BOSCH RA1200 User guide

Operating/Safety Instructions

Consignes de fonctionnement/sécurité Instrucciones de funcionamiento

y seguridad

RA1200

IMPORTANT: IMPORTANT : IMPORTANTE:

Read Before Using Lire avant usage Leer antes de usar

For English Parlez-vous français? ¿Habla español? See page 2 Voir page 22 Ver página 42

Consumer Information

Renseignement des consommateurs

Información para el consumidor

Toll Free Number: Appel gratuit : Número de teléfono gratuito:

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

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Read and understand the tool manual and these instructions for the use of this table with your router. Failure to follow all instructions listed below may

result in serious personal injury.

SAVE THESE INSTRUCTIONS

Work Area

Keep your work area clean and well lit.

Cluttered benches and dark areas invite accidents.

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

tools create sparks which may ignite the dust or fumes.

Keep bystanders, children, and visitors away while operating a power tool.

Distractions can cause you to lose control.

Electrical Safety

Double Insulated tools are equipped with a polarized plug (one blade is wider than the other.) This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized outlet. Do not change the plug in any way. Double

Insulation eliminates the need for the three wire grounded power cord and grounded power supply system. Before

plugging in the tool, be certain the outlet voltage supplied is within the voltage marked on the nameplate. Do not use “AC only” rated tools with a DC power supply.

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

of electric shock if your body is grounded. If operating the power tool in damp locations is unavoidable, a Ground Fault Circuit Interrupter must be used to supply the power to your tool. Electrician’s rubber gloves and footwear will further enhance your personal safety.

Don't expose power tools to rain or wet conditions. Water entering a power tool will

increase the risk of electric shock.

Do not abuse the cord. Never use the cord to carry the tools or pull the plug from an outlet. Keep cord away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately.

Damaged cords increase the risk of electric shock.

When operating a power tool outside, use an outdoor extension cord marked "W-A" or "W." These cords are rated for outdoor

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

Personal Safety

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

operating power tools may result in serious personal injury.

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

or long hair can be caught in moving parts. Keep handles dry, clean and free from oil and grease.

Avoid accidental starting. Be sure switch is “OFF” before plugging in. Carrying tools

with your finger on the switch or plugging in tools that have the switch “ON” invites accidents.

Remove adjusting keys or wrenches before turning the tool “ON”. A wrench or

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

Do not overreach. Keep proper footing and balance at all times. Proper footing

and balance enables better control of the tool in unexpected situations.

Use safety equipment. Always wear eye protection. Dust mask, non-skid safety

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

Tool Use and Care

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

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

Do not force tool. Use the correct tool for your application. The correct tool will do

WARNING

Power Tool Safety Rules

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the job better and safer at the rate for which it is designed.

Do not use tool if switch does not turn it “ON” or “OFF”. Any tool that cannot be

controlled with the switch is dangerous and must be repaired.

Disconnect the plug from the power source before making any adjustments, changing accessories, or storing the tool.

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

Store idle tools out of reach of children and other untrained persons. Tools are

dangerous in the hands of untrained users.

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

tools, with sharp cutting edges are less likely to bind and are easier to control. Any alteration or modification is a misuse and may result in a dangerous condition.

Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tools operation. If damaged, have the tool serviced before using. Many accidents are

caused by poorly maintained tools. Develop a periodic maintenance schedule for your tool.

Use only accessories that are recommended by the manufacturer for your model. Accessories that may be

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

Service

Tool service must be performed only by qualified repair personnel. Service or

maintenance performed by unqualified personnel could result in a risk of injury. For example: internal wires may be misplaced or pinched, safety guard return springs may be improperly mounted.

When servicing a tool, use only identical replacement parts. Follow instructions in the Maintenance section of this manual.

Use of unauthorized parts or failure to follow Maintenance Instructions may create a risk of electric shock or injury. Certain cleaning agents such as gasoline, carbon tetrachloride, ammonia, etc. may damage plastic parts.

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Unplug tool before setting up in table, making adjustments or changing bits.

Accidental start-up of the tool can cause injury.

Fully assemble and tighten all the fasteners required for this table and mounting the router. Also remember to occasionally check

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

Before operating make sure the entire unit is placed on a solid, flat, level surface. Serious

injury could occur if tool is unstable and tips.

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

table is tipped or the cutting tool is accidentally contacted. Do not store materials on or near the table such that it is necessary to stand on the table or its stand to reach them.

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

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

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

personal injury or tool failure.

Never start the tool when the bit is engaged in the material. The bit cutting edge may grab

the material causing loss of control of the workpiece.

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

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

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

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

Never place hands near the spinning bit. Use push sticks, vertical and horizontally mounted feather boards (spring sticks) and other jigs to hold down the workpiece and keep your hands away from the spinning blade. Router cuts are blind cuts but the bit still

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

We do not recommend cutting material that is warped, wobbly or otherwise unstable. If this situation is unavoidable, always cut the material with the concave side against the table. Cutting the material with the concave

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

Use the adjustable fence in straight cutting applications. When routing along an entire

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

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

Piloted bits are used when routing internal and external contours on a workpiece. The bearing of the piloted bit assists in maintaining control of the workpiece. Whenever possible, the starter pin should also be used.

After changing the bits or making any adjustments, make sure the collet nut and any other adjustment devices are securely tightened. Loose adjustment devices can

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

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

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

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

Safety Instructions for Large Router Table

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IMPORTANT: Some of the following symbols may be used on your tool. Please study them

and learn their meaning. Proper interpretation of these symbols will allow you to operate the tool better and safer.

Symbol Name Designation/Explanation

V Volts Voltage (potential)

A Amperes Current

Hz Hertz Frequency (cycles per second)

W Watt Power

kg Kilograms Weight

min Minutes Time

s Seconds Time

Diameter Size of drill bits, grinding wheels, etc.

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

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

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

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

This symbol

designates that this tool complies to NOM Mexican Standards.

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

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Model number: RA1200 Voltage rating:

120 V 60Hz

Amperage rating: 15 A

FOR USE WITH BOSCH ROUTER

MODELS:

1601A, 1602A, 1604A, 1606A, 1613, 1613EVS, 1613AEVS, 1617, 1617EVS, and 1619EVS.

TOOLS REQUIRED:

BEFORE YOU ASSEMBLE THIS

ROUTER STAND:

Sort out and account for all parts to make sure that you have all necessary materials to assemble your stand. Do not discard packing material until all parts are accounted for.

PARTS FOR STAND ASSEMBLY

Qty. Part Description

(1) Table Assembly (1) Power Switch (2) Power Switch Screw (6) Nylon Leveler Screw (6) Spring

PARTS FOR ROUTER MOUNTING

Qty. Part Description

(1) Mounting Plate (4) 1/4"-20 x 1 1/2" Machine Screw (4) 1/4" Washer (4) 1/4" Nut (4) 4mm x 20mm Machine Screw (4) 10-24 3/4" Machine Screw (4) Corner Snugger (4) 10-24 Screw (4) Lock Nut

PARTS FOR FENCE ASSEMBLY

Qty. Part Description

(1) Aluminum Fence (2) Fence Face (4) 3/8” x 2” Carriage Bolt (6) 3/8” Female Wing Knob (2) 3/8” x 2-1/2” Carriage Bolt (2) 1/32" Shim (4) 1/16" Shim (1) Vacuum Port (2) 10-24 Vacuum Port Screw (1) Clear Blade Guard (2) Featherboard (2) Threaded Rod (8) Knurled Steel Nut (2) Nut (8) Washer

OTHER PARTS FOR ASSEMBLY

Qty. Part Description

(2) Insert Rings (1) Starter Pin (2) Featherboard Mounts (2) Nylon Spacer Washer (2) 1/4" Wing Knob (1) Auxiliary Guard

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Router Table Assembly

Phillips Screwdriver

Adjustable Wrench

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INSTALL POWER SWITCH

Lay the table upside down on a smooth surface. Place switch bracket’s holes over pre-drilled holes on front underside of table with the red switch facing out. Using a No. 2 Phillips screwdriver, drive the two #10 wood screws through the bracket and into the predrilled holes to affix the switch. Do not over-tighten because this could strip the holes. (Fig. 1).

SET UP TABLE

1. Unfold router table legs until they are fully extended and the leg braces spring into the locked position (Fig. 2).

2. Position yourself at the front or rear of the table.

3. Using the opening for the mounting plate and the bottom edge of the tabletop, lift the table to its upright position.

4. Locate the table on a level or nearly-level surface. Stabilize the table by rotating the leveler foot up or down until all four legs contact the floor. The table must not be able to rock or tilt (Fig. 3).

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Router Table Assembly

FIG. 1

FIG. 2

FIG. 3

POWER

SWITCH

POWER

SWITCH

TABLE

LEG BRACES

LEVELER FOOT

PREDRILLED

HOLES

#10 WOOD

SCREWS

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ATTACH ROUTER TO MOUNTING PLATE

1. Remove the black phenolic sub-base from your Bosch router (Fig. 4).

2. If your router has its own dust extraction hood that mounts to the top of the metal router base and you want to use it under the router table, this is a convenient time to install it.

3. Using the chart below, determine the hardware (included) needed and mount type for your Bosch router.

• For the 1601A, 1602A, 1604A, 1606A, and

the 1617 series routers, the screws are driven into threaded holes in the router’s base (mount type 1).

• For the 1613 and 1619 series routers: the

screws go all the way through the base and are fastened with washers and nuts (mount type 2).

The top and front of the mounting plate is determined by the location of the guide pin holes. These holes are to the right of the bit opening.

4. Refer to the mounting plate illustration (Fig.

6) on page 9, and align the appropriate mounting plate holes for your Bosch router to the router base holes. Make sure that the depth adjustment controls on the router face the front of the mounting plate.

5. Mount your Bosch router to the mounting plate (Fig. 5).

6. Once the router has been mounted to the mounting plate, install the desired router bit as per the router’s instruction manual.

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Router Table Assembly

FIG. 4

FIG. 5

REMOVE

SUB-BASE

DEPTH

ADJUSTMENT

Bosch Required Mount Router Model Hardware Type

1601A, 1602A, 4mm x 20mm phillips

1604A, 1606A machine screws (4)

1613,

1/4"-20 x 1-1/2" phillips machine

1613EVS,

screws, washers and nuts (3)

1613AEVS

1617, 10-24 x 3/4" phillips

1617EVS, machine screws (3)

1/4"-20 x 1-1/2" phillips machine

1619EVS

screws, washers and nuts (4)

MOUNT TYPE 1

MOUNT TYPE 2

MOUNTING PLATE

ROUTER BASE

MOUNTING PLATE

ROUTER BASE

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Router Table Assembly

TOP FRONT OF PLATE

FIG. 6

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1601A, 1602A, 1604A, 1606A

1613 SERIES

1617 SERIES

1601A, 1602A, 1604A, 1606A

1619EVS

1617

SERIES

1613 SERIES

1613

1619EVS

1601A, 1602A, 1604A, 1606A

STARTER PIN HOLE

1617 SERIES

1601A, 1602A, 1604A, 1606A

1619EVS

STARTER PIN

STORAGE HOLE

DRILLING HOLES IN THE

MOUNTING PLATE

(Only necessary if the holes in your router’s base don’t line up with factory drilled holes in the mounting plate.)

You can drill additional holes in the RA1200 mounting plate or purchase a blank RA1250 Bosch mounting plate from your Bosch dealer.

Your router’s sub-base will be your drilling pattern.

1. Orient the mounting plate for drilling. The bottom of the plate, which has concentric rings, should be facing up. The guide-pin hole should be just to the left of the opening. The nearest edge of the plate is the front edge of the plate. (Fig. 7)

2. Decide how you want your router positioned under the table. These are the things to consider:

• Location of router depth adjustment

controls

• Location of router speed control.

• Location of router depth lock lever.

• Location of router handles. If the router is

very large and you want to rotate it slightly to allow the handles to easily fit though the opening, make sure the handles will not hit the table frame at any depth setting.

3. Remove router’s sub-base.

4. Using the concentric rings on the underside of the mounting plate, center your router’s sub-base. Line up the mounting holes on the radial lines. Use tape to hold the sub-base in position (Fig. 8).

Note: Make sure that the intended locations for your mounting holes do not run into the holes for the router table’s guide pin or the factory-drilled mounting holes for Bosch routers.

5. Firmly clamp the sub-base to the mounting plate using no-mar wood clamps or "C" clamps. To avoid any slippage, don’t use spring clamps (Fig. 9).

6. Place a piece of scrap wood under the mounting plate below drilling location. Drill through the mounting plate using a drill bit of the same size as the holes in your router’s sub-base (Fig. 9).

7. Remove the clamps and sub-base. Turn the mounting plate over.

8. Countersink the new holes using a singleflute countersink at a slow speed to achieve a clean cut (Fig. 10). Use a drill press if available. Make sure the screw heads are sub-flush when installed.

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FIG. 7

FIG. 9

FIG. 10

Router Table Assembly

FIG. 8

CONCENTRIC RINGS

ROUTER SUB-BASE

CLAMPS

SINGLE-FLUTE COUNTERSINK

DRILL OR

DRILL

PRESS

RADIAL

LINES

TAPE

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CONNECT THE ROUTER AND THE

ROUTER TABLE SWITCH

To prepare for use of the switch, (Fig. 12)

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

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

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

4. Turn the router’s own switch to "ON" and activate lock-on button, if it has one.

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

This switch has a 15 amp rating and is intended only for turning the router "ON" and "OFF". Do not use it to operate additional equipment, such as a vacuum cleaner.

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Router Table Assembly

FIG. 11

FIG. 12

PLUG ROUTER INTO

THIS SOCKET

TABLE

POWER SWITCH

PLUG INTO

WALL OUTLET

DEPTH ADJUSTMENT

INSTALL ROUTER/PLATE

IN ROUTER TABLE

1. Place the router/plate assembly into the router table. Orient the mounting plate so that the depth adjustment controls on the router face the front side of the table (Fig. 11).

2. Install the six nylon mounting plate leveling screws with springs into the six holes around the mounting plate opening. Adjust the mounting plate height so that it is level and

even with the table. A turn to the right raises the mounting plate, and a turn to the left lowers the plate. Mounting plate must be level with table surface for proper performance. Make sure that all of the leveling screws are adjusted to be snug against the mounting plate. (Fig. 11)

3. Assemble mounting plate snuggers using 10-24 screws and lock nuts to the four corners of the mounting plate. To hold the plate in position, push snuggers into corners and tighten. (Fig. 11)

SNUGGER

LOCK

NUT

10-24 SCREW

LEVELING

SCREW

SPRING

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ATTACHING FENCE FACES TO FENCE

Using 3/8" x 2" carriage bolts and black wing knobs, tighten the fence faces against fence. The fence faces are symmetrical and can be installed on either side of the fence with either end of the face facing center. (Fig. 14)

INSERT RINGS

When smaller diameter router bits are used, use the mounting plate’s throat insert rings to provide additional support to the workpiece as it nears the bit and minimize the amount of debris that falls through the throat opening. (Fig. 13)

The rings are designed to fit snugly to stay in place and remain level. Considerable force may be required to install and remove the rings.

• To insert the outer ring, press it into the mounting plate. Make sure the tabs on the ring goes into one of the notches in the mounting plate.

• To insert the inner ring, press it into the outer ring (considerable force may be required).

• To remove, tap out from the back side with a soft mallet or piece of wood.

Don't pry them out or they may be damaged. If you

want a slightly looser fit, lightly sand the outside diameter of each ring.

• When removing the inner ring, it may be necessary to press down on the outer ring.

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Router Table Assembly

FIG. 14

FIG. 13

3/8" X 2"

CARRIAGE

BOLT

STARTER

PIN HOLES

OUTER RING

WING KNOB

FENCE

FACE

INNER RING

CAUTION

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VACUUM PORT

To minimize the amount of debris and dust in the work area, always connect a vacuum cleaner to the router table. The vacuum port opening is sized to connect to standard 2-1/2" vacuum hoses.

Orient the vacuum port such that the internal positioning ribs are on the top and sides and the warning is on the top. Attach vacuum port using the two 10-24 screws. Insert the end of the hose into the port. (Fig. 17)

Do not reach into area of the bit while the router is

plugged in.

FIG. 15

THREADED ROD

KNURLED STEEL NUT

WASHERS

NUT

FEATHERBOARD

TOP VIEW

FENCE

CLEAR BIT GUARD

KNURLED STEEL NUTS

ASSEMBLE VERTICAL FEATHERBOARD

AND GUARD SYSTEM

This system makes it easy to correctly position the clear bit guard and the vertical featherboard, which helps keep the workpiece pressed against the table and reduces the possibility and intensity of kickback.

This system is especially beneficial when routing small pieces. Following figures 15 & 16, assemble the vertical featherboard and guard system. Note in particular the orientation of featherboard and the knurled steel knobs. The “feathers” should point in the feed direction. (The two featherboards are the same and either one can be used as the vertical featherboard.)

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Router Table Assembly

FIG. 17

FIG. 16

10-24

SCREWS

VACUUM PORT

FENCE

CLEAR BIT GUARD

FEED DIRECTION

FEATHER

BOARD

WARNING

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PREPARING THE ROUTER TABLE FOR TRANSPORTATION AND/OR STORAGE

To prepare the table for transportation and storage:

1. Remove fence.

2. Remove the mounting plate and router.

3. Fold up table legs: Make sure the cord stays clear of the legs. Fold in the leg on the power switch side first. Push in the leg brace lock buttons, push leg braces in, then fold down legs.

4. After removing the router for the mounting plate, you can securely store the mounting

plate to the router table by using the back end of the corner snuggers (Fig. 20)

HORIZONTAL FEATHERBOARD ASSEMBLY

The horizontal featherboard helps keep the workpiece pressed against the fence and reduces the possibility and intensity of kickback. It is especially beneficial when routing small pieces.

To install:

1. Screw a bolt into each of the two hex nuts so that bolt heads are recessed and tightened into the bottom of the nuts.

2. Slide the two hex nut and bolt assemblies into the track from the right end. Attach the second of the two matching featherboards to the bolts using the nylon spacer washers and small wing knobs. Position the feathers so that they point in the feed direction (Fig. 19).

ATTACHING FENCE TO TABLE

Attach fence to table using the two 3/8" x 2-1/2" carriage bolts and two wing knobs provided.

When securing the fence assembly in place, it may be necessary to reach under the table to provide finger pressure to stop the bolt from spinning. Or you can tap each bolt with a mallet so that its neck becomes slightly embedded in the hole.

Figure 18 illustrates the assembled fence for most operations, which uses the front set of holes.

For making cuts in the middle of the workpiece, such as slotting cuts, the fence can be mounted using the rear set of holes.

Use extra caution when

positioning the fence for slotting cuts, due to the increased exposure of the spinning bit before and after the cut.

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Router Table Assembly

FIG. 18

3/8" X 2-1/2"

CARRIAGE

BOLT

WING KNOB

FRONT HOLE

REAR HOLE

FIG. 20

WARNING

SNUGGER

MOUNTING PLATE

UNDERSIDE

OF TABLE

WING KNOB

FEATHER

BOARD

FEED

DIRECTION

TRACK

HEX NUT

BOLT

WASHER

FIG. 19

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Operating Instructions

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POSITIONING THE FENCE FOR

EDGE FORMING STRAIGHT PIECES

For safe operation and

quality routing results when edge-forming straight pieces, the workpiece, fence, and router bit must be positioned according to these guidelines:

• The workpiece must be positioned against

the fence faces and must slide smoothly along the faces.

• If a piloted (or “bearing”) bit is used, the front

of the bearing should be even with the front of the fence faces.

POSITIONING THE FENCE FOR

SLOTTING CUTS

Slotting cuts are made in the middle of the workpiece, such as grooves and dados. Mount the fence to the table using the front or rear set of holes, as appropriate (Fig. 22).

For safe operation and

quality results when slotting, the workpiece and router bit must be positioned as follows:

• Only non-piloted bits can be used.

• The bit must not cut though the top of the

workpiece.

• Always feed the workpiece from right to left.

WARNING

ROUTER PREPARATION

Install the desired bit into the router according the router’s instructions. (It is often easier to do this when the router and mounting plate assembly have been removed from the router table.)

Install or remove insert rings as appropriate to minimize the opening without touching the desired bit.

Adjust the router bit to the desired height according the router’s instructions.

POSITIONING THE FENCE FACES

The fence faces can be moved left and right to properly position the faces for the desired operation. Loosen the fence face wing knobs.

For safe operation and to

avoid tear-out on the workpiece, position the faces as closely as possible to the bit without touching the bit.

Once the proper location has been determined, secure the faces in place by tightening the wing knobs behind the fence (Fig. 14).

Additional fence face sets are available from your Bosch dealer.

WARNING

FIG. 21

FIG. 22

WORKPIECE

DIRECTION OF FEED

BIT

BEARING

NON-BEARING

BIT

TOP VIEW

FENCE FACE

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IMPROPER FENCE LOCATION AND

WORKPIECE FEED

The fence and/or workpiece are improperly located

anytime it would result in:

• The front of the bit is exposed during the actual cutting (Fig. 23).

• “Climb-cutting” - The bit must not enter the workpiece in the same direction as the feed direction, which is likely to cause the workpiece to "climb" and may lead to loss of control during operation (Fig. 24).

"Fence Traps": One type of improper fence location warrants special attention: "Fence traps" happen when the fence is positioned so far back that front side (power switch side) of the workpiece would be behind the router bit.

Fence traps are dangerous for two reasons:

• Exposure of the bit on the front side (power switch side) of the workpiece.

• Likeliness of climb cut, which can cause loss of control.

Figure 23 shows a fence trap.

Do not feed the workpiece from left to right: (Fig. 24)

• It would cause climb-cutting.

• It would be difficult to keep the workpiece against the fence faces because the bit rotation would push the workpiece away from the fence.

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Operating Instructions

FIG. 23

FIG. 24

WARNING

WORKPIECE

EXPOSED BIT

WORKPIECE

CLIMB-CUTTING

DIRECTION OF FEED

CORRECT DIRECTION OF FEED

INCORRECT

DIRECTION

For slots that require multiple passes to achieve the desired total width, make each subsequent pass using a right-to-left feed. This helps push the workpiece against the fence. Adjust the fence and workpiece for subsequent passes as follows:

- To widen the slot on the side that is on the front side (power switch side), simply move

the fence farther back as required to widen the slot.

- To widen the slot on the side that is closest to the fence, first turn the workpiece around, then move the fence farther back as required to widen the slot.

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POSITIONING THE VERTICAL

FEATHERBOARD AND BIT GUARD

The vertical featherboard

and guard are essential for proper safety and performance and must always be used (except when using the starter pin and auxiliary guard instead of the fence.)

Once the fence is secured in the desired position, do the following:

1. Place the workpiece on the table against the

fence faces near the bit.

2. Loosen the knurled steel knobs in front and

back of the raised areas of fence housing to allow the featherboard and guard to move front-to-back.

3. Move the featherboard and guard assembly

forward or back as needed so that the featherboard is centered over the cutting area. When using small bits to route the edge of the workpiece, this means the fence should be placed against or near the fence faces. For larger bits, the featherboard should be positioned farther away from the fence.

4. Tighten the four knurled steel knobs against

the fence housing.

5. Loosen the knurled knobs behind the

featherboard.

6. Press the featherboard down enough to keep

the workpiece pressed against the table and to create a slight drag on the workpiece.

7. While continuing to press down on the

featherboard, tighten the knurled steel knobs to secure the featherboard at this level.

8. Loosen the front two sets of knurled steel knobs

9. Lower the guard vertically about 1/8" above the top of the workpiece.

10. Secure the guard with the front two sets of

knurled steel knobs.

Repeat steps 1-10 after any adjustments to the bit, fence, or workpiece.

Before switching on the

router, make sure that all of the knurled steel knobs on the featherboard and guard are secured tightly so that nothing moves unexpectedly or falls into the spinning bit.

-17-

Operating Instructions

FIG. 25

WARNING

GUARD

FEATHERBOARD

FEED

DIRECTION

FENCE

FACE

WORKPIECE

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HORIZONTAL FEATHERBOARD

The horizontal featherboard greatly improves performance and should be used whenever possible (except when routing a workpiece that is too wide to use the horizontal featherboard or when using the starter pin and auxiliary guard instead of the fence). It is especially beneficial when routing small workpieces. (Fig. 26)

1. Loosen the featherboard wing knobs.

2. Move the horizontal featherboard assembly in the track until the "feathers" are centered in front of the bit.

3. Press the featherboard in against the workpiece enough to keep the workpiece pressed against the table and create a slight drag on the workpiece.

4. While continuing to press on the featherboard, tighten the small wing knobs to secure the featherboard.

Two or more horizontal featherboard assemblies placed at even intervals along the miter slot provide enhanced guidance. This is especially beneficial when routing long workpieces and/or using large bits, such as panel-raising bits. Additional featherboards fasteners are available separately.

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Operating Instructions

FIG. 26

FEATHERBOARD

FEED

DIRECTION

FENCE

FACE

WORKPIECE

FEEDING THE WORKPIECE

When using the fence, ALWAYS feed the workpiece from right to left. The correct feed direction is also shown on fence housing and on the featherboards, when they have been properly installed. (Fig. 25)

Whenever possible, use a push stick (not included) to push the workpiece, especially when working with narrow pieces.

(See "Using the Guide Pin for Edge Forming of Curves" for details on feeding when guide pin is used.)

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 keep the motor operating at high speed. Feed the workpiece at a rate that does not cause a significant change in the router RMP. Soft materials require a faster feed rated than hard materials.

The router may stall if improperly used or overloaded. Reduce feed rate to prevent possible damage to the tool.

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ON-OFF SWITCH

Your router should be turned "ON" and "OFF" using the router table switch.

This switch has a 15 amp rating is intended only for turning the router "ON" and "OFF". Do not use it to operate additional equipment, such as a vacuum cleaner.

Always keep the workpiece away from the bit when

turning the unit on or off. Contact the bit with

the workpiece only after the router has reached the full desired speed, and remove the workpiece before turning it off. Operating in this manner will prolong switch and motor life and will greatly increase the quality of your work.

Before turning the table’s switch on, make sure router’s own switch is set to its "ON" position.

TO TURN THE TOOL "ON": Lift the switch to turn the unit "ON".

TO TURN THE TOOL "OFF": Press the switch in to turn it "OFF".

When the router table is not in use, we suggest locking the switch in the off position with a lock (not included).

-19-

Operating Instructions

OFFSETTING THE OUTFEED FENCE

AND JOINERY

When trimming the entire edge of a thin workpiece, the outfeed fence face can be moved forward to provide the necessary support to prevent workpiece chatter. The outfeed fence can also be moved forward for joinery, which is the process of making flat, square and straight mating edges.

Using a router table for jointing has several advantages over other methods, such as using a freestanding power jointer, though it cannot completely replace a power jointer.

• Small and short pieces of wood can be safely and successfully routed because the opening between the faces can be adjusted down to a minimum.

• Because routers spin much faster than typical jointers, the cut quality is much better. This is especially useful on types of woods that are prone to tear-out.

Shims are provided to easily and accurately position the outfeed fence forward and to provide the necessary support.

OPTIONAL MITER GAUGE

The Bosch table saw miter gauge can also be inserted into the track in the middle of the table. (A T-slot miter gauge can also be used.) A miter guide will allow angled workpieces to be precisely guided across the table. (Fig. 27)

Do not use the miter gauge and the fence at the same

time.

FIG. 27

WARNING

FIG. 28

OFF

LOCK (NOT INCLUDED)

CAUTION

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USING THE STARTER PIN FOR

EDGE FORMING OF CURVES

The starter pin is used instead of the fence for operations that involve routing curves in the workpiece. When edge forming curves or complex shapes you must use bits that have pilot bearings.

The red insert ring has a threaded brass insert for attaching the auxiliary guard.

Attach the auxiliary guard to the mounting plate by threading a #10-32x3/8” truss head machine screw through the hole in the guard post and into the threaded insert in the red insert ring.

Align the guard with the hole in the mounting plate so it is over the bit and tighten.

• Always use the auxiliary guard when routing with the starter pin.

• When using the starter pin, the feed direction of the workpiece is always right to left across the front of the bit (Fig. 30).

• Set the workpiece against the front of the starter pin and swing it slowly into the bit.

• While routing, make sure the workpiece is always in contact with the bit’s pilot bearing.

Always use the auxiliary

guard when routing with the starter pin. Keep fingers at least 6” away from spinning bit. Do not attempt to route small workpieces. Serious injury can occur if you contact the spinning bit.

-20-

Operating Instructions

PREPARING THE ROUTER AND

TABLE FOR OFFSET OUTFEED

1. Install a 1/2" diameter straight bit or spiral bit in your router, because they are the strongest bits and have the least potential for deflecting. To further minimize the potential for deflection, use a bit with the shortest possible cutter height that is sufficient to do the job.

2. Loosen the outfeed fence knobs.

3. Slide both fence faces towards the bit to minimize the space between the faces and router bit.

4. To properly offset the outfeed fence, determine the desired offset. Two (2) 1/32" shims and four (4) 1/16" shims are included. Place the desired combination of metal shims over the outfeed fence bolts between the

fence faces and the aluminum fence. The same shim configuration must be placed behind each of the bolts.

5. Use a straight edge to ensure the front of outfeed fence face is even with the front of the router bit.

6. Tighten the fence clamping knobs. Readjust if necessary. Remove straight edge when done.

7. Tighten the vertical featherboard, bit guard, and horizontal featherboard in the proper positions.

8. Switch on the router and begin.

If the cut does not stay straight throughout the entire length of the workpiece, stop the router and realign the outfeed fence face to the router bit.

FIG. 29

WORKPIECE

FENCE FACE

TOP VIEW

FEED DIRECTION

SHIMS

OUTFEED FENCE KNOBS

OFFSET

AUXILIARY

GUARD

STARTER

FEED

DIRECTION

WORKPIECE

PILOT

BEARING BIT

WARNING

FIG. 30

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