Bosch PR20EVSNK, PR20EVSK, PR10E 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

PR10E PR20EVSK PR20EVSNK

Call Toll Free for

Consumer Information

& Service Locations

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

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

For English Version Version française Versión en español

See page 2

Voir page 22 Ver la página 42

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General Safety Rules

WARNING

all of the warnings listed below refers to your mains-operated (corded) power tool or batteryoperated (cordless) power tool.

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

The term “power tool” in

SAVE THESE INSTRUCTIONS

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.

tools create sparks which may ignite the dust or fumes.

Keep children and bystanders away while operating a power tool.

cause you to lose control.

Distractions can

Power

Electrical safety

Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools.

and matching outlets will reduce risk of electric shock.

Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges and refrigerators.

is an increased risk of electric shock if your body is earthed or grounded.

Do not expose power tools to rain or wet conditions.

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.

entangled cords increase the risk of electric shock.

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

outdoor use reduces the risk of electric shock.

Do not use AC only rated tools with a DC power supply.

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

Water entering a power tool will

Use of a cord suitable for

While the tool may appear to

Unmodified plugs

There

Damaged or

If operating the power tool in damp locations is unavoidable a Ground Fault Circuit Interrupter (GFCI) must be used to supply the power to your tool.

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

GFCI and

Personal safety

Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication.

inattention while operating power tools may result in serious personal injury.

Use safety equipment. Always wear eye protection.

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

Avoid accidental starting. Ensure the switch is in the off-position before plugging in.

finger on the switch or plugging in power tools that have the switch on invites accidents.

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

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.

better control of the power tool in unexpected situations.

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

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.

related hazards.

Safety equipment such as dust

Carrying power tools with your

Loose clothes, jewelry or long hair can

Use of these devices can reduce dust-

A moment of

A wrench

This enables

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Keep handles dry, clean and free from oil and grease.

control the power tool.

Slippery hands cannot safely

Power tool use and care

Do not force the power tool. 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.

that cannot be controlled with the switch is dangerous and must be repaired.

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.

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 tools operation. If damaged, have the power tool repaired before use.

poorly maintained power tools.

Many accidents are caused by

Any power tool

Such preventive safety

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 i

nstructions and in the manner intended for the particular type of power tool, 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.

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 control.

Holding the work by hand

Service

Have your power tool serviced by a qualified repair person using only identical replacement parts.

safety of the power tool is maintained.

Develop a periodic maintenance schedule for your tool. When cleaning a tool be careful not to disassemble any portion of the tool since internal wires may be misplaced or pinched or safety guard return springs may be improperly mounted.

gasoline, carbon tetrachloride, ammonia, etc. may damage plastic parts.

Certain cleaning agents such as

This will ensure that the

SAVE THESE INSTRUCTIONS

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.

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 control.

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.

Contact with a "live" wire will

Holding the work by hand

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.

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

Clamping the material and guiding

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Using personal safety devices and working in safe environment reduces risk of injury.

fter 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.

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 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.

Loose adjustment

The bit cutting

NOTE: inside and

Damaged

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.

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.

After use the bit is too hot to

The

Some dust created by power sanding, sawing,

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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

Disconnect the plug from the power source before making any assembly, adjustments or changing accessories

measures reduce the risk of starting the tool accidentally.

Palm Router

FIG. 1

Variable-Speed Dial

(PR20EVS model)

Rocker

On/Off Switch

Quick-Clamp

System Lever

Depth Scales

(Imperial & Metric)

Air Vents

. Such preventive safety

Power Cord

Brush Cap

Contoured Grip Area

Coarse Adjustment Unlock/Lock Indicator

Rugged Aluminum Base

Spindle Lock

Finger Support Pockets

Collet Nut

Finger Guards

Sub-Base

Model Number

PR10E PR20EVS

Voltage rating 120 V 60 Hz 120 V 60 Hz Amperage Rating No load speed n

5.7A 35,000/min n016,000-35,000/min

5.7A

Bit Capacity 1/4" shank 1/4" shank Max. Cutter Diameter * *

*Cutter diameter must be at least 1/4” smaller than opening for the bit and cutter.

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Microfine Depth Adjustment

Bit Rotation Arrow

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Assembly

Your Bosch palm router is designed for a wide variety of routing applications that use 1/4" shank bits. These include woodworking applications such as edge forming, grooving, and sign making. This router is also ideal for trimming laminates, phenolics, and other materials that have been bonded to a substrate edge trimming and overhang the substrated typically by about 1/8" (3 mm).

A wide assortment of router bits with different profiles are available as accessories. Only use good quality bits.

WARNING

from power source before removing or installing bits or accessories.

1. Lay router on its side with the backside of base resting on the bench. The router's top has a flat design so the router can be stood on end during bit changes, if preferred.

2. Press spindle lock to prevent rotation of collet chuck. rotate collet nut to engage spindle lock (Fig. 2).*

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) (Fig. 3).*

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".

*As an alternative to the spindle lock, a thin 10mm wrench can be used on the ‘flats’ of the spindle.

WARNING

opening for the bit and cutter.

To prevent damage to tool, do not tighten collet without a bit.

SELECTING BITS

To prevent personal injury, always remove the plug

Installing a Router Bit

NOTE: it may be necessary to

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

FIG. 2

FIG. 3

NOTE:

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

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

Press spindle lock to prevent rotation of collet chuck, 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 the spindle, and the router bit can be removed.

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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 b

rush. 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.

1. Open the clamping lever (Fig. 5).

2. Turn the motor so that the single triangle

3. Pull the motor away from base until it stops

4. Turn motor counterclockwise until it stops

5. Pull motor out of base (Fig. 6).

COLLET CHUCK CARE

REMOVING MOTOR FROM BASE

on the base lines up with “unlocked” symbol on the motor. (Make sure that the indication the base is aligned with the line under the “unlocked” symbol on the motor. Otherwise, the router can be damaged.) (Fig. 5)

(Fig. 5).

(Fig. 6).

IG. 4

FIG. 5

Collet

Nut

Collet

Chuck

FIG. 6

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INSTALLING THE MOTOR INTO BASE

1. Open the clamping lever (Fig. 7).

2. Align the double triangles on the base and

motor then insert motor into base until it stops (Fig. 7).

FIG. 7

3. Turn motor clockwise until single triangle

lines up with “unlocked” symbol. (Make sure that the indication the base is aligned with the line under the “unlocked” symbol on the motor. Otherwise, the router can be damaged.) (Fig. 8)

4. Move motor into base until the approximate

desired depth has been reached. (Fig. 8)

FIG. 8

tension of the clamping lever can be changed by re-adjusting the nut.) (Fig. 9)

FIG. 9

CHECK SUBBASE LOCATION

Make sure that the bit and its cutter are centered in the subbase opening. If necessary, adjust the location of the subbase as follows:

1. Loosen the four screws that hold the subbase.

2. Adjust the location of the subbase as needed so that the bit and its cutter are centered in the subbase opening.

3. Tighten the four screws that hold the subbase (Fig. 10).

WARNING

opening for the bit and cutter.

When the subbase has been centered in this manner, the left and right edges of the subbase are equidistant from the cutter, and either side of the subbase can be used as a guiding surface without worrying about a difference in the cut line. See "Guiding The Router" on page 12.

Note: This subbase is not designed for use with templet guides. See optional PR009 and PR010 Accessories for use of templet guides with the palm router.

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

FIG. 10

5. Turn motor clockwise triangle lines up with “locked” symbol. (Fig. 9)

6. Close the clamping lever. Always make sure the motor sits tightly in the base. (The

about 1/4”

until single

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Operating Instructions

Bosch routers are designed for speed, accuracy and convenience in performing cabinet work, fluting, beading, cove-cutting, rounding edges, dovetailing, etc. They will enable you to accomplish inlay work, decorative edges and many types of special routing.

SETTING THE DEPTH OF CUT

Adjust the depth-of-cut only when the motor is switched off.

1. Install desired router bit.

2. Place the router on the workpiece.

3. Open the clamping lever. Fig. 11(A)

4. Turn the motor about 1/4” counterclockwise so that the single triangle on the base lines up with “unlocked” symbol on the motor. Fig. 11(B) (Make sure that the indication the base is aligned with the line under the “unlocked” symbol on the motor. Otherwise, the router can be damaged.)

5. Slowly lower the motor until the router bit touches the workpiece. Fig. 11(C)

6. Note the reading on the scale (below the clamp lever) and add the desired depth-ofcut to this value to determine the target scale value.

7.Lower the motor until the target scale value is reached. Fig. 11(C)

8.Turn motor clockwise about 1/4” until single triangle lines up with “locked” symbol. Fig. 11(B)

9. Close the clamping lever. Always make sure the motor is held tightly in the base. Fig. 11(A) (The tension of the clamping lever can be changed by re-adjusting the nut.)

10. Check the depth-of-cut and make fine

adjustment, if necessary. (Note: the depth of the motor and bit may shift very slightly when the clamping lever is close.)

11. Make a trial cut to verify that the router

is set to make the cut as desired.

Adjust the depth-of-cut only when the motor is switched off.

1. Open the clamping lever. Fig. 11(A)

2. Adjust the desired depth-of-cut with the

FINE DEPTH ADJUSTMENT

knurled wheel on back of base. Fig. 11(D)

FIG. 11

3.Rotate the knurled wheel clockwise to increase the routing depth, counterclockwise to decrease the cutting depth. Each complete rotation of the dial equals 1.25 mm (approximately 3/64").

4. Close the clamping lever. Fig. 11(A) Always make sure the motor is held tightly in the base. Re-adjusting the nut can change the tension of the clamping lever. (See “To Clamp Motor”, below)

Check the depth-of-cut and make an

5. additional fine adjustment, if necessary. (Note: the depth of the motor and bit may shift very slightly when the clamping lever is closed.)

6. Make a trial cut to verify that the router is set to make the cut as desired.

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 8 mm wrench, rotate clamp nut clockwise SLIGHTLY (1/8 turn or less), then test clamp. Do not over-tighten.)

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

TO CLAMP MOTOR

DEEP CUTS

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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“.

O 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”.

Electronic feedback control minimizes torque twist customary in routers by limiting the speed at which motor starts.

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

The router's Constant Response™ Circuitry monitors and adjusts power to maintain the desired RPM for consistent performance and control.

In addition to the main palm-grip area at the back of the motor housing and base, the base has Bosch-exclusive finger support

SOFT START FEATURE

ELECTRONIC VARIABLE SPEED

1 16000 2 18000 3 20000

4 22500 5 26500 6 35000

CONSTANT RESPONSE™ CIRCUITRY

CONTROL

(Model PR20EVS Only)

Larger-diameter bits and cutters.

}

Softwoods, plastics, laminates, smaller diameter bits and

}

cutters

FEEDING THE ROUTER

pockets to provide additional stability for the router. The pockets feature finger guards to provide a barrier between the finger pockets and the bit area (Fig 12).

FIG. 12

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:

Wrong direction of feed — hard to control.

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.

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.

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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 m

aterials.

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.

It may be necessary to make the cut in more than one pass with progressively deeper settings to avoid overloading the motor. If the bit cuts freely and the motor does not slow down, the cutting depth is generally correct.

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. 14).

PR002 STRAIGHT ROUTER GUIDE

(Included with PR20EVSK & PR20EVSNK,

also available as optional accessory)

The router guide is an optional accessory that will guide the router parallel to a straight edge (Fig. 15).

The router guide is supplied in two part held together with a bolt, wing nut and washer. It also includes a wing screw and washer to fasten the guide to the router.

The guide also features a scale 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 router guide can also be positioned directly under the router base for operations where a cut is needed close to or at the edge of the work, such as when rounding off deck planks.

RATE OF FEED

GUIDING THE ROUTER

FIG. 13

Workpiece

Direction of router feed

FIG. 14

FIG. 15

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USING SELF-PILOTED BITS

Self-piloted bits have an integral round tip or ball bearing which rides against the work surface above or below the cutters to control horizontal cutting depth (Fig. 16). When using these bits, neither the roller guide or straight guide is required. When guiding a

gainst a laminated surface, use wax or other lubricant and do not apply excess pressure or the piloted end may mar the work. Bearing pilots must be kept clean and free of adhesive or other residue. Router bit bearings are sealed and permanently lubricated, and should be replaced when they no longer turn freely to avoid damaging the work surface.

PR003 ROLLER/BUSHING GUIDE

(Included with PR20EVSNK, also available

The optional PR003 Roller/Bushing Guide is used when edge-forming or trimming with unpiloted bits, non-bearing bits.

Attachment of Roller/Bushing Guide

The PR003 roller/bushing guide (Fig. 17) is attached using the wing screw and washer.

Adjustment of Roller/Bushing Guide

Vertical Adjustment:

Loosen the wing screw and adjust up or

down as necessary to allow roller/bushing to ride on the intended guiding surface.

2. Tighten wing screw.

Horizontal Adjustment:

Whether making straight or bevel cuts, the width of material removed is determined by the distance between the front of the router bit’s cutter and the front of the roller/bushing. Adjust the front of the roller/bushing as follows:

1. Loosen wing nut at bottom.

2. Rotate the wing nut on the back of the

guide to move the roller/bushing in or out to create amount of cutter exposure needed to trim the laminate flush with the guiding surface or to create the desired bevel.

3. Be sure the bit clears the top of the

roller/bushing guide by at least 1/8" (3 mm) to avoid damage.

4.Tighten wing nut on the bottom of the

guide assembly

as optional accessory)

FIG. 16

FIG. 17

5. Make a trial cut to check the setting and readjust as necessary.

Use of the Roller/Bushing Guide

1. 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.

To maintain a consistent width of cut, a

2. consistent angle must be maintained between the router and the workpiece.

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PR009 AND PR010 ROUND SUBBASES &

USE OF TEMPLET GUIDE BUSHINGS

(

Available as optional accessories)

ptional large round subbases are available separately and allow various templet guide bushings to be used with the palm routers.

Templet guide bushings are used to guide the router to repeated make consistent openings and inlays using various templets (also referred to as patterns and jigs). Templets for standard routing applications are available commercially, such as the Bosch hinge templet kit; and templets for specialty applications are typically made by users for their specific needs.

The PR009 Round Subbase accepts the Bosch RA-Series Templet Guide Adapters.*

The PR010 Round Subbase accepts threaded templet guide adapters

*Note: The RA1100 Adapter for Threaded Templets allows use of conventional threaded templet guides with the PR009 Round Subbase.

PR009 Attachment of Templet Guide and

Round Subbase (Fig. 18)

1. Remove regular subbase.

2. Insert templet guide into top of round

subbase such that the anti-rotation stops in the subbase fit into the corresponding places in the templet guide. (When using the RA1100 adapter, first place the rubber O-ring between the anti-rotation stops and the subbase.) (Fig. 19).

3. Loosely attach round subbase using panhead

screws that come with that accessory.

Center the templet guide around the bit. (The

optional Bosch RA1150 Centering Cone can be used to ensure that the templet guide is properly centered.)

5. Tighten the panhead screws to hold the

templet guide and subbase in position.

Note: If a templet guide seems loose, repeat steps 2- 5 after adding the rubber O-ring.

PR010 Attachment Round Subbase of

Threaded Templet Guide (Fig. 20)

1. Remove regular subbase.

2. Loosely attach round subbase using panhead

screws that come with that accessory.

Attach the threaded templet guide by putting

the templet guide through the bottom and attaching the ring from the top.

4. Center the templet guide around the bit. (The

optional Bosch RA1150 Centering Cone can be used to ensure that the templet guide is properly centered.)

FIG. 18

Panhead

Screws

FIG. 19

Anti-

Rotation

Stops

FIG. 20

Templet Guide

Panhead

Screws

FIG. 21

Router Bit

Offset

Rubber O-Ring

(If necessary)

Templet

Guide

PR009 Subbase

Router Base

Collet Chuck

Templet

Guide

Rubber O-Ring

(If necessary)

Rotation

Templet Guide

Ring

PR010 Subbase

Sub-Base

Templet

Workpiece

5. Tighten the panhead screws to hold the templet guide and subbase in position.

Creating Templets

Templet patterns can be made of plywood, hardboard, metal or even plastic. 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 (the “offset”), as the final workpiece will differ in size from the templet pattern by that amount, due to the bit position (Fig. 21).

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Router

Base

Anti-

Stops

Router

Pattern

guide

BM 2609140437 05-06 5/23/06 3:15 PM Page 15

(Included with PR20EVSNK. Also available

The PR004 Offset Base is designed for routing in confined areas, especially for trimming laminates in areas that are inaccessible with the standard fixed base, e

specially locations that are close to adjacent vertical surfaces, such as the tops of alreadyinstalled counter backsplash backsplashes (Fig. 22).

The PR004 allows routing extremely close to vertical surface in front of tool, as close as 1/2” when 3/4” bit is used (Removal of black offset spindle cover further reduces distance from 3/4” bit and vertical surface to 3/8”.) The 1-1/16” base opening makes it possible to use bits that have cutters as wide 13/16”.

The PR004 can also be used to scribe the back of a new counter backsplash so that it will mate precisely with the wall against which it will rest (Fig. 23).

for more than 10 minutes continuously.

Prolonged continuous use will result in the tool becoming hot to the touch.

The nature of a belt drive mechanism like the one in the PR004 Offset Base creates more heat than when the motor is used in its other bases. To help minimize heat build-up, the PR004 has been designed with large bearings, 25,000 RPM speed*, speciallydesigned heat sinks, carefully-directed airflow and plastic heat shields. Depending on the application, the PR004 Offset Base can be used for up to about 10 minutes continuously before it will need to be left idle so that it can cool off.

*13,000-RPM 25,000 when used with PR20EVE motor.

1.Remove collet from motor and install

toothed drive pulley using collet wrench. Make sure that drive gear is fully tightened onto the motor’s spindle. (Fig. 24)

2. The motor is then installed into the base

according to the instructions on page 9.

3. Insert screwdriver (not included) through

the U-shaped opening in the subbase to fit belt over drive pulley. (Fig. 25)

PR004 OFFSET BASE

as optional accessory)

Heat Build-Up

WARNING

To reduce the risk of injury, do not use the offset base

Motor Installation

FIG. 22

FIG. 23

FIG. 24

Drive Gear

FIG. 25

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1. Insert bit to the desired depth as per the

Installation of Bit

instructions on page 7.

2. Press large red spindle lock button on top

of offset spindle (Fig. 26).

3. Tighten collet nut using the same collet

wrench as is used on the motor’s own collet nut. (The collet used on the PR004 is the same type of self-releasing collet used on the motor itself when used with the other bases.)

4. Make a trial cut to check the depth and

readjust as necessary.

Using the Offset Router

The principles of using the offset router are basically the same as for the regular router set-up (motor in fixed-base assembly), with the following differences

1. The offset router should be gripped with

one hand gripping the motor gripping area and the other gripping resting on the top of the offset spindle holding the front of the motor (Fig. 22).

2. For routing backsplashes and other

elevated workpieces, some installers mount the offset base to a wood block that matches the height of the laminated backsplash. This helps to maintain a consistent angle between the bit’s cutter and the workpiece and to provide addition stability.

Offset Base Roller/Bushing Guide

The PR004’s roller/bushing guide is required when edge-forming or trimming with unpiloted non-bearing bits.

Attachment of Roller/Bushing Guide

The PR004’s roller/bushing guide is attached using two screws with a Philips screwdriver (not included). Fig. 27

Adjustment of Roller/Bushing Guide

1. Using a Phillips screwdriver, to adjust,

loosen screw.

2. Rotate the knurled knob on back of the

guide to move the roller/bushing in or out to create amount of cutter exposure needed to trim the laminate flush with the guiding surface or to create the desired bevel.

FIG. 26

FIG. 27

Mounting

Screw

Mounting

Screw

FIG. 28

Clamping

Screw

3. Be sure the bit clears the top of the roller/bushing guide by at least 1/8" (3 mm) to avoid damage.

4. Tighten clamping screw using a Phillips screwdriver.

5. Make a trial cut to check the setting and readjust as necessary.

Use of the PR004 with

Roller/Bushing Guide

1. 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.

2. To maintain a consistent width of cut, a consistent angle must be maintained between the router and the workpiece.

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Knurled

Knob

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(Included with PR20EVSNK. Also available

The PR005 Tilt Base (Fig. 29) is used for the following purposes:

• Trimming laminated edges at the point that t

hey reach adjacent vertical surface, such

as a kitchen counter’s backsplash (Fig. 31).

• Trimming special angles (Fig. 30)

• Making bevel cuts. 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. 14).

The motor is installed according to the instructions on page 9.

The total tilt range is 75º, from 45º forward to 30º backward.

To adjust the angle (Fig. 31):

1. Loosen the two wing screws.

2. Adjust the angle as desired using the scale on the left side of the base. Note that there are detents at every 7.5º. Whenever possible, the base should be positioned with the motor tilted toward the closed end of the base.

3. Tighten the wing screws. Be careful not to over-tighten, or the base may be damaged.

The depth is adjusted according to the instructions on page 10.

The principles of using the tilt router are basically the same as for the regular router set-up (motor in fixed-base assembly), with the following difference.

1. The PR005 should always be used with a self-piloted or bearing bit.

The proper grip position depends on the

2. angle of the cut and the tool. The router should be gripped with one hand gripping the motor and the other gripping the elsewhere on the back of the tool.

WARNING

directly above or next to the exposed bit.

3. When trimming edges while the bit is tilted toward the direction of feed, it is extremely

PR005 TILT BASE

as optional accessory)

Motor Installation

Angle Adjustment

Depth Adjustment

Using the Tilt Router

To reduce the risk of injury, never grip the base

FIG. 29

FIG. 30

FIG. 31

Wing

Screw

Scale

Wing Screw

important to keep the base square with the surface to be routed. If the tilt router is shifted in the direction of the surface it is riding on, the upper part of the cutter can dig far into the workpiece.

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PR006 UNDERSCRIBE ATTACHMENT

(Included with PR20EVSNK. Also available

as optional accessory)

The PR006 Underscribe Attachment is used to create precision-fit seams between two sheets of laminate (Fig. 32), such as stile and r

ail constructions and very large surfaces. It

FIG. 32

is attached to the bottom of the PR001 Fixed Base.

Installation (Fig. 33)

1. Remove rear screws used to hold subbase onto PR001 Fixed Base.

2. Attach infeed side of PR006 to the Fixed Base using hex screw*

3. Insert eccentric adjuster into pocket on outfeed side of PR006.

4. Attach outfeed side of PR006 to the Fixed

FIG. 33

Base using hex screw*

*When used with PR007 Side-Handle Base, the longer set of attachment screws should be used.

Bit Installation

• The recommend bit for use with the Underscribe Attachment is the Bosch 85213M with 1/8” cutting diameter.

• It should be installed according to the instructions on page 7.

Bit Height Adjustment

After installing the bit, the height should be adjusted as follows:

1. Lower bit until it just enters the recess that

FIG. 34

is machined in the underscribe attachment’s aluminum plate.

The tool is now ready for making a test

2. cut.

Front-to-Back Adjustment

If necessary, the cutting point can be adjusted front-to-back as follows (Fig. 34):

1. Loosen the two screws holding the

Wrench

aluminum plate.

Using the pin wrench, adjust the eccentric

2. adjuster as follows:

For a tighter seam, turn the eccentric

• adjuster clockwise (as viewed from under the base)

• For a looser seam, turn the eccentric adjuster counterclockwise, (as viewed from under the base)

3. Retighten the screws

4. Make a test cut

Repeat steps 1-4 as necessary

To create a precision seam, make sure he

1. guiding piece of laminate has a clean, straight edge, because it will serve as the guide for the underscribe attachment.

2. Contact cement should be applied to the substrate core material and the guiding piece of laminate up to 1” from its guiding edge.

Hex Screw

Eccentric Adjuster

Hex Screw

Eccentric Adjuster

Creating a Seam

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BM 2609140437 05-06 5/23/06 3:15 PM Page 19

3. The overlapping piece of laminate should overlap the guiding piece by about 1/2". (The overlapping sheet of laminate will then pass over the aluminum plate and be cut at the proper point by the router bit.)

4. Keep steady pressure on the tool so that t

he guiding edge of the base remains in contact with the fixed piece of laminate throughout the operation. This is especially important at the beginning and end of a cut.

PR007 SIDE-HANDLE SUBBASE

(Available as optional accessory)

See PR007 instruction sheet for complete information about this accessory.

The PR007 Side-Handle Subbase and Dust Extraction Kit (Fig. 35) is a versatile accessory that provides several useful features:

• Additional means of supporting the router

• Dust extraction and collection capability

PR007 Attachment to Palm Router

1. Remove regular subbase

Attach side handle subbase with the

2. panhead screws that are included with it.

Additional Means of Supporting

The knob handle on the PR007 subbase provides an additional gripping point for the palm router / side-handle subbase assembly. It is designed for use when the palm routers are being used in applications that are wide enough that the knob sits over the workpiece. Holding the knob and keeping it pressed down over the workpiece helps keep the routers’ angle to the workpiece unchanged, and is especially helpful when routing edges.

Attachment of PR006 Underscribe

The PR006 Underscribe Attachment can also be used with the palm router and the sidehandle subbase.

Note: When the underscribe attachment is used with the side-handle subbase, the longer set of attachment screws should be used.

Please refer to PR006 Underscribe Attachment section for further instructions.

Dust Extraction & Collection Capability

If you have a shop vacuum system, you can connect it to the PR007’s dust extraction

the Router

Attachment

5. It is also necessary to keep the laminate pressed down tightly near the seam to keep these chips from getting under the laminate. This is especially important on larger pieces of material. The optional PR007 Side Handle Subbase includes a dust extraction hood port that connects to a

vacuum hose and helps to keep chips

from getting under the laminate.

FIG. 35

attachment to remove routing dust and debris for enhanced utility, visibility and accuracy.

The dust collection capability of the PR007 can be used in both common types of router applications:

1. Routing on flat surfaces

2. Edge-forming

WARNING

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.

Dust Extraction when Routing on

Attach the dust port on the back end of the subbase.

1. Position the port on the backside of subbase

Affix using two thumbscrews included.

Dust Extraction when Edge-forming

Attach the dust hood and port on the back end of the subbase.

Position the hood on the backside of

1. subbase

2. Position the port on the backside of the dust hood.

3. Affix using two thumbscrews included.

To reduce the risk of injury, do not reach in area

Flat Surfaces

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BM 2609140437 05-06 5/23/06 3:15 PM Page 20

Vacuum Hose Compatibility

The dust port is sized to accept 35mm vacuum hoses. The PR007 includes the VAC002 adapter that will allow the port to be

PR008 BASE COVER

(Included with PR004 Offset Base. Also

available as optional accessory) The optional PR008 Base Cover (Fig. 36) is available to provide insulation from tool heat in continuous and/or high-usage applications. It can be used on the PR001 Fixed Base, PR005 Tilt Base, and PR004 Offset Base (with which it is standard equipment).

Installation of Base Cover

1. Remove clamp.

2. Slide cover over the top of the base and

into position

3. Reattach clamp. Make sure that washers

sit on outside of cover.

connected to 1-1/4” and 1-1/2” vacuum hoses. An adapter to connect the hood to 21/2" hoses is also available separately.

FIG. 36

Base

Remove

Clamp

Cover

Maintenance

Service

WARNING

personnel may result in misplacing of internal wires and components which could cause serious hazard.

recommend that all tool service be performed by a Bosch Factory Service Center or Authorized Bosch Service Station.

Your Bosch tool has been properly lubricated and is ready to use. It is recommended that tools with gears be regreased with a special gear lubricant at every brush change.

Preventive maintenance performed by unauthorized

TOOL LUBRICATION

The brushes and commutator in your tool

CARBON BRUSHES

have been engineered for many hours of dependable service. To maintain peak efficiency of the motor, we recommend every two to six months the brushes be examined. Only genuine Bosch replacement brushes specially designed for your tool should be used.

BEARINGS

After about 300-400 hours of operation, or at every second brush change, the bearings should be replaced at Bosch Factory Service Center or Authorized Bosch Service Station. Bearings which become noisy (due to heavy load or very abrasive material cutting) should be replaced at once to avoid overheating or motor failure.

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