Bosch Power Tools 1618EVS, 16186, 1617EVSTB, 1617EVSPK, 1617EVS 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 1617EVSPK 1618EVS

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 Voir page 25 Ver la página 48

Pour obtenir des informations

et les adresses de nos centres

de service après-vente,

appelez ce numéro gratuit

Llame gratis para

obtener información

para el consumidor y

ubicaciones de servicio

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General Power Tool Safety Warnings

WARNING

Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE

The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

Work area safety

Keep work area clean and well lit. Cluttered

or dark areas invite accidents.

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

tools create sparks which may ignite the dust or fumes.

Keep children and bystanders away while operating a power tool. Distractions can

cause you to lose control.

Electrical safety

Power tool plugs must match the outlet. Never modify the plug in any way. Do not us e a ny adapter pl ug s with earthe d (grounded) power tools. Unmodified plugs

and matching outlets will reduce risk of electric shock.

Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk

of electric shock if your body is earthed or grounded.

Do not expose power tools to rain or wet conditions. Water entering a power tool will

increase the risk of electric shock.

Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled

cords increase the risk of electric shock.

When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use

reduces the risk of electric shock.

If operating a power tool in a damp location is unavoidable, use a Ground Fault Circuit Interrupter (GFCI) protected supply. Use of

an GFCI reduces the risk of electric shock.

Personal safety

Stay alert, watch what you are doing and us e co mmon sense w hen opera ting a

power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention

while operating power tools may result in serious personal injury.

Use personal protective equipment. Always wear eye protection. Protective equipment

such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.

Prevent unintentional starting. Ensure the sw itch is in th e o ff-po sitio n b efore connecting to power source and / or battery pa ck, picki ng up or carrying the t ool.

Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.

Remove any adjusting key or wrench before turning the power tool on. A wrench or a

key left attached to a rotating part of the power tool may result in personal injury.

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

co ntrol of the power to ol in unexpe ct ed situations.

Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves away from moving parts. Loose

clothes, jewelry or long hair can be caught in moving parts.

If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-

related hazards.

Power tool use and care

Do not forc e the power to ol. Use the correct power tool for your application. The

correct power tool will do the job better and safer at the rate for which it was designed.

Do not use the power tool if the switch does not turn it on and off. Any power tool that

ca nn ot be co nt ro ll ed wi th th e swi tc h is dangerous and must be repaired.

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Disconnect the plug from the power source and/or the battery pack from the power tool before making any adjustments, changing accessories, or storing power tools. Such

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

Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are

dangerous in the hands of untrained users.

Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use.

Ma ny acci de nt s ar e ca us ed by poorly maintained power tools.

Safety Rules for Routers

Hold power tool by insulated gripping surfaces, because the cutter may contact its own cord. Cutting a ”live” wire may make

exposed metal parts of the power tool ”live” and shock the operator.

Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by your

hand or against the body leaves it unstable and may lead to loss of control.

Do not drill, fasten or break into existing walls or other blind areas where electrical wiring ma y ex ist. If this s it ua tion is

unavoidable, disconnect all fuses or circuit breakers feeding this worksite.

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

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

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

the tool with both hands is safer.

Never lay workp ie ce on top of hard surfaces, li ke co nc re te, stone, etc. ..

Protruding cutting bit may cause tool to jump.

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

Keep cutting tools sharp and clean. Properly

maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.

Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the

power tool for operations different from those intended could result in a hazardous situation.

Service

Have your power tool serviced by a qualified re pa ir person u sing on ly identical replacement parts. This will ensure that the

safety of the power tool is maintained.

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 ot her ad justmen t devices are se cu re ly ti gh te ned. L oo se ad ju st me nt

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

Never start the too l wh en the bi t is engaged in the material. The bit cutting

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

Al wa ys hold the to ol with two ha nd s during start-up. The reaction torque of the

motor can cause the tool to twist.

The direction of feeding the bit into the material is very important and it relates to the direction of bit rotation. When viewing th e tool from t he to p, the bit rot at es clockwise. Feed direction of cutting must be counter-clockwise. NOTE: inside and

outside cu ts will req ui re differe nt feed direction, refer to se ction on fee ding the router. Feed in g the to ol in the wro ng direction, causes the cutting edge of the bit to climb out of the work and pull the tool in the direction of this feed.

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

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

Never touch the bit during or immediately after the use. After use the bit is too hot to

be touched by bare hands.

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

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

Additional Safety Warnings

GFCI and personal protection devices like electrician’s rubber gloves and footwear will further enhance your personal safety.

Do not use AC only rated tools with a DC power supply. While the tool may appear to

work, the electrical components of the AC rated tool are likely to fail and create a hazard to the operator.

Keep handles dry, clean and free from oil and grease. Slippery hands cannot safely

control the power tool.

Use clamps or other practical way to secure and support the work pie ce to a stable platform. Holding the work by hand or against

your body leaves it unstable and may lead to loss of control.

Develop a periodic maintenance schedule for your tool. When cleaning a tool be careful not to disassemble any portion of th e tool sinc e interna l wires may be misplaced or pinched or safety guard return sp rings may be improperly moun ted.

Certain cleaning agents such as gasoline,

Never use bi ts t hat ha ve a cut ti ng diameter greater than the opening in the base.

The rated speed of the accessory must be at least equal to the ma ximum sp eed marked on the power tool. Accessories

running faster than their RATED SPEED can break and fly apart.

carbon tetrachloride, ammonia, et c. may damage plastic parts.

Risk of injury to user. The power cord must only be serviced by a Bosch Factory Service Center or Autho rized Bosch Service Station.

WARNING

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 chromiu m from chemicallytreated lumber.

Yo ur ri sk from these expo su re s var ie s, 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, grinding,

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Safety Rules for Router Table

Read and understand the tool manual and these instructions for the use of this table wi th yo ur ro ut er . Fa il ur e to f ol lo w all

instructions listed below may result in serious personal injury.

Unplug tool before setting up in table, making adj ust ments or changing bits.

Accidental start-up of the to ol can cause injury.

Fully ass em ble and tig ht en al l the fa st en er s required f or th is table and mounting the router. Also remember to

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

Before operati ng make sure the e ntire unit is pla ce d on a soli d, f la t, level surface. Serious injury could occur if tool is

unstable and tips.

Never stand on the table or use as ladder or scaffolding. Serious injury could occur if

th e table is tipped or the cutting tool i s acciden ta ll y contac te d. Do not st or e materials on or near the table such that it is necessary to stand on the table or its stand to reach them.

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

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

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

can lead to personal injury or tool failure.

Never start the too l wh en the bi t is engaged in the material. The bit cutting

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

Router bits are intended for wood, wood products and plastic only. Be sure the workpiece does not contain na ils, etc. before routing. Cutting a nail or the like will

ca us e the car bi de s to be di slodged, fly toward the operator side, and possibly strike you or bystanders.

Feed the workpiece against the rotation of the bit. The bit rotates counter-clockwise

as viewed from the top of table. Feeding

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

Never 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 yo ur hands aw ay from t he spinning bit. Router cuts are blind cuts but

the bit still protrudes through the table and you must be aware of the position of your hands relative to the spinning bit.

We do not recommend cutting material that is war pe d, wobbly o r otherw is e unstable. If this situation is unavoidable always cut the material with the concave side against the table. Cutting the material

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

Use the a dj us table fe nc e in stra ig ht cutting applications. When routing along

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

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

interna l a nd externa l c on tours o n a workpiece. The bearing of the piloted bit assists in m ai nt aining c ontrol o f t he 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 ot her ad justmen t devices are se curel y tigh tened . Lo ose ad justm ent

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

Never touch the bit during or immediately after the use. Contact with a spinning bit

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

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

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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.

n Rated speed Maximum attainable speed

.../min Revolutions or reciprocation 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

per minute 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

Li-ion RBRC seal Designates Li-ion battery recycling

program

Ni-Cad RBRC seal Designates Ni-Cad battery recycling

program

Read manual symbol Alerts user to read manual

Wear eye protection symbol Alerts user to wear eye protection

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Symbols (continued)

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.

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

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

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

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

This symbol designates that this tool is listed by the Canadian Standards Association, to United States and Canadian Standards.

This symbol designates that this tool is listed by the Intertek Testing Services, to United States and Canadian Standards.

This symbol designates that this tool complies to NOM Mexican Standards.

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Functional Description and Specifications

WARNING

Di sc onnect t he plug fro m the pow er source bef or e making an y assembly, adjustments or changing accessories. Such preventive safety

measures reduce the risk of starting the tool accidentally.

Routers

SPEED CONTROL DIAL

Models 1617EVS

& 1618EVS only

ROCKER ON\OFF

SWITCH

BASE CLAMP LEVER

ROUND

HANDLE

SUB-BASE

BIT ROTATION ARROW

AIR VENTS

FIG. 1

1617EVS

MOTOR HOUSING

MOTOR ALIGNMENT

ARROW

BASE TYPE S

CHIP DEFLECTOR

TEMPLET GUIDE

QUICK CHANGE LEVER

(Not included, available as

accessory)

SPEED CONTROL DIAL

Models 1617EVS

& 1618EVS only

POWER ON/OFF

SWITCH

BASE TYPE D

REVERSIBLE

HANDLE

BIT ROTATION ARROW

AIR VENTS

FIG. 2

1618EVS

"LOCK-ON"

BUTTON

TRIGGER

SWITCH

D-HANDLE

TEMPLET GUIDE

QUICK CHANGE LEVER

(Not included, available as accessory)

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FIG. 3

1617EVSPK

AIR VENTS

SPEED CONTROL DIAL

Model 1617EVSP only

MOTOR HOUSING

PLUNGE LOCK

LEVER

PLUNGE HANDLE

DEPTH ROD FINE

ADJUSMENT KNOB

DEPTH ROD

DEPTH STOP TURRET

BASE TYPE P

ROCKER ON\OFF SWITCH

ALIGNMENT ARROW

DEPTH INDICATOR

DEPTH ROD KNOB

CHIP DEFLECTOR

SUB-BASE

BIT ROTATION ARROW

Collet capacities 1/4", 3/8", 1/2", 8mm

NOTE: For tool specifications refer to the nameplate on your tool.

MOTOR

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) 1618EVS router motor (16186)

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

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) 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 c huck a ss embly in cou nt erclockwise direction (viewed from under the router).

4. Once you have verified that the bit's shank is of the proper diameter for the collet to be used, insert the shank of the router bit into the collet chuck assembly as far as it will go, then back the shank out until the cutters are approximately 1/8" to 1/4" away from the collet nut face.

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

To prevent personal injury, al wa ys remov e the p lu g

FIG. 4

COLLET

WRENCH

To tighten or loosen collet nut, hold both wrenches in one hand and and squeeze the wrenches together.

WARNING

base, do not use router bits greater than 2" in diameter as they will not fit through the sub-base.

WARNING

opening for the bit and cutter.

CAUTION

without a bit.

NOTE: The bit shank and chuck should be

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

REMOVING THE ROUTER BIT

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

2. Once t he c ol le t chuck assem bl y is loosened continue to turn the collet chuck assembly until it pulls the collet free from its t ap er , and the route r 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.

When t he templet guid e ha s been remov ed fro m

Cutter diameter must be at least 1/4” smal le r th an

To prevent d am ag e 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 fr ee of the shaft . To as sure a firm gri p, 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 (Fig. 6)

To remove motor from non-plunge bases:

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

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

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

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

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

INSTALLING MOTOR IN BASE

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

To install motor in non-plunge base:

1. Release the base clamp lever.

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

• To position switch on the right side of the

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

• To position switch on the left, line up the

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

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

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

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

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

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

To install motor in plunge base:

1. Release the base clamp lever.

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

• To position switch on the right side of the

base, line up the base’s arrow with arrow

on the motor housing that is below the cord.

• 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 felt. (The base’s guide pin is now engaged into slot on motor.)

4. Turn the motor clockwise until it stops.

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

6. Fasten the base clamp lever.

FIG. 6

COARSE

ADJUSTMENT

LEVER

BASE CLAMP LEVER

FIG. 7

BASE

CLAMP

LEVER

MOTOR

FIG. 8

ALIGNMENT

ARROWS

BASE

COARSE

ADJUSTMENT

NOTCHES

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CHIP DEFLECTOR

WARNING

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 remov e 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. 9). Then flex s ides o f deflector while pushing until it snaps into place. The plunge base’s chip shield can also be flipped out.

Al ways we ar eye pr otectio n. Th e c hi p

FIG. 9

Operating Instructions

FIG. 10

FINE ADJUSTMENT DIAL

INDICATOR RING

CAST INDICATOR MARKS

COARSE

ADJUSTMENT

LEVER

Bo sch routers are designed for speed, accuracy a nd con venience i n 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 microme ter typ e fine adjustm ent 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 de sired, this device may b e ad ju sted t o 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. (A pproximat ely 12.7 mm), by simply depressing the coarse adjustment release lever.

NOTE: All depth adjustments must be made with the base clamp lever released.

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

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

BASE CLAMP LEVER

TO ADJUST DEPTH

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3. COARSE ADJUSTMENT:

To make a large depth adjustment, depress coarse adjustment release lever and raise or lo wer to desir ed dep th. Th ere ar e th ree no tches in t he m otor h ousing whic h 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" o r 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 10.

5. After making depth adjustments, re-clamp the motor.

The indicator ring may be reset to zero without moving the fine adjustment knob, to allow the us er to begin the adj ustment fro m an y reference point desired.

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 RA10 02 Fi ne Adjustm en t C ontrol Extension, an optional accessory for the non-

plunge bases, allows fine adjustment from beyond the top of the motor housing. To install, simply press the RA1002 into the end of the base’s own fine adjus tment knob. (Fig. 11)

TO CLAMP MOTOR

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

DEEP CUTS

For deeper cuts, make several progressively deeper cuts by starting at one depth and th en make several su bs equent passe s, 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. 11

DEPTH ADJUSTMENT WITH PLUNGE

BASE PLUNGING ACTION

Th e pl unge fe at ure simplif ies 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. 12 ). The plunge lock lever is spr ing 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 work piece.

FIG. 12

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The depth rod and the depth stop turret are

DEPTH ROD AND TURRET

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 kn ob an d lower the depth rod until it contacts the lowest step of the turret. Slide

FIG. 13

DEPTH

INDICATOR

DEPTH INDICATOR

KNOB

DEPTH ROD FINE

ADJUSMENT KNOB

the depth indicator until the red line indicates zero on the depth scale, indicating the point at w hich the bit jus t contacts the w ork (Fig. 13).

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

4. The desir ed dep th of cut may n ow b e achieved by plunging the router until the depth rod contacts the selected stop on the turret.

DEPTH ROD

DEPTH STOP

TURRET

DEEP CUTS

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

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

FINE ADJUSTMENT

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

Ea ch comple te revoluti on of th e 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.

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Notes:

• When micro-adjusting the plunge depth, it is mo re conv enient t o mo ve th e fi ne adjustme nt stop up than down. Before setting the depth rod and turret, make sure the fine adjustment stop has been turned se veral revo lutions do wn 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.

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-

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 tu rned "ON" or "OFF " by squ eezing 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 model 1617 hold the tool with both hands while starting the tool, since torque from the motor can cause the tool to twist.

ON"BUTTON

(Model 1618EVS only)

If the “Lock-ON” button is co ntinuou sl y be ing

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 sc rew fo r the ad ju stable step. Th e 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".

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 ma terial hardnes s fo r i mp roved finish , extended bit life, and higher performance. Speed c hanges 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 turns

FEEDING THE ROUTER

cl ockwise an d the cuttin g e dges face accordingly. Therefore, the most efficient cut is made by feeding the router so that the bit turns into the work, not away. Figure 14 shows proper feed for various cuts. How fast you 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.

FIG. 14

START

HERE

WORK

BIT

DIRECTION OF ROUTER FEED

If the router is hard to control, heats up, runs ve ry sl owly or le aves an imperfect cu t, consider these causes:

1. Wrong direction of feed — hard to control.

2. Feeding too fast — overloads motor.

3. Dull bit — overloads motor.

4. Cut is too large for one pass — overloads motor.

5. Feeding too slow — leaves friction burns on work.

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

RATE OF FEED

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

The router may stall if improperly used or overloaded. Reduce the feed rate to prevent possible damage to the tool. Always be sure the collet chuck is tightened securely before use. Always use router bits with the shortest cu tting len gth necessa ry t o pr oduce the desired cut. This will minimize router bit run-out 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 t o a st raight edg e. 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. 15).

FIG. 15

SECURELY CLAMP

BOARD GUIDE

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FEED

DIRECTION

BOARD GUIDE

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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 ho od to 2-1/2" hoses is als o availa ble separately.

ROUTER DUST COLLECTION FOR

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 ca n att ach the dust extra ct ion hood fo r im proved visibi li ty, ac curacy and u tility, particularly in freehand routing.

To attach, position as shown and secure ad apter to base with th e thum bscrews provided (Fig. 16).

DUST EXTRACTION HOOD FOR

WARNING

manual for use of these accessories.

Do not reach in area of the bit while the router 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, 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. 17 & 18). Se curely t ighten t he two knurled thumbscrews.

USING THE HOOD FOR BACKSIDE OF

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

PLUNGE BASE

BACKSIDE OF FIXED BASE

Read and understand these in st ru ct ions and tool

To avoid entangling hoses, do not u se th is dust

FIXED BASE

FIG. 16

DUST EXTRACTION HOOD

(Optional Accessory)

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.

M4 THUMB

SCREWS

FIG. 17

M5 SCREW

DUST

EXTRACTION

HOOD

ROUTER

BASE

FIG. 18

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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 extraction hood.

This dust extraction hood (optional accessory) is used for dust collection when edge-forming (Fig. 19).

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 20 & 21).

FIG. 21

OTHER BASES

FIG. 19

ROUTER

SUB-BASE

WORKPIECE

EDGE

DUST

EXTRACTION

HOOD

M4 x 16mm

SCREW

FIG. 20

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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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. 22). In addition, it features a fine adjustment knob and indicator for accurately positioning the edge guide relative to the bit. With the guide installed and adjusted, the router should be fed

FIG. 22

BASE

CUT

DESIRED

WIDTH

M6 WING

SCREW

WORKPIECE

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 ro uter guid e in cludes 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

M6 WING SCREW

FINE

ADJUSTMENT

INDICATOR

ROUTER

GUIDE

FINE

ADJUSTMENT

KNOB

RODS

This router can also be used with the optional

TEMPLET GUIDES

Bosch-exclusive quick-change templet guide system, which firmly grips the guides with a sp ring-load ed ri ng. Unl ik e conve ntional threaded templet guides, there is no threaded ring that can come loose while routing.

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 cu tt ing re pe ated p at te rns, s pe cial 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 p at te rn will h av e to b e m ad e 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. 24).

FIG. 24

ROUTER BIT

-19-

OFFSET

TEMPLET GUIDE

ADAPTER

TEMPLET GUIDE RELEASE LEVER

TEMPLET GUIDE

(optional accessory)

COLLET CHUCK

TEMPLET

GUIDE

WORKPIECE

FIG. 23

ROUTER

SUB-BASE

TEMPLET PATTERN

D D

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INSTALLING TEMPLET GUIDE ADAPTER

(Not included, available as accessory)

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. 25)

CENTERING THE SUB-BASE OR

TEMPLET GUIDES

Your router features the Bosch “Precision Centering Design”. Its sub-base is precisely centered at the factory. This positions the bit at th e ce nter o f th e sub- base and o ptional templet guides.

Precision centering allows you to use the edge of the subbase or templet guides to 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 relative to the jig.

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

FIG. 25

TEMPLET GUIDE

ADAPTER

(optional accessory)

MOUNTING SCREWS

tapered heads.) The flathead screws and countersunk holes will pull the sub-base into a position that is very close to centered.

To most precisely re-center the sub-base or templet guides, attach the sub-base using the optional Bosch RA1151 Centering Device. Follow steps 1-8 (Fig. 26 & 27).

1. If a templet guide is to be centered, Install the templet guide adapter and template guide (optional attachments) as described elsewhere in this manual.

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

3. Insert the pan-head screws through the subbase and tighten them until they are snug, but still allow the sub-base to move.

CENTERING CONE

(optional accessory)

FIG. 26

PLUNGE BASE

CENTERING SHAFT

(optional accessory)

TEMPLET GUIDE

(optional accessory)

CENTERING SHAFT

(optional accessory)

CENTERING SHAFT

(optional accessory)

FIG. 27

OTHER BASES

A=M4 COUNTERSUNK SCREW HOLES

B=M4 PAN-HEAD SCREW HOLES

SUB-BASE

-20-

C=TEMPLET GUIDE ADAPTER

SCREW HOLES

D=HOLES FOR ATTACHING

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

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4. Prepare the Centering Device:

• Us e na rrow end of steel s haft when inserting into 1/4” collet, wider end of cone when inserting into 1/2” collet.

• When centering subbase or templet guide that has opening of more than ½”, slide the wide plastic sleeve over the steel shaft.

5. Slide centering sleeve through the sub-base or templet guide and into collet. Tighten

MAXIMUM BIT/CUTTER SIZE FOR

TEMPLET GUIDES

When using a templet guide, use only router bit with cutters that are 1/16” less than the internal diameter of the templet guide, such as in the table below.

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

6. Lightly press centering sleeve into sub-base or templet guide to center.

7. Tighten the pan-head screws. Remo ve centering sleeve.

8. The precision centering of the sub-base or templet guide is complete.

CENTERING CONE – Used when centering the subbase itself or wide templet guides.

USE WITH THREADED

TEMPLET GUIDES

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.

Bosch Bushing External Internal Max

Templet Depth Diameter Diameter Bit/Cutter

Guide Diameter

ABB

RA1101 3/16” 5/16” 1/4” 3/16” RA1103 9/64” 5/16” 17/64” 13/64” RA1105 9/64” 7/16” 3/8” 5/16” RA1107 5/16” 7/16” 3/8” 5/16” RA1109 7/16” 1/2” 13/32” 11/32” RA1111 3/16” 5/8” 17/32” 15/32” RA1113 1/2” 5/8” 17/32” 15/32” RA1115 3/16” 3/4” 21/32” 19/32” RA1117 31/64” 13/16” 5/8” 9/16” RA1119 31/64” 1” 25/32” 21/32” RA1121 7/16” 1-3/8” 1-19/64” 1-15/64”

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

The RA1166 Plunge Base is not recommended for use

in a router table. Damage to plunge router

base may occur. To eliminate the hassle of ins talling 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

BM 2610018532 01-12:BM 2610018532 01-12.qxp 1/23/12 9:21 AM Page 22

The undertable base accessory includes the screws needed to fasten the base to a router table m oun ting plate, as well as a T-hex wrench for above-table depth adjustment.

ATTACHING BASE TO

MOUNTING PLATE

At tach t he RA116 1 to the ro uter t ab le’s mounting plate using either or both sets of enclosed mounting screws.

The base has two sets of threaded holes for mounting the base:

• Three 10-24 holes in industry-standard 3-hole pattern.

• Four M4 holes in Bosch 4-hole pattern.

Mounting screws required for the RA1161: (not included with all models).

• Three 10-24 screws.

• Four M4 screws.

The length will depend on the thickness of your router table or router table mounting plate.

If your router table mounting plate does not have countersunk holes in either of those patterns, you will need to determine the hole locations, drill and countersink them, also locate an d dr ill a hole for the over -table adjustment wrench.

CONNECT THE ROUTER AND THE

ROUTER TABLE SWITCH

To prepare for use of the switch,

1. Make sure the router switch and the router table switch are both turned off.

2. Plug the router table switch cord to wall outlet.

3. Plug the router into the "pigtail" socket on the router table switch.

4. Lock router switch on: squeeze trigger, depress lock-on button, and release trigger.

5. Use the router table switch to start and stop the router.

DEPTH ADJUSTMENT (See page 12-13)

FEEDING THE WORKPIECE

ON A ROUTER TABLE

Always use your router table's fence or starter pin and the appropriate guard and follow the router table's instruction manual. ALWAYS feed the workpiece from right to left across the front of the bit. On Bosch router tables, the correct feed direction is also shown on fence housing and on the featherboards, when they have been properly installed. (Fig. 29)

Whenever possible, when using the fence, use a push stick to push the workpiece , especially when working with narrow pieces.

For complete instructions on operation of a router in a router table, please refer to the instructions that come with the router table.

TOP VIEW

NOTE: For clarity, guard and featherboard

removed from drawing.

FIG. 29

DIRECTION

OF FEED

FENCE FACE

BIT

BEARING

FENCE FACE

WORKPIECE

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