting depth is reached.
Threaded Guide Rod
The threaded guide rod 9 is fitted with three stop
nuts 6. When not in use, these nuts should be
snugly seated at the top and bottom of the rod so
that they do not interfere with the plunge action.
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If a shorter stroke is desired, turn the upper stop
7
20
19
8
nut closest to the cast boss 14 on the motor
down to the desired position, and lock in place
by firmly tightening the other upper stop nut
against it. If a fixed depth setting is desired, (no
plunge action) tighten a stop nut on either side
of the boss and the depth of cut will be rigidly
set.
Direction of Feed
The router rotates in a clockwise direction as
viewed from the top. The correct relationship
between direction of bit or cutter rotation and
router feed is shown below. It is very important
to move the router in the proper direction or 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 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.
start the tool when the bit is engaged. Always be
sure the collet nut is tightened securely before
use. Always use bits with the shortest cutting
length necessary to produce the desired cut to
minimize router bit run-out and chatter.
Templet Guides
To use the templet guides 19 that are listed in
the BOSCH catalog, your router is supplied
with a templet guide adaptor 18, which is fastened to the base with the two countersunk
screws provided. Optional templet guides may
be inserted and held in place along their edges
with the two screws provided with the templet
guide. Some templet guides have holes for
mounting, but these holes are not required for
use with the adaptor plate shown, as it grips the
edge of the templet guide.
18
19
Templet guides are used with a number of
accessories which are listed in your BOSCH
catalog. In addition, special templets are easily
prepared for cutting repeated patterns, designs,
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 generally 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. Do not attempt to
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.
Patterns must compensate for the distance between the router bit and the templet guide, as the
final workpiece will differ in size from the
templet
pattern by
that
amount,
due to the
cutter position.
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(1615EVS) RA1001
Fine Adjustment Accessory
Installation and Operating Instructions
The RA1001 fine-adjustment accessory will
allow precise bit height adjustments on Bosch
routers. It is important to note that this accessory restricts the movement of the router motor
on the plunge base and effectively replaces the
normal plunge action with a threaded feed.
CAUTION; Always disconnect the tool from
the power source before installing bits, accessories, or making any adjustments. Never adjust this accessory when the tool is running or
the bit is in contact with the workpiece.
Installation
1. Plunge router down so that boss O on the
motor is not in contact with nuts J on threaded
guide rod I. Remove the 17mm locknut and two
flat nuts J from rod I with a suitable wrench
(Fig. 1).
Fig. 1
J
O
I
Fig. 2
Place washer K over
threaded rod, and reinstall one of the flat
nuts J about 3/8" from
the top of rod I. A
light film of general
purpose grease may
K
be applied to washer
K to help reduce friction (Fig. 2).
will protrude slightly from the cutaway end of
the RA1001 so that the face of the nut (NOT the
RA1001) will contact washer K. Figure 3
shows the RA1001 properly installed. If desired, 17mm nut J below boss O may be used to
lock the router in a fixed depth setting by
tightening it against the opposite side of boss O.
(Note: Keep the nuts you have removed in a
safe place so that they may be reinstalled on
your router if the RA1001 is removed for any
reason.)
Fig. 3
J
Operation
To use the RA1001, depress the plunge release
lever and turn the RA1001 clockwise to lower,
or counterclockwise to raise the bit. (Note that
one full turn of the knob will raise or lower the
bit approximately .060", or 1.5mm.) It is necessary to exert slight downward pressure on the
router handle opposite the RA1001, to avoid
cocking the motor on the posts (Fig. 4).
Fig. 4
2. Place the threaded end of the RA1001 over
the top of rod I and press it down to compress
the spring until the cutaway portion engages nut
J and thread adjuster onto rod. When the
RA1001 is properly installed, the 17mm nut J
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J
9
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 BOSCH plunge router may be fitted with
a chip extraction attachment to help keep your
work environment cleaner. This attachment
can be used for general routing, and has an
adjustable brush attachment that is especially
well-suited to grooving applications. Please
see your BOSCH Power Tool distributor for
more details about these and other optional
accessories.
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.
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.
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