Bosch 601617061, 1617PK, 1617, 1618EVS, 1618 User Manual

...

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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

Call Toll Free for

Consumer Information

& Service Locations

1-877-BOSCH99 (1-877-267-2499) www.boschtools.com

For English Version Version française Versión en español

See page 2

Pour obtenir des informations

et les adresses de nos centres

de service après-vente,

appelez ce numéro gratuit

Voir page 24 Ver la página 46

Llame gratis para

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ubicaciones de servicio

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Power Tool Safety Rules

WARNING

Read and understand all instructions. Failure to follow all instructions listed below, may result in electric shock, fire and/or serious personal injury.

SAVE THESE INSTRUCTIONS

Work Area

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.

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.

Power

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.

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.

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.

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.

cords increase the risk of electric shock.

There is an increased risk

Water entering a power tool will

Before

Damaged

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

use and reduce the risk of electric shock. Refer to “Recommended sizes of Extension Cords” in the Accessory section of this manual.

These cords are rated for outdoor

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.

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.

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.

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 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.

balance enables better control of the tool in unexpected situations.

Use safety equipment. Always wear eye protection.

shoes, hard hat, or hearing protection must be used for appropriate conditions.

A moment of inattention while

Loose clothes, jewelry,

Carrying tools

A wrench or

Proper footing and

Dust mask, non-skid safety

Tool Use and Care

Use clamps or other practical way to secure and support the workpiece to a stable platform.

or against your body is unstable and may lead to loss of

Holding the work by hand

control.

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Do not force tool. Use the correct tool for your application.

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”.

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.

dangerous in the hands of untrained users.

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

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

The correct tool will do the

Any tool that cannot be

Tools are

Properly maintained

serviced before using.

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.

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

Accessories that may be

Many accidents are

Service

Tool service must be performed only by qualified repair personnel.

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.

Service or

Safety Rules for Routers

Hold tool by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord.

make exposed metal parts of the tool "live" and shock the operator.

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.

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.

Contact with a "live" wire will

If cutting into

Clamping the material and guiding

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.

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.

edge may grab the material causing loss of control of the cutter.

Always hold the tool with two hands during start-up

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

. The reaction torque of the

Loose adjustment

The bit cutting

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

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.

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.

be touched by bare hands.

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

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.

After use the bit is too hot to

NOTE: inside and

Damaged

The

Safety Rules for Router Table

WARNING

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 chemicallytreated 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.

Some dust created by power sanding, sawing,

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

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.

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.

the table is tipped or the cutting tool is accidentally contacted. Do not store materials on or near the table such that it is

Failure to follow all

Also remember to

Serious injury could occur if

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.

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.

can lead to personal injury or tool failure.

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

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.

cause the carbides to be dislodged, fly toward the operator side, and possibly strike you or bystanders.

Overloading the tool

Cutting a nail or the like will

Damaged

The bit cutting

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

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.

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.

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.

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.

Router cuts are blind cuts but

Cutting the material

When routing along

Feeding

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

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.

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.

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.

Contact with a spinning bit will

Loose adjustment

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Symbols

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.

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

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

No load speed Rotational speed, at no load

orbits etc. per minute

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

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 is listed by Underwriters Laboratories, and listed to Canadian Standards by Underwriters Laboratories.

This symbol

designates that this tool complies to NOM Mexican Standards.

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Functional Description and Specifications

WARNING

easures reduce the risk of starting the tool accidentally.

Disconnect the plug from the power source before making any a

ssembly, adjustments or changing accessories

Routers

SPEED CONTROL DIAL

FIG. 1

BASE CLAMP LEVER

Models 1617EVS

& 1618EVS only

ROCKER ON\OFF

SWITCH

ROUND

HANDLE

SUB-BASE

BIT ROTATION ARROW

AIR VENTS

Such preventive safety

MOTOR HOUSING

MOTOR ALIGNMENT

ARROW

BASE TYPE S

CHIP DEFLECTOR

TEMPLET GUIDE

QUICK CHANGE LEVER

FIG. 2

POWER ON/OFF

SWITCH

BASE TYPE D

REVERSIBLE

HANDLE

BIT ROTATION ARROW

AIR VENTS

"LOCK-ON"

BUTTON

D-HANDLE

TRIGGER

SWITCH

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FIG. 3

PLUNGE LOCK

LEVER

PLUNGE HANDLE

DEPTH ROD FINE

ADJUSMENT KNOB

DEPTH STOP TURRET

SPEED CONTROL DIAL

Model 1617EVSP only

BASE TYPE P

DEPTH ROD

SUB-BASE

AIR VENTS

MOTOR HOUSING

ROCKER ON\OFF SWITCH

MOTOR

ALIGNMENT ARROW

DEPTH INDICATOR

DEPTH ROD KNOB

CHIP DEFLECTOR

BIT ROTATION ARROW

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)

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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.

WARNING

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.

With the router bit inserted and the shaft

5. 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".

WARNING

base, do not use router bits greater than

To prevent personal injury, always remove the plug

When the templet guide has been removed from

FIG. 4

COLLET

WRENCH

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

WARNING

opening for the bit and cutter.

CAUTION

without a bit.

NOTE:

clean and free of dust, wood, residue and grease before assembling.

1. Use the shaft and collet chuck wrenches

2. Once the collet chuck assembly is

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

The bit shank and chuck should be

REMOVING THE ROUTER BIT

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

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

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

To prevent damage to tool, do not tighten collet

SHAFT

WRENCH

With the router bit removed, continue to turn

COLLET CHUCK CARE

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.

FIG. 5

COLLET

CHUCK

COLLET

NUT

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

1. Hold router in horizontal position, open

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.

Set final height position as described

7. 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.

FIG. 6

FIG. 7

FIG. 8

ALIGNMENT

ARROWS

COARSE

ADJUSTMENT

LEVER

BASE

CLAMP

LEVER

BASE

CLAMP

LEVER

MOTOR

COARSE

ADJUSTMENT

NOTCHES

BASE

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• 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.)

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)

CHIP DEFLECTOR

WARNING

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.

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.

FIG. 9

TEMPLET GUIDE

ADAPTER

MOUNTING SCREWS

FIG. 10

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Operating Instructions

FINE ADJUSTMENT DIAL

INDICATOR RING

FIG. 11

CAST INDICATOR MARKS

COARSE

ADJUSTMENT

LEVER

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

All depth adjustments must be made

NOTE:

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.

BASE CLAMP LEVER

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.

After making depth adjustments, re-clamp

5. 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.

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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)

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.)

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

DEPTH ADJUSTMENT WITH PLUNGE

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.

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

TO CLAMP MOTOR

DEEP CUTS

BASE PLUNGING ACTION

DEPTH ROD AND TURRET

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

FIG. 13

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.

The desired depth of cut may now be

4. achieved by plunging the router until the depth rod contacts the selected stop on the turret.

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IG. 14

DEPTH

INDICATOR

DEPTH INDICATOR

KNOB

DEPTH ROD FINE

ADJUSMENT KNOB

DEPTH ROD

DEPTH STOP

TURRET

For deeper cuts, make several progressively

DEEP CUTS

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".

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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-

(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.

WARNING

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.

ON"BUTTON

If the “Lock-ON” button is continuously being

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

(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.

DIAL

SETTING RPM APPLICATION

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

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

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.

SPEED CONTROL

Nonferrous metals, larger diameter bits,

}

and cutters

Softwoods, plastics, counter tops, smaller

}

diameter bits, and cutters

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As seen from the top of the router, the bit

FEEDING THE ROUTER

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.

FIG. 15

START

HERE

WORK

BIT

DIRECTION OF ROUTER 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 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.

The router can be guided through the work in

GUIDING THE ROUTER

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. 16

SECURELY CLAMP

BOARD GUIDE

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FEED

DIRECTION

BOARD GUIDE

D D

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CENTERING THE SUB-BASE AND

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.

TEMPLET GUIDES

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.

WARNING

opening for the bit and cutter.

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

FIG. 17

PLUNGE BASE

CENTERING CONE

(optional accessory)

TEMPLET GUIDE

(optional accessory)

FIG. 18

OTHER BASES

A = M4 COUNTERSUNK SCREW HOLES

B = M4 PAN-HEAD SCREW HOLES

SUB-BASE

-17-

C = TEMPLET GUIDE ADAPTER

SCREW HOLES

D = HOLES FOR ATTACHING

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

CENTERING CONE

(optional accessory)

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

The router is equipped with an exclusive

TEMPLET GUIDES

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).

FIG. 19

TEMPLET GUIDE

ADAPTER

TEMPLET GUIDE RELEASE LEVER

TEMPLET GUIDE

(optional accessory)

FIG. 20

ROUTER BIT

OFFSET

COLLET CHUCK

TEMPLET

GUIDE

ROUTER

SUB-BASE

TEMPLET PATTERN

WORKPIECE

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.

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).

FIG. 21

DUST EXTRACTION HOOD

(Optional Accessory)

M4 THUMB

SCREWS

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.

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DUST EXTRACTION HOOD FOR

BACKSIDE OF FIXED BASE

WARNING

manual for use of these accessories.

Do not reach in area of the bit while the r

outer is ON or plugged in.

CAUTION

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

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

Read and understand these instructions and tool

To avoid entangling hoses, do not use this dust

FIXED BASE

FIG. 22

M5 SCREW

DUST

EXTRACTION

HOOD

FIG. 23

ROUTER

BASE

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EDGEFORMING DUST

EXTRACTION HOOD

WARNING

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).

FIG. 26

OTHER BASES

FIG. 24

ROUTER

SUB-BASE

WORKPIECE

EDGE

DUST

EXTRACTION

HOOD

M4 x 16mm

SCREW

FIG. 25

PLUNGE BASE

M4 x 16mm

SUB-BASE

SCREW

M4 x 16mm

SCREW

DUST

EXTRACTION

HOOD

DUST

EXTRACTION

HOOD

M4 x 16mm

SCREW

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

FIG. 27

BASE

CUT

DESIRED

WIDTH

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

M6 WING

SCREW

WORKPIECE

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.

FEED

DIRECTION

FINE

ADJUSTMENT

KNOB

M6 WING SCREW

FINE

ADJUSTMENT

INDICATOR

ROUTER

GUIDE

RODS

Your router can also be used in a router table.

USE IN 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.

CAUTION

in a router table.

The RA1166 Plunge Base is not recommended for use

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!

FIG. 28

10-24 Screw

Mounting

Plate

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

-21-

Hex

Wrench

Hole for Hex

Wrench

Shown after

subbase has

been removed

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