1619EVS
Operating/Safety Instructions
Consignes de fonctionnement/sécurité
Instrucciones de funcionamiento
y seguridad
1619EVS
IMPORTANT: IMPORTANT : IMPORTANTE:
Read Before Using Lire avant usage Leer antes de usar
For English Parlez-vous français? ¿Habla español?
See page 2 Voir page 20 Ver página 38
Consumer Information
Renseignement des consommateurs
Información para el consumidor
Toll Free Number: Appel gratuit : Número de teléfono gratuito:
1-877-BOSCH99 (1-877-267-2499) http://www.boschtools.com
BM2610995777 10/03 10/7/03 4:51 PM Page 1
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. Power
tools create sparks which may ignite the dust
or fumes.
Keep bystanders, children, and visitors
away while operating a power tool.
Distractions can cause you to lose control.
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
eliminates the need for the three wire
grounded power cord and grounded power
supply system. Before 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. There is an increased risk 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. Water entering a power tool will
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. Damaged cords increase
the risk of electric shock.
When operating a power tool outside, use
an outdoor extension cord marked "W-A"
or "W." These cords are rated for outdoor use
and reduce the risk of electric shock. Refer to
“Recommended sizes of Extension Cords” in
the Accessory section of this manual.
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. A moment of inattention while
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. Loose clothes, jewelry, 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. Carrying tools 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 wrench or 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. Proper footing and
balance enables better control of the tool in
unexpected situations.
Use safety equipment. Always wear eye
protection. Dust mask, non-skid safety
shoes, hard hat, or hearing protection must be
used for appropriate conditions.
Tool Use and Care
Use clamps or other practical way to
secure and support the workpiece to a
stable platform. Holding the work by hand or
against your body is unstable and may lead to
loss of control.
Do not force tool. Use the correct tool for
your application. The correct tool will do the
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”. Any tool that cannot be
controlled with the switch is dangerous and
must be repaired.
-2-
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
!
WARNING
Power Tool Safety Rules
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-3-
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. Tools are
dangerous in the hands of untrained users.
Maintain tools with care. Keep cutting tools
sharp and clean. Properly maintained 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
serviced before using. Many accidents are
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. Accessories that may be suitable
for one tool, may become hazardous when
used on another tool.
Service
Tool service must be performed only by
qualified repair personnel. Service or
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.
Hold tool by insulated gripping surfaces
when performing an operation where the
cutting tool may contact hidden wiring or
its own cord. Contact with a "live" wire will
make exposed metal parts of the tool "live"
and shock the operator. If cutting into
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. Clamping the material and
guiding 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.
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. Loose adjustment
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. The bit cutting
edge may grab the material causing loss of
control of the cutter.
Always hold the tool with two hands
during start-up. The reaction torque of the
motor can cause the tool to twist.
When routing or cutting, the direction of
feed with the bit’s cutting edge into the
material is very important. Always feed
the bit into the material in the same
direction as the cutting edge is exiting
from the material (which is the same
direction as the chips are thrown). NOTE:
inside and 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.
Safety Rules for Routers
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-4-
Read and understand the tool manual and
these instructions for the use of this table
with your router. Failure to follow all
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. 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 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. Serious injury could occur if
the table is tipped or the cutting tool is
accidentally contacted. Do not store
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 tool when the bit 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 nails, etc.
before routing. Cutting a nail or the like will
cause the carbides to be dislodged, fly
toward the operator side, and possibly strike
you or bystanders.
Feed the workpiece against the rotation
of the bit. The bit rotates counterclockwise 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 your hands away from the
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.
Safety Rules for Router Table
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 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.
Never use bits that have a cutting
diameter greater than the opening in the
base.
Some dust created by
power sanding, sawing,
grinding, drilling, and other construction
activities contains chemicals known to
cause cancer, birth defects or other
reproductive harm. Some examples of
these chemicals are:
• Lead from lead-based paints,
• Crystalline silica from bricks and cement
and other masonry products, and
• Arsenic and chromium from chemically-
treated lumber.
Your risk from these exposures varies,
depending on how often you do this type of
work. To reduce your exposure to these
chemicals: work 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.
!
WARNING
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-5-
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. 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 adjustable fence in straight
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
internal 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. Loose adjustment
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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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
0
No load speed Rotational speed, at no load
.../min Revolutions or reciprocation per minute Revolutions, strokes, surface speed,
orbits etc. per minute
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
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
Symbols
0
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
complies
to NOM
Mexican
Standards.
This symbol designates
that this tool is listed by
Underwriters Laboratories,
and listed to Canadian
Standards by Underwriters
Laboratories.
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-7-
Functional Description and Specifications
Disconnect the plug from the power source before making any assembly,
adjustments or changing accessories. Such preventive safety measures
reduce the risk of starting the tool accidentally.
!
WARNING
FIG. 1
FIG. 2
VENTS
SPEED
CONTROL DIAL
BASE
RIGHT HANDLE
DIRECTION OF BIT
ROTATION
LEFT
HANDLE
FINE ADJUSTMENT KNOB
“LOCK-ON”
BUTTON
ON/OFF TRIGGER
SWITCH
PLUNGE LOCK
LEVER
SPINDLE LOCK
SPRING DEFEAT BUTTON
BACK VIEW
FRONT VIEW
Router
Model number: 1619EVS
Voltage rating: 120 V 50 - 60Hz
Amperage rating: 15 A
No load speed: n0 8,000-21,000/min
Collet capacities: 1/4", 3/8", 1/2", 8mm
COARSE ADJUSTMENT
INDICATOR
COARSE ADJUSTMENT KNOB
DEPTH STOP TURRET
COLLET
CHUCK
DUST EXTRACTION HOOD
COARSE ADJUSTMENT
LOCK
PLUNGE LOCK
OVERRIDE LEVER
FINE ADJUSTMENT
INDICATOR
SUB-BASE
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SELECTING BITS
A wide assortment of router bits with different
profiles are available as accessories. Use 1/2"
shank whenever possible, and only use good
quality bits.
To prevent personal injury,
always remove the plug from
power source before removing or
installing bits or accessories.
INSTALLING A ROUTER BIT
1. Lay router on its side with the flat side of base
resting on the bench.
2. Press spindle lock to prevent rotation of collet
chuck. NOTE: it may be necessary to rotate
collet nut to engage spindle lock (Fig. 3).
3. Next, use the collet wrench to loosen the
collet chuck assembly in counter-clockwise
direction (viewed from bottom of 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.
5. With the router bit inserted and the spindle
lock engaged, use the collet wrench to firmly
tighten the collet chuck assembly in a
clockwise direction (viewed from bottom of
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".
When the templet guide
adapter has been removed
from base, do not use router bits greater
than 2" in diameter as they will not fit
through the sub-base.
For use with larger bits, see “Preparation for
use with Bosch Router Table” on page 16.
To prevent damage to tool,
do not tighten collet without
a bit.
NOTE: The bit shank and chuck should be
clean and free of dust, wood, residue and
grease before assembling.
REMOVING THE ROUTER BIT
1. Press spindle lock to prevent rotation of collet
chuck, and turn the collet chuck assembly in
a counter-clockwise direction.
2. Once the collet chuck assembly is loosened,
continue to turn the collet chuck assembly
until it pulls the collet free from its taper, and
the router bit can be removed.
NOTE: The collet chuck is self-extracting; it is
NOT necessary to strike the collet chuck to free
the router bit.
COLLET CHUCK CARE
With the router bit removed, continue to turn
the collet chuck counter-clockwise until it is
free of the shaft. To assure a firm grip,
occasionally blow out
the collet chuck with
compressed air, and
clean the taper in the
armature assembly
shaft with a tissue or
fine brush. The collet
chuck is made up of
two component parts
that snap together (Fig. 4); 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.
-8-
Assembly
FIG. 3
BIT
COLLET CHUCK
SPINDLE LOCK
SHANK
WRENCH
BASE
!
WARNING
!
CAUTION
!
WARNING
COLLET
COLLET
NUT
FIG. 4
COLLET
CHUCK
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Bosch plunge routers are designed for speed,
accuracy and convenience in performing
cabinet work, routing, fluting, beading, covecutting, dovetails, etc. This will enable you to
accomplish inlay work, decorative edges and
many types of special carving.
PLUNGING ACTION
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. 7). 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.
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. 6).
ROUTER DUST COLLECTION
Your router is equipped with a dust extraction
hood. 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, align tabs on hood with notches in
base, and position as shown. Rotate hood
slightly counter-clockwise and secure adapter to
base with the thumbscrew provided (Fig. 5).
To further enhance the dust collection efficiency,
insert the extraction enhancement ring. To
remove, press the two tabs inward, and lift out.
Make sure ring does not touch bit at any time.
The dust extraction hood itself is sized to accept
35mm vacuum hoses. Also included is an
adapter that will connect the hood to 1-1/4” and
1-1/2” vacuum hoses.
Also available as an optional accessory is a
special dust collection for edge forming. Do not
use both hoods at the same time.
-9-
Operating Instructions
TEMPLET GUIDE
ADAPTER
TEMPLET GUIDE
RELEASE LEVER
PLUNGE
LOCK
LEVER
MOUNTING SCREWS
FIG. 6
FIG. 5
DUST EXTRACTION
HOOD
EXTRACTION
ENHANCEMENT
RING
THUMB
SCREW
FIG. 7
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COARSE DEPTH ADJUSTMENT
This system allows you to quickly make large
changes in plunge depth or bit height.
1. To unlock the coarse adjustment knob, move
the coarse adjustment lock to the left.
(counter-clockwise).
2. Rotate the coarse adjustment knob clockwise
to lower the depth rod, producing a shallower
cut. Rotate the coarse adjustment knob
counter-clockwise to raise the depth rod,
producing a deeper cut (Fig. 8).
3. To lock the depth rod at desired setting,
simply turn the coarse adjustment lock to the
right and press down firmly.
COARSE ADJUSTMENT INDICATOR
The coarse adjustment indicator can be moved
independently of the coarse adjustment knob.
This allows the indicator to be zeroed at any
given depth. After zeroing, when the knob is
rotated, the indicator rotates with it, indicating
the change in the depth of cut in fractions of an
inch. Increasing numbers indicate deeper cut.
(An optional metric coarse adjustment indicator
is available separately.)
-10-
FINE ADJUSTMENT KNOB
The fine adjustment knob allows extremely
precise adjustment of the bit depth. One
complete revolution equals 2mm or
approximately 5/64". It should be adjusted only
after the coarse adjustment lock is locked.
Rotating the fine adjustment knob counterclockwise causes the depth rod to move up,
producing a shallower cut. Rotating the fine
adjustment knob clockwise causes the depth
rod to move down, producing a deeper cut
(Fig. 9).
FINE ADJUSTMENT INDICATOR
The fine adjustment indicator can be moved
independently of the fine adjustment knob.
This allows the indicator ring to be zeroed at
any given depth. After zeroing, when the knob
is rotated, the indicator turns with it, indicating
the fine change in the depth of cut (in mm or
fractions of an inch). Fine depth adjustment in
increments as small as 0.1 mm (.004") is
possible (Fig. 9).
FIG. 9
FINE
ADJUSTMENT
KNOB
FINE
ADJUSTMENT
INDICATOR
FIG. 8
COARSE
ADJUSTMENT
INDICATOR
REFERENCE
MARK
REFERENCE
MARK
COARSE
ADJUSTMENT KNOB
COARSE
ADJUSTMENT
LOCK
DEPTH ROD
BM2610995777 10/03 10/7/03 4:51 PM Page 10
0
MAKING PROGESSIVELY DEEPER
PLUNGE CUTS
When making deep cuts, especially slot cuts
away from the edge of the workpiece, it is
advisable to make several successive cuts
using the depth stop turret’s six 1/8" steps,
rather than making a single deep cut:
1. Align the lowest step of turret with the depth
rod. (Fig. 10)
2. With the bit installed, gently lower the motor
until router bit just contacts the level surface
the router is sitting on. Release the plunge
lock lever, locking the motor at this position.
(Fig. 10)
3. Loosen the coarse adjustment lock and
lower the depth rod until it contacts the
lowest step on the turret. Turn the coarse
depth indicator until zero lines up with the
reference mark. This is the "zero" position,
which indicates the point at which the bit just
contacts the workpiece. Release the plunge
lock lever and allow the motor to return to its
normal position. (Fig. 10)
4. To set the desired total cutting depth, turn
the coarse adjustment knob counterclockwise as close as possible to the desired
cutting depth, and secure the rod by turning
the coarse adjustment lock to the right and
press down firmly (Fig. 11). Make any
necessary refinements with the fine
adjustment knob (Fig. 9).
5. Align the top step of the turret with the depth
rod, and make the first cut pass in the
workpiece. After each pass, rotate the depth
stop turret to the next lower step and make
another pass as necessary until the desired
final depth is reached. (Fig. 11)
The router’s Precision Centering Design helps
to ensure that each successive pass with follow
the same cut as previous passes.
To be certain that your depth settings are as
desired, you may want to make test cuts in
scrap material before beginning work.
-11-
REFERENCE
MARK
COARSE
ADJUSTMENT
INDICATOR
DEPTH STOP
TURRET
COARSE
ADJUSTMENT
LOCK
DEPTH ROD
FIG. 10
BIT
REFERENCE
MARK
COARSE
ADJUSTMENT
KNOB
DEPTH STOP
TURRET
COARSE
ADJUSTMENT
LOCK
DEPTH ROD
FIG. 11
BIT
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-12-
TRIGGER SWITCH AND
“LOCK-ON” BUTTON
Your router can be turned ON or OFF by
squeezing or releasing the trigger. Your router is
also equipped with a “Lock-ON” button located
to the left of trigger that allows continuous
operation without holding the trigger.
TO LOCK SWITCH ON: Squeeze trigger,
depress button and release trigger (Fig. 2).
TO UNLOCK THE SWITCH: Squeeze trigger
and release it without depressing the “Lock-ON”
button.
If the “Lock-ON” button
is continuously being
depressed, the trigger cannot be released.
Always make sure that the bit is not touching 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.
SOFT START FEATURE
Electronic feedback control minimizes torque
twist customary in larger routers by limiting the
speed at which motor starts.
ELECTRONIC VARIABLE SPEED CONTROL
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 Speed Control Dial
FORWARD to decrease speed, BACK to increase
speed, as indicated on housing (Fig. 12). Speed
may be changed while tool is on. The reference
numbers on the dial facilitate re-setting 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.
CONSTANT RESPONSE™ CIRCUITRY
The router's Constant Response™ Circuitry
monitors and adjusts power to maintain the
desired RPM for consistent performance and
control.
!
WARNING
FIG. 12
SPEED
CONTROL
DIAL
DIAL
SETTING RPM APPLICATION
1 8,000
2 9,000
3 11,000
4 13,000
5 17,000
6 21,000
}
}
}
Large diameter bits
(Raised Panel)
Hardwood,
Non-ferrous metals,
soft Plastics
Softwoods, counter tops,
Smaller dia. router bits,
Hard plastics,
Decorative Edges
BM2610995777 10/03 10/7/03 4:51 PM Page 12
FEEDING THE ROUTER
As seen from the top of the router, the bit 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 13 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.
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.
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 run-out and
chatter.
EDGE FORMING
When edge forming, always use piloted or
bearing bits. The lower portion of a pilot
tipped bit is a shaft with no cutting edges.
Bearing guide bits have a ball bearing to pilot
the bit, as shown in (Fig. 14).
This pilot slides along the edge of the work as
the rotating blades make the cut, forming
molding or decorative edges. The edge on
which the pilot slides should be perfectly
smooth since any irregularities are transferred
to the shaped surface.
When routing a workpiece that requires edge
forming on the endgrain, always rout the
endgrain edge before routing the edges that
follow the grain. This minimizes the possibility
of damage from any blowout at the end of
endgrain.
FIG. 14
PILOT OR BEARING SLIDES
ALONG EDGE OF WORKPIECE
CUTTER PART OF
PILOT TIPPED BIT
CUT
-13-
FIG. 13
BIT
WORK
DIRECTION OF
ROUTER FEED
START
HERE
BM2610995777 10/03 10/7/03 4:51 PM Page 13
-14-
DUST COLLECTION WHILE
EDGE FORMING
The RA1170 dust extraction hood (optional
accessory) is used for dust collection when
edge-forming (Fig. 15).
Read and understand
these instructions and tool
manual for use of these accessories.
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.
ATTACHING DUST EXTRACTION HOOD
You can attach the 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 (Fig. 16).
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.
DUST
EXTRACTION
HOOD
ROUTER
SUB-BASE
WORKPIECE
EDGE
!
WARNING
!
CAUTION
M4 x 16mm
SCREW
SUB-BASE
DUST
EXTRACTION
HOOD
M4 x 16mm
SCREW
FIG. 16
FIG. 15
BM2610995777 10/03 10/7/03 4:51 PM Page 14
CENTERING THE SUB-BASE AND
TEMPLET GUIDES
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 to closely
follow jigs such as straight guides, templets, and
dovetail fixtures without worrying about bit walkoff 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 sub-base,
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.
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
sub-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.
-15-
GUIDING THE ROUTER
The router can be guided through the work in
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. 18).
FIG. 18
BOARD GUIDE
SECURELY CLAMP
BOARD GUIDE
FEED
DIRECTION
FIG. 17
CENTERING CONE
(optional accessory)
SUB-BASE
D
DD
B
B
B
B
CC
D
AA
AA
1
A = COUNTERSUNK SCREW HOLES
B = PAN-HEAD SCREW HOLES
C = TEMPLET GUIDE ADAPTER
SCREW HOLES
D = HOLES FOR ATTACHING
ROUTER TO ROUTER TABLE
MOUNTING PLATE
BM2610995777 10/03 10/7/03 4:51 PM Page 15
TEMPLET GUIDES
The router is equipped with an exclusive quickchange 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 tabs 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).
-16-
TEMPLET GUIDE
(optional accessory)
TEMPLET GUIDE
ADAPTER
TEMPLET GUIDE
RELEASE LEVER
FIG. 19
COLLET CHUCK
WORKPIECE
ROUTER BIT
OFFSET
TEMPLET
GUIDE
TEMPLET
PATTERN
FIG. 20
ROUTER
SUB-BASE
FIG. 21
DESIRED
WIDTH
CUT
BASE
WORKPIECE
ROUTER GUIDE
RODS
THUMB SCREW
THUMB SCREW
(BEHIND POST)
FINE ADJUSTMENT
KNOB
FINE ADJUSTMENT
INDICATOR
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 six thumb screws to fasten the guide
(Fig. 21). 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 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.
For complete instructions on installation and
operation, please refer to the instructions which
are included with this accessory.
FEED
DIRECTION
BM2610995777 10/03 10/7/03 4:51 PM Page 16
-17-
Your router is uniquely suited for use in the
Bosch router table. For detailed instructions
about router table procedures, please refer to
the manual that is supplied with the router table.
To prepare the 1619EVS for table mounting, do
the following:
1. Engage plunge lock override lever as follows:
Facing the rear of the router, move plunge
lock lever approximately 90 degrees
clockwise. Depress small override lever and
slowly release plunge lock lever until override
lever catches firmly on metal housing as
shown in diagram. The motor is now free to
move up and down on the posts (Fig. 22).
2.Engage the plunge return spring defeat
(Fig. 23).
Note: This unique feature makes it easier to
adjust the height of the bit when the router is
mounted under a router table.
a. Move the depth rod to its highest position,
and lock in place with coarse adjustment lock.
b. Remove the collet chuck.
c. Rotate depth stop turret to the position shown
in Fig. 23.
d. Plunge the router motor down as far as it
will go.
e. While holding the motor down, press and hold
down spring defeat button.
f. Allow the motor to move up slightly.
g. Release the button.
The plunge return spring pressure is now
disengaged.
3. Connect the depth rod to the depth stop
turret by rotating the depth stop turret so that
the large end of keyhole slot is aligned with
the lower end of the depth rod. Release
coarse adjust lock, and lower depth rod into
the large end of keyhole slot. Rotate depth
stop turret until the smaller end of the keyhole
traps the end of depth rod (Fig. 24). (To keep
the rod in the keyhole, there is a raised rim
around the underside of the smaller end of the
keyhole. When inverted, the weight of the
router keeps the depth rod inside the raised
rim.) Note: When the router motor is at its
further point away from the base, the motor
must be moved slightly closer to the base so
the depth rod can clear the raised rim.
Preparation For Use With Bosch Router Table
PLUNGE
LOCK LEVER
PLUNGE LOCK
OVERRIDE LEVER
HOUSING
KEYHOLE
SPRING DEFEAT
BUTTON
DEPTH ROD
DEPTH STOP
TURRET
FIG. 24
FIG. 22
FIG. 23
SPRING
DEFEAT BUTTON
COARSE
ADJUSTMENT
LOCK
BM2610995777 10/03 10/7/03 4:51 PM Page 17
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