PR20EVSNK
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
For English Version Version française Versión en español
See page 2
Voir page 22 Ver la página 42
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BM 2609140437 05-06 5/23/06 3:15 PM Page 1
-2-
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
use any adapter plugs with earthed
(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.
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.
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.
GFCI and
personal protection devices like electrician’s
rubber gloves and footwear will further
enhance your personal safety.
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.
A moment of
inattention while operating power tools may
result in serious personal injury.
Use safety equipment. Always wear eye
protection.
Safety equipment such as dust
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.
Carrying power tools with your
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.
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 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.
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 these devices can reduce dust-
related hazards.
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
all of the warnings listed below refers to your mains-operated (corded) power tool or battery-
operated (cordless) power tool.
SAVE THESE INSTRUCTIONS
!
WARNING
General Safety Rules
BM 2609140437 05-06 5/23/06 3:15 PM Page 2
Keep handles dry, clean and free from oil
and grease.
Slippery hands cannot safely
control the power tool.
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.
Any power tool
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.
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 tools operation.
If damaged, have the power tool repaired
before use.
Many accidents are caused by
poorly maintained power tools.
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.
Holding the work by hand
or against your body is unstable and may
lead to loss of control.
Service
Have your power tool serviced by a
qualified repair person using only identical
replacement parts.
This will ensure that the
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.
Certain cleaning agents such as
gasoline, carbon tetrachloride, ammonia, etc.
may damage plastic parts.
SAVE THESE INSTRUCTIONS
-3-
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.
Contact with a "live" wire will
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.
Holding the work by hand
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.
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.
BM 2609140437 05-06 5/23/06 3:15 PM Page 3
Using personal safety devices and working in
safe environment reduces risk of injury.
A
fter 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.
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.
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.
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.
-4-
!
WARNING
BM 2609140437 05-06 5/23/06 3:15 PM Page 4
-5-
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
A
0
A
A
0
A
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.
BM 2609140437 05-06 5/23/06 3:15 PM Page 5
-6-
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
Palm Router
Microfine Depth
Adjustment
Bit Rotation Arrow
Collet Nut
Contoured
Grip Area
Brush Cap
Variable-Speed Dial
(PR20EVS model)
Finger Support Pockets
Finger Guards
Power Cord
Quick-Clamp
System Lever
Depth Scales
(Imperial & Metric)
Spindle Lock
Sub-Base
Rugged Aluminum
Base
Coarse Adjustment
Unlock/Lock Indicator
Rocker
On/Off
Switch
Air Vents
FIG. 1
Model Number
PR10E PR20EVS
Voltage rating 120 V 60 Hz 120 V 60 Hz
Amperage Rating
5.7A
5.7A
No load speed n
0
35,000/min n
0
16,000-35,000/min
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.
BM 2609140437 05-06 5/23/06 3:15 PM Page 6
SELECTING BITS
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.
To prevent personal injury,
always remove the plug
from power source before removing or in-
stalling bits or accessories.
Installing a Router Bit
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.
NOTE: it may be necessary to
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.
Cutter diameter must be at
least 1/4” smaller than
opening for the bit and cutter.
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
the spindle, 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.
-7-
Assembly
!
WARNING
2
1
FIG. 2
FIG. 3
!
WARNING
BM 2609140437 05-06 5/23/06 3:15 PM Page 7
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
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.
REMOVING MOTOR FROM BASE
1. Open the clamping lever (Fig. 5).
2. Turn the motor so that the single triangle
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)
3. Pull the motor away from base until it stops
(Fig. 5).
4. Turn motor counterclockwise until it stops
(Fig. 6).
5. Pull motor out of base (Fig. 6).
-8-
2
1
3
Collet
Collet
Chuck
Nut
F
IG. 4
FIG. 5
1
5
4
FIG. 6
BM 2609140437 05-06 5/23/06 3:15 PM Page 8
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).
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)
5. Turn motor clockwise
about 1/4”
until single
triangle lines up with “locked” symbol. (Fig. 9)
6. Close the clamping lever. Always make
sure the motor sits tightly in the base. (The
tension of the clamping lever can be
changed by re-adjusting the nut.) (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).
Cutter diameter must be at
least 1/4” smaller than
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.
-9-
4
3
FIG. 8
1
2
FIG. 7
!
WARNING
FIG. 10
5
6
FIG. 9
BM 2609140437 05-06 5/23/06 3:15 PM Page 9
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” counter-
clockwise 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-of-
cut 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.
FINE DEPTH ADJUSTMENT
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
knurled wheel on back of base. Fig. 11(D)
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)
5.
Check the depth-of-cut and make an
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.
TO CLAMP MOTOR
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.)
DEEP CUTS
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.
-10-
C
A
D
B
Operating Instructions
FIG. 11
BM 2609140437 05-06 5/23/06 3:15 PM Page 10
-11-
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“.
T
O TURN THE TOOL “ON”:
P
ush the side
of the switch marked “I”.
TO TURN THE TOOL “OFF”: Push the side
of the switch marked “O”.
SOFT START FEATURE
Electronic feedback control minimizes torque
twist customary in routers by limiting the
speed at which motor starts.
ELECTRONIC VARIABLE SPEED
CONTROL
(Model PR20EVS Only)
The electronic speed control feature allows
motor speed to be matched to cutter size and
material hardness for improved finish,
extended bit life, and higher performance.
Speed changes are achieved by rotating
Control Dial RIGHT to increase speed, LEFT
to decrease as indicated on housing (Fig. 1).
Speed may be changed while tool is on. The
reference numbers on the dial facilitate 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.
FEEDING THE ROUTER
In addition to the main palm-grip area at the
back of the motor housing and base, the
base has Bosch-exclusive finger support
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).
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.
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.
DIAL
SETTING RPM APPLICATION
1 16000
2 18000
3 20000
4 22500
5 26500
6 35000
}
}
Larger-diameter bits
and cutters.
Softwoods, plastics,
laminates, smaller
diameter bits and
cutters
FIG. 12
BM 2609140437 05-06 5/23/06 3:15 PM Page 11
-12-
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
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 run-
out 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.
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. 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.
FIG. 15
FIG. 14
FIG. 13
Workpiece
Direction of router feed
BM 2609140437 05-06 5/23/06 3:15 PM Page 12
-13-
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
as optional accessory)
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:
1.
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
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.
2.
To maintain a consistent width of cut, a
consistent angle must be maintained
between the router and the workpiece.
FIG. 16
FIG. 17
BM 2609140437 05-06 5/23/06 3:15 PM Page 13
PR009 AND PR010 ROUND SUBBASES &
USE OF TEMPLET GUIDE BUSHINGS
(
Available as optional accessories)
O
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.
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.)
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.
3.
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.)
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
guide
(the “offset”), as the final workpiece will differ in
size from the templet pattern by that amount,
due to the bit position (Fig. 21).
-14-
Workpiece
Router Bit
Offset
Templet
Guide
Templet
Pattern
Router
Sub-Base
FIG. 20
FIG. 21
PR010 Subbase
Templet Guide
Ring
Router Base
Panhead
Screws
Templet
Guide
FIG. 18
Router
Base
Panhead
Screws
Templet
Guide
PR009 Subbase
Rubber O-Ring
(If necessary)
FIG. 19
Rubber O-Ring
(If necessary)
Anti-
Rotation
Stops
Anti-
Rotation
Stops
Collet Chuck
BM 2609140437 05-06 5/23/06 3:15 PM Page 14
-15-
PR004 OFFSET BASE
(Included with PR20EVSNK. Also available
as optional accessory)
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 already-
installed 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).
Heat Build-Up
To reduce the risk of injury,
do not use the offset base
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*, specially-
designed 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.
Motor Installation
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)
FIG. 25
!
WARNING
FIG. 22
FIG. 23
FIG. 24
Drive Gear
BM 2609140437 05-06 5/23/06 3:15 PM Page 15
Installation of Bit
1. Insert bit to the desired depth as per the
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
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 (Fig. 28):
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.
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.
-16-
FIG. 26
FIG. 27
FIG. 28
Mounting
Screw
Mounting
Screw
Clamping
Screw
Knurled
Knob
BM 2609140437 05-06 5/23/06 3:15 PM Page 16
PR005 TILT BASE
(Included with PR20EVSNK. Also available
as optional accessory)
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).
Motor Installation
The motor is installed according to the
instructions on page 9.
Angle Adjustment
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.
Depth Adjustment
The depth is adjusted according to the
instructions on page 10.
Using the Tilt Router
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.
2.
The proper grip position depends on the
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.
To reduce the risk of
injury, never grip the base
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
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.
-17-
FIG. 29
FIG. 30
FIG. 31
Wing Screw
Scale
Wing
Screw
!
WARNING
BM 2609140437 05-06 5/23/06 3:15 PM Page 17
-18-
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
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
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
is machined in the underscribe
attachment’s aluminum plate.
2.
The tool is now ready for making a test
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
aluminum plate.
2.
Using the pin wrench, adjust the eccentric
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
5.
Repeat steps 1-4 as necessary
Creating a Seam
1.
To create a precision seam, make sure he
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.
FIG. 32
FIG. 33
FIG. 34
Hex Screw
Pin
Wrench
Eccentric
Adjuster
Eccentric
Adjuster
Hex Screw
BM 2609140437 05-06 5/23/06 3:15 PM Page 18
-19-
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
2.
Attach side handle subbase with the
panhead screws that are included with it.
Additional Means of Supporting
the Router
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
Attachment
The PR006 Underscribe Attachment can also
be used with the palm router and the side-
handle 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
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
To reduce the risk of
injury, 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.
Dust Extraction when Routing on
Flat Surfaces
Attach the dust port on the back end of the
subbase.
1. Position the port on the backside of
subbase
2.
Affix using two thumbscrews included.
Dust Extraction when Edge-forming
Attach the dust hood and port on the back
end of the subbase.
1.
Position the hood on the backside of
subbase
2. Position the port on the backside of the
dust hood.
3. Affix using two thumbscrews included.
FIG. 35
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.
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.
!
WARNING
BM 2609140437 05-06 5/23/06 3:15 PM Page 19
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.
Service
Preventive maintenance
performed by unauthorized
personnel may result in misplacing of
internal wires and components which
could cause serious hazard.
We
recommend that all tool service be performed
by a Bosch Factory Service Center or Autho-
rized Bosch Service Station.
TOOL LUBRICATION
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.
CARBON BRUSHES
The brushes and commutator in your tool
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.
!
WARNING
Maintenance
-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
connected to 1-1/4” and 1-1/2” vacuum
hoses. An adapter to connect the hood to 2-
1/2" hoses is also available separately.
FIG. 36
Base
Cover
Remove
Clamp
BM 2609140437 05-06 5/23/06 3:15 PM Page 20
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