RA1181 - Milling machine BOSCH - Free user manual and instructions

USER MANUAL RA1181 BOSCH

Operating/Safety Instructions Consignes de fonctionnement/sécurité Instrucciones de funcionamiento y seguridad RA1181 IMPORTANT: Read Before Using IMPORTANT : Lire avant usage IMPORTANTE: Leer antes de usar For English See page 2 Parlez-vous français? Voir page 34 ¿Habla español? Ver página 64 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.com2 Power Tool Safety Rules Table of Contents Work Area Keep your work area clean and well lit. Cluttered benchesand dark areas invite accidents.Do not operate power tools in explosive atmospheres,such as in the presence of flammable liquids, gases, ordust. Power tools create sparks which may ignite the dustor fumes.Keep bystanders, children, and visitors away whileoperating a power tool. Distractions can cause you tolose control. Electrical Safety Grounded tools must be plugged into an outlet properlyinstalled and grounded in accordance with all codesand ordinances. Never remove the grounding prong ormodify the plug in any way. Do not use any adaptorplugs. Check with a qualified electrician if you are indoubt as to whether the outlet is properly grounded.If the tools should electrically malfunction or break down,grounding provides a low resistance path to carry electricityaway from the user. Improper grounding can shock, burn,or electrocute. Grounded tools are equipped with three-conductor cord and three-prong type plugs. 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.Double-insulated tools are equipped with a polarizedplug (one blade is wider than the other.) This plug will fitin a polarized outlet only one way. If the plug does notfit fully in the outlet, reverse the plug. If it still does notfit, contact a qualified electrician to install a polarizedoutlet. Do not change the plug in any way. DoubleInsulation eliminates the need for the three-wiregrounded 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 aspipes, radiators, ranges and refrigerators. There is anincreased risk of electric shock if your body is grounded. Ifoperating the power tool in damp locations is unavoidable, aGround Fault Circuit Interrupter must be used to supply thepower to your tool. Electriciansʼ rubber gloves and footwearwill further enhance your personal safety.Donʼt expose power tools to rain or wet conditions.Water entering a power tool will increase the risk ofelectric shock.Do not abuse the cord. Never use the cord to carry thetools or pull the plug from an outlet. Keep cord awayfrom heat, oil, sharp edges, or moving parts. Replacedamaged cords immediately. Damaged cords increasethe risk of electric shock.When operating a power tool outside, use an outdoorextension cord marked “W-A” or “W.” These cords arerated for outdoor use and reduce the risk of electric shock.Refer to “Important Information About Extension Cords” inyour router table manual. Personal Safety Stay alert, watch what you are doing and use commonsense when operating a power tool. Do not use toolwhile tired or under the influence of drugs, alcohol, ormedication. A moment of inattention while operating powertools may result in serious personal injury.Keep guards in place. Maintain the guards in working orderand in proper adjustment and alignment.Avoid accidental starting. Be sure switch is “OFF”before plugging in. Carrying tools with your finger onthe switch or plugging in tools that have the switch “ON”invites accidents.Remove adjusting keys or wrenches before turningthe tool “ON.” A wrench or a key that is left attached toa rotating part of the tool may result in personal injury.Do not overreach. Keep proper footing and balanceat all times. Proper footing and balance enable bettercontrol of the tool in unexpected situations.Use safety goggles (head protection). Wear safetygoggles (must comply with ANSI Standard Z87.1) at alltimes. Wear non-slip footwear and a hard hat, if appropriate.Also, use face or dust mask if cutting operation is dustyand ear protectors (plugs or muffs) during extended periodsof operation. Tool Use and Care Use clamps or other practical way to secure andsupport the workpiece to a stable platform. Holding thework by hand or against your body is unstable and may leadto loss of control.

IMPORTANT SAFETY INFORMATION . . . 2–6

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . 7–10 Router Table Assembly . . . . . . . . . . . . 11–21 Router Table Operation . . . . . . . . . . . . 22–32 Read and understand the tool manual and these instructions for the use of this table with yourrouter. Failure to follow all instructions listed below may result in serious personal injury.

SAVE THESE INSTRUCTIONS3

Do not force tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed. Do not use tool if switch does not turn it “ON” or “OFF.” Any tool that cannot be controlled with the switch is dangerous and must be repaired. 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.

eep guards in place. Maintain the guards in working order and in proper adjustment and alignment. Store idle tools out of reach of children and other untrained persons. Tools are dangerous in the hands of untrained users. Never leave tools running unattended. Turn the power OFF. DO NOT leave tool until it comes to a complete stop. 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 damaged guards or parts, misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the toolʼs operation. If damaged, have the tool properly repaired or replaced 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. 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, and ammonia may damage plastic parts. Additional Safety Warnings for Router Tables Lift router table only by the table edges. Lifting table by any other surface could cause personal injury. Do not use the router table until all assembly and installation steps have been completed. Prior to each use, verify that fasteners and the router clamps are tight. A loose table or router is unstable and may shift in use, resulting in property damage or serious personal injury. Disconnect the router from the power supply before installing router into the table, making adjustments, changing accessories, removing the router from the table, performing maintenance, or storing the tool. Such precautionary safety measures reduce the risk of unintentional tool operation. Do not plug router motor power cord into standard wall outlet. Always plug router cord into the router table switch box. Power tool switches and controls need to be within your reach in emergency situations. Do not permit fingers to touch terminals on the plug when inserting or removing plug from the outlet. Risk of Electric Shock. Before connecting router or vacuum to router table switch box, ensure that the router or vacuum switch is off and that the router table switch box is unplugged. Such precautionary safety measures reduce the risk of unintentional tool operation. Before using the router table, verify that the router is securely clamped to the router table base. While working, periodically check the router base fastener clamping tightness. Vibrations from cutting operations can cause router motor clamps to loosen and the router motor may fall from the table. Before starting to work, ensure that the power cords from the router accessories, the switch box, and the extension cord do not and cannot come in contact with the router or any moving parts of the router. Such precautionary safety measures reduce the risk of injury due to loss of control. Do not use the router table without the overhead guard unless required by a particular cutting operation. Replace guard immediately after completion of cutting operation. Remove all dust, chips, and any other foreign particles that can affect its function. The guard will aid in keeping hands from unintended contact with the rotating bit. Do not use bits that have a cutting diameter that exceeds the clearance hole in the tabletop insert plate or insert rings. The bit could contact the insert plate or insert ring, throwing fragments. Never use dull or damaged bits. Damaged bits can snap during use. Dull bits require more force to push the workpiece, possibly causing the bit to break or the material to kick back. Handle sharp bits with care. Such precautionary safety measures reduce risk of injury. Do not alter insert ring or insert plate bit hole. Match the cutting diameter of the bit to the inner diameter of the insert ring or insert plate bit hole such that the difference is no less than 1/16 ″ on a side. Insert rings are meant to reduce the gap between the cutting diameter of the bit and the table so that workpieces maintain full support of the table while routing. Install bit in accordance with instructions in the router manual. Securely clamp the router bit in the collet chuck before making any cuts. Securing the bit before cutting reduces the risk of the bit becoming loose during operation. Never place your fingers near a spinning bit or under the guard when the router is plugged in. Such precautionary safety measures reduce the risk of injury. Never hold the workpiece on the outfeed side of the bit. Pressing the workpiece against the outfeed side of the fence may cause material binding and possible kickback, pulling your hand into the bit. Guide the workpiece with the fence to maintain control of the workpiece. Do not place the workpiece between the router bit and fence while routing the edge. This placement will cause the material to become wedged, making kickback possible. Only use routers for working with wood, woodlike products, plastic, or laminates. Do not use router and router table for cutting or shaping metals. Be sure workpiece does not contain nails or other hard objects. Cutting nails may cause loss of control of the tool or workpiece.4 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. Feed the workpiece only against the rotation of the bit. Do not “back feed” the workpiece into the bit. The bit rotates counterclockwise as viewed from the top of the table. “Back feeding” will cause the workpiece to “climb” up on the

it, pulling the workpiece and possibly your hands into the rotating bit. Do not feed the workpiece into the bit where the majority of the workpiece is between the fence and the bit. This creates a “fence trap” which is a hazardous situation due to the bit being exposed. This will cause the work to “climb-cut” away from the tabletop and may lead to loss of control during operation. Do not cut material that is warped, wobbly, or otherwise unstable. The router table is designed to cut flat, straight, and squared materials. If the material is slightly curved but otherwise stable, cut the material with the concave side against the table or fence. Cutting the material with the concave side up or away from the table may cause the warped or wobbly material to roll and kick back, causing the user to lose control. Use auxiliary infeed and outfeed supports for long or wide workpieces. Oversize workpieces without adequate support can flip off the table or cause the table to tip. Use push stick, vertically and horizontally mounted featherboards (spring sticks), and other jigs to hold down the workpiece. Push sticks, featherboards, and jigs eliminate the need to hold the workpiece near the spinning bit. Never let go of the workpiece when routing until the cut has been completed and the workpiece is completely clear of the bit. Such precautionary safety measures reduce the risk of injury and property damage. Featherboards aid in holding the workpiece in position when routing on a router table. They are not intended to hold the workpiece in place alone when the workpiece is in contact with the bit, or at any other time when the bit is turning. Always hold the workpiece against the router table fence when routing. Such precautionary measures increase accuracy in routing and improve control of the workpiece, reducing the risk of injury. Never leave the router unattended while it is running or before it comes to a complete stop. Such precautionary safety measures reduce the risk of injury and property

amage. Do not use the table as a workbench or work surface. Using it for purposes other than routing may cause damage and make it unsafe to use in routing. Never stand on the table or use as a ladder or scaffolding. The table could tip or the cutting tool could be accidentally contacted. When servicing the tool, use only recommended Bosch replacement parts. Follow instructions in the Maintenance section of this manual. Use of unauthorized parts or failure to follow maintenance instructions can result in personal injury. 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, cement, and other masonry products

• 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. Additional Safety Warnings for Router Tables5 An extension cord with adequate size conductors that is capable of carrying the current for your tool must be used. This will prevent excessive voltage drop, loss of power, or overheating. Grounded tools must use 3-wire extension cords that have 3-prong plugs and receptacles. NOTE: The smaller the gauge number, the heavier the cord.

Tool’s AmpereRatingCord Size in A.W.G.Wire Sizes in mm

Important Information About Extension Cords Improper Fence Location and Workpiece Feed Do not feed the workpiece where the majority of the workpiece is between the fence and the bit. This creates a “fence trap” which is dangerous for two reasons:

• The front of the bit is exposed during the cutting operation (Fig. A).

• The bit can “Climb-cut,” where the bit enters the

orkpiece in the same direction as the feed direction. This is likely to cause the workpiece to “climb” away from the tabletop and may lead to loss of control during operation (Fig. A). Feed the workpiece only against the rotation of the bit. Do not “back feed” the work into the bit. The bit rotates counterclockwise as viewed from the top of the table. “Back feeding” the work is dangerous for two reasons:

• It will cause climb-cutting where the workpiece can “climb” off the tabletop in the direction of the bit rotation, pulling the workpiece and possibly your hands into the rotating bit (Fig. B).

• It is difficult to keep the workpiece against the fence face as the bit rotation will push the workpiece away from the fence. FIG. A FIG. B

MPORTANT: 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)

Amperes Current Hz Hertz Frequency (cycles per second) W Watt Power kg Kilograms Weight min Minutes Time s Seconds Time Ø Diameter Size of drill bits, grinding wheels, etc. n0 No load speed Rotational speed, at no load .../min Revolutions or reciprocation Revolutions, strokes, surface speed, orbits per minute 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 Speed is increasing from 0 setting with off 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 the Canadian Standards Association. 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. This symbol designates that components of this tool are recognized by Underwriters Laboratories and recognized to Canadian Standards by Underwriters Laboratories.7 Parts List Refer to Parts List below and on pages 8–10.

• If ANY of the parts are missing, DO NOT attempt to assemble, install, or use your router table until the missing parts have been found or replaced and your router table has been properly and correctly assembled per this manual.

• For missing parts or technical assistance, call 1-877-BOSCH99 (877-267-2499).

• In order to simplify handling and to minimize any damage that may occur during shipping, your router table comes mostly unassembled. Note that the

witch box and some fasteners are preassembled to facilitate identification and installation.

• Separate all parts from the packaging materials and check each part against the illustrations and the parts lists to make sure that all parts have been included. Do this before discarding any of the packaging material. Key No. Description Quantity

Parts List Key No. Description Quantity FASTENERS (FOR TABLE ASSEMBLY)

⁄4″ Carriage Bolt (40) M4 x 20 Pan-Head Phillips Machine ScrewRouter Table Assembly HELPFUL TOOLS (not included)

• Phillips screwdriver

• Small sized adjustable wrench

⁄2″ long carriage bolts (30) through the router tabletop (1) as shown in Fig. 2.

2. Assemble the legs (6) to the router table as shown

(26) and a 1/4-20 KEPS nut (25) onto each of the bolts.

4. Securely tighten the fasteners.

NOTE: It may be easier to assemble the legs by laying the router table on its front or back, or by using adhesive tape over the carriage bolt heads to hold them in place and turning the router table upside down. FIG. 2

ASSEMBLING THE ROUTER TABLE

TABLE LEG INSERTS (Fig. 1) The router table includes two table leg inserts:

• Leg storage panel (7) for convenient storage of accessories

• Leg cord wrap panel (8) The table leg inserts must be installed before attaching the tabletop.

1. Place the table leg insert (7 or 8) into the opening in

the table leg (6) so that it is positioned at the very top of the opening.

2. Press the insert in so that it is completely flush with

3. Push the insert down as far as it will go to lock it

in place. NOTE: The cord wrap panel has two tabs at the top of the panel that lock under the table top. These tabs help prevent the panel from coming unhooked when wrapping or unwrapping the cord. FIG. 1

Router Table Assembly

ATTACH THE SWITCH/FASCIA ASSEMBLY

TO THE ROUTER TABLE (Fig. 4) NOTE: The fascia assembles to the inside of both the table legs and the router tabletop.

1. Line up the holes on the fascia panel with the holes

in the table legs and the two slots on the front of the router tabletop.

2. Attach the fascia panel to the router table top using

two #10-32 x 3/4″ truss-head machine screws (29) and two #10-32 KEPS nuts (23), toothed side out, as shown in Fig. 4.

3. Attach the fascia to the legs using four #10-32 x 3/4″

truss-head machine screws (29) and four #10-32 KEPS nuts (23), toothed side out, as shown in Fig. 4.

1. Align the two outermost holes on the top of the

switch assembly (10) with the holes in the front fascia panel (9), as shown in Fig. 3.

2. Insert two #10-32 KEPS nuts (23) into the

hex-shaped recesses in the back of the switch

ssembly (10), toothed side out, and secure the switch to the fascia panel with two #10-32 x 3/4″ truss-head machine screws (29) while holding the KEPS nuts in place in the recess with your finger.

Router Table Assembly

ASSEMBLING THE FENCE

ASSEMBLING THE FENCE (Figs. 5 and 6)

1. Insert the pins molded into the top of the vacuum

port (13) into the holes on the rear of the aluminum fence (11), as shown in Fig. 5.

2. From the underside of the fence, insert two #10-32 x

5/8″ countersunk machine screws (32) up through the holes in the bottom of the fence and vacuum port. Secure in place with two #10-32 KEPS nuts (23) (Fig. 5).

3. Place the fence (11) right-side up on a flat surface

and align the counterbored holes in the fence facings (12) with the slotted holes in the fence. The counterbored side of the facings should face OUT (Fig. 6).

4. Attach both fence facings (12) to the front of the fence,

using two 1/4-20 x 1″ carriage bolts (33) and two large clamping knobs (14) for each fence facing (Fig. 6).

5. From the front of the overhead guard (15), insert two

⁄2″ carriage bolts (30) through the holes in the guard. Slide a spacer (16) on each bolt so that the tabs on the spacers fit into the slots on the guard (Fig. 6).

6. From the front of the fence, insert the carriage bolts

through the holes in the top center of the fence. The tabs on the spacers will fit into the top channel on the fence. Secure in place with a small clamping knob (17) on each bolt (Fig. 6). NOTE: To simplify installation of the router adapter plate and router, do not install the fence onto the router table at this time.

NOTE: Two plastic jointing shims (18) are included to provide the proper fence offset when jointing. For more about jointing operations and shim placement, see page 28. FIG. 5 FIG. 6

• 1/8″ Allen wrench (31) (included)

• Phillips screwdriver (not included)

• S traight edge (not included)

• Small-sized adjustable wrench (not included) NOTE: The fences must NOT be installed on the router table for the following procedures.

1. Completely thread a #10-32 ESNA stop nut (24)

onto each of the eight #10-32 x 3/4″ countersunk socket-head screws (28) as shown in Fig. 7A. The orientation of the stop nut on the screw must be as shown in Fig. 7A. NOTE: It will be helpful to use the included Allen wrench and an adjustable wrench because the nut has tight-fitting threads.

2. Place the eight assembled screws and nuts into

the eight hex-shaped pockets in the recess on the tabletop as shown in Fig. 7B. The screw threads are to be inserted into the holes at the bottom of the pockets.

3. Place the router mounting plate into the opening

in the tabletop so that it rests on the heads of the screws as shown in Fig. 7B.

4. Position a straight edge or level across the mounting

plate as shown in Fig. 7C. The straight edge must be long enough to extend completely over the opening in the router tabletop.

5. Insert the Allen wrench through the eight round

holes in the mounting plate, engaging the hex socket in the screw heads (Fig. 7C).

6. Raise and lower the mounting plate by turning the

screws until the mounting plate is level and flush with the top of the router table.

7. Remove the mounting plate from the tabletop.

NOTE: It may be necessary to make slight adjustments after final installation of the router mounting plate. FIG. 7A

IG. 7B FIG. 7C Router Table Assembly

DETERMINE THE MOUNTING METHOD

TO BE USED (see chart on page 16) If your router model is listed in the chart on page 16, proceed to step 1 below. If it is NOT listed, you must purchase a BOSCH RA1186 Router Adapter Plate, available separately. If your router model is listed:

1. Determine the hole pattern that matches the

mounting hole pattern for your router.

2. Determine which fasteners you will need to attach

the router to the router adapter plate.

3. Determine which mount type (1 or 2) is used for your

10-32 THREADEDHOLE FOR STARTERPIN GUARDOVER-TABLE ADJUSTMENT HOLE Before using the router table, verify that the router is securely clamped to the router table base. While working, periodically check the router base fasteners clamping tightness. Router motor vibration can loosen fasteners during use, causing the router to fall from the table.

MOUNT TYPE 1 MOUNT TYPE 2 MOUNTING PLATEROUTER BASEMOUNTING PLATEROUTER BASEBefore using the router table, verify that the router is securely clamped to the router table base. While working, periodically check the router base fastenersʼ clamping tightness. Router motor vibration can loosen fasteners during use, causing the router to fall from the table.

4. Refer to the mounting plate guide (Fig. 8) on page

15 and align the appropriate mounting plate holes for your router to the router base holes. Make sure that the depth adjustment controls on the router face the front of the mounting plate. Figure 8 shows the proper orientation of the plate when installed on the table.

Securely mount your router to the mounting plate (Fig. 10). Router Table Assembly Router Router Hole Fasteners Mount Brand Model Pattern Required Type

ashers (26), and 1/4-20 nuts (25) Bosch 1617 series (fixed B #10-24 x 1/2 ″ Pan-head Phillips machine screws (37) 1 base models only) Bosch 1619EVS C #10-16 x 1/2″ Pan-head Phillips machine screws (36), 2 washers (26), and 1/4-20 nuts (25) Bosch MR Series B M4 x 20 Pan-head Phillips machine screws (40) 1 Craftsman Most Craftsman E 5/16-18 x 1/2″ Pan-head Phillips machine screws (39) 1 1/2″ collet routers DeWalt DW616, DW618 B #8-32 x 1/2″ Pan-head Phillips machine screws (38) 1 (fixed base only) Hitachi M12VC B #10-32 x 1/2″ Pan-head Phillips machine screws (35) 1 Makita RF1100, RF1101 B #10-24 x 1/2″ Pan-head Phillips machine screws (37) 1 Milwaukee 5615, 5616 B #10-24 x 1/2″ Pan-head Phillips machine screws (37) 1 Porter-Cable 690 series, B #10-24 x 1/2″ Pan-head Phillips machine screws (37) 1 7529 plunge router, and 892–895 series (fixed base only) Ryobi R161, R162, R163 E 5/16-18 x 1/2″ Pan-head Phillips machine screws (39) 1 Ryobi RE170, RE180 PL F 5/16-18 x 1/2″ Pan-head Phillips machine screws (39)* 1 Skil 1810, 1815, 1820, 1825 D #10-32 x 1/2″ Pan-head Phillips machine screws (35) 1

ATTACH ROUTER TO MOUNTING PLATE

(Figs. 9 and 10) Disconnect the router from the power supply before installing router into the table, making adjustments, changing accessories, removing the router from the table, performing maintenance, or storing the tool. Such precautionary safety measures reduce the risk of unintentional tool operation.

1. Remove the plastic subbase from your router (unless

otherwise specified in Chart 1) (Fig. 9).

• If you wish to mount the router with the subbase, you may need to purchase longer fasteners. Using the subbase affects the range of cutting depth.

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 Chart 1, determine the hardware and mount

type for your router.

• For most router models, the screws are driven into threaded holes in the routerʼs base (mount type 1).

• For some router models, the screws go all the way through the base and are fastened with washers and nuts (mount type 2).

• Competitor routers are outside of BOSCHʼs control. Changes made to these routers may affect the compatibility to the fasteners specified and/or supplied with this table.

• Always make sure the screw is fully seated on the adapter plate and that the router base is firmly against the adapter plate to ensure secure mounting. If the router, plate, and fasteners do not seat together properly, you may need to purchase new fasteners of a different length or size. REMOVESUBBASE CHART 1 *RE170 requires the subbase attached for specified fastener length.

1. Place the router mounting plate, with router

attached, on the leveling screws in the tabletop. NOTE: Be careful not to trap the cord between the

outer mounting plate and the router tabletop.

2. Recheck the router mounting plate to be sure it is

level. If necessary, adjust the leveling screws with the included Allen wrench as needed.

3. Secure the router mounting plate (3) to the table

with four #10-32 x 1″ pan-head Phillips machine screws (27) through the inner corner holes in the plate and four #10-32 ESNA stop nuts (24) from the underside of the tabletop in the recesses provided (Fig. 11). Tighten the screws snugly, but do not overtighten.

The router adapter plate features an access hole to allow use with the over-table height adjustment feature on the BOSCH 1617 series routers. Refer to your router manual for additional information on using this feature. For other brands of routers with over-table height adjustment features, it may be necessary to drill an access hole in the router mounting plate as follows:

1. Remove the subbase from the router and align

the mounting holes in the subbase with the corresponding mounting holes in the adapter plate. Be sure to orient the subbase so that the router switch will be toward the front of the table.

2. Using a pencil or centerpunch, mark the location of

the over-table height adjustment hole on the router adapter plate.

3. Remove the subbase from the adapter plate and

carefully drill the over-table height adjustment hole.

4. Make sure that the hole will accommodate the height

adjustment tool for your router. Remove any burrs or rough edges with sandpaper.

Make sure that the router is NOT plugged into a power outlet when installing into the table, removing from table, making adjustments or changing accessories. Router could accidentally start.

THE FENCE MUST BE REMOVED FROM

THE ROUTER TABLE WHEN REMOVING OR

REINSTALLING THE ROUTER MOUNTING PLATE. To remove the router without removing the mounting plate, see step 3.

1. Remove the four #10-32 x 1″ pan-head Phillips

machine screws (27) and four #10-32 ESNA stop nuts (24) holding the router mounting plate to the tabletop (Fig. 11).

2. Lift the router mounting plate and router upwards

3. Remove the pan-head Phillips machine screws

securing the router to the mounting plate.

4. When reinstalling the router mounting plate, be

sure that the plate is level with the tabletop. If needed, readjust as described above.

Router Table Assembly

ATTACHING THE FENCE TO THE TABLE

⁄4″ carriage bolts (34) up through the slots in the tabletop and the holes in the bottom of the fence. Slide a washer (26) onto each bolt and loosely attach a large clamping knob (14) onto each bolt.

2. Make sure that the fence assembly slides smoothly

from front to back. NOTE: Use the scale on the tabletop as a guide when aligning the fence for routing operations. Once the fence is positioned and aligned correctly, tighten the clamping knobs SECURELY.

1. Set the router table on a workbench or other stable

and sturdy surface, with the FRONT (switch side) of the router table facing toward you.

2. While holding the router table in the desired position,

mark the location of the four mounting holes (one in each corner).

3. Remove the router table from the workbench and set

appropriately sized hole (for machine screws) at the marked locations.

5. Place the router table on the workbench and align

the mounting holes in the router table legs with the holes drilled in the workbench.

6. Secure the router table in place using wood screws

and washers (not provided) or machine screws, washers, and nuts (not provided). If using wood screws, applying a little bar soap or bees wax to the screw threads will make it easier to thread the screws into the pilot holes.

7. TIGHTEN all screws SECURELY.

FIG. 13 MOUNTING THE ROUTER TABLE TO A WORK SURFACE OR WORKBENCH Before operating, make sure the entire unit (table with router installed) is placed on and secured to a solid, flat, level surface and will not tip. Use of auxiliary in-feed and out-feed supports is necessary for long or wide workpieces. Long workpieces without adequate support can cause the router table to tip over. HELPFUL TOOLS AND PARTS (not included)

• Phillips screwdriver

• Small-sized adjustable wrench

• Electric or hand drill with drill bits (depending on mounting method used)

• Fasteners (not included): – Four #14, #16, or #18 x 2″ pan-head wood screws (for solid wood work surfaces or workbenches), or – Four 5/16″ pan-head machine screws, washers, and hex nuts, or – C-clamps20 Router Table Assembly ALTERNATE METHOD (Figs. 15 and 16)

⁄4″ wide by 29″ long from a piece of 3/4″ thick plywood or other flat stock.

2. Set the router table on the board, with the FRONT

(switch side) of the router table facing toward you, so that the spacing between the router table legs and the edges of the board is equal on all sides.

3. While holding the router table in the desired position,

mark the location of the four mounting holes (one in each corner).

4. Remove the router table from the board and set it

5. Drill a 1/8″ pilot hole (for wood screws) at the

6. Place the router table on the board and align the

mounting holes in the router table legs with the holes drilled in the board.

7. Secure the router table in place using wood screws

and washers (not provided). Applying a little soap to the screw threads will make it easier to thread the screws into the pilot holes.

stable and sturdy surface. Firmly secure the board to the workbench with screws (Fig. 15), clamps (Fig. 16), or other suitable means. FIG. 15 FIG. 14 METHOD 2 (Fig. 14)

1. Set the router table on a workbench or other

stable and sturdy surface, with the FRONT (switch side) of the router table facing toward you.

2. Secure the router table legs to the workbench with

clamps, making sure to tighten them SECURELY. IMPORTANT: Be sure the placement of the clamps will not interfere with operation of the router table. 3/4

THICK BOARD21 Router Table Assembly Disconnect the router from the power supply before installing router into the table, making adjustments, changing accessories, removing the router from the table, performing maintenance, or storing the tool. Such

recautionary safety measures reduce the risk of unintentional tool operation. TABLETOP INSERT RINGS (Fig. 17) This router table includes three insert rings with the following hole sizes: (3) 1″ in diameter, for use with bits with diameters up to 7/8″ (4) 2″ in diameter, for use with bits with diameters up to 1

⁄4″ in diameter, for use with bits with diameters up to 2

⁄8″ No insert ring is used for bits with diameters over 2

⁄2″. Do not use the router table with bits over 3½

in diameter. Bits larger than 3½

exceed the clearance hole in the tabletop insert rings. Bits larger than 3½″ can contact insert plate or insert ring, throwing fragments. Do not alter tabletop insert ring or insert plate bit hole. Match the cutting diameter of the bit to the inner diameter of the insert ring or insert plate bit hole such that the difference is no less than 1/16

on a side. Insert rings are meant to reduce the gap between the cutting diameter of the bit and table so that workpieces maintain full support of the table while routing.

1. Select the insert ring (3–5) that best accommodates

the router bit to be used.

2. Press the insert ring (3–5) into the large hole in the

router mounting plate (2). If the fence is in the way, loosen the clamping knobs on the fence support brackets and slide the fence back out of the way.

3. Press down evenly over the tabs until the insert ring

(3–5) locks into place.

4. To remove, pull up gently until the tabs disengage.

When not in use, store inserts rings (3–5) behind the storage panel (7) in the table leg or in another convenient place. Do not use, attempt to change, or remove tabletop insert rings from the tabletop unless the router is off and unplugged. Such precautionary safety measures reduce the risk of unintentional tool operation.

Do not plug router motor power cord into standard wall outlet. It must be plugged into the router table switch. Power tool switches and controls need to be within your reach in emergency situations. GENERAL INFORMATION The power switch is designed for use with most BOSCH Router Tables. It provides the convenience of an ON (RESET)-OFF switch at the front of the table, thus eliminating the need to reach underneath the table to turn the router ON and OFF. The power switch also provides an optional simultaneous ON-OFF control of an additional accessory, such as a light, wet/dry vac, etc. The switch has an internal, resettable circuit breaker to provide overload protection. ELECTRICAL REQUIREMENTS The switch box cord should only be plugged into a 14-gauge (or heavier), three-wire extension cord with a three-hole grounding receptacle and three-prong grounding plug. The extension cord must be plugged into a matching outlet that has been installed by a licensed electrician and grounded in accordance with all local codes and ordinances.

DAMAGED OR WORN EXTENSION CORDS ARE

NOT TO BE USED AND ARE TO BE REPLACED IMMEDIATELY. The electrical outlets at the back of the switch box will accept three-hole extension cords. The electrical receptacles at the back of the switch box will accept either three-prong or two-prong plugs from a router or accessory. In the event of a malfunction or breakdown, grounding provides the path of least resistance for electrical current in order to reduce the risk of electrical shock. This switch box is equipped with an electrical cord that has an equipment-grounding connector and a grounding plug. DO NOT modify the plug from the switch if it does not plug into the extension cord. Obtain an extension cord with the proper outlet. Improper connection of the equipment-grounding conductor can result in risk of an electrical shock. The conductor with insulation that has a green outer surface, with or without yellow stripes, is the equipment- grounding conductor.

Router Table Operation

DO NOT CONNECT THE EQUIPMENT-GROUNDING

CONDUCTOR TO A LIVE TERMINAL. Check with a licensed electrician if the grounding instructions are not completely understood or if there is doubt as to whether the electrical outlet or extension cord is properly grounded. Do not permit fingers to touch terminals of the plug when inserting or removing the plug from the outlet. Risk of Electric Shock. Use the switch box only when properly assembled to the router table. Use only with a router that has also been properly installed on a properly assembled router table. Such precautionary safety measures reduce the risk of injury due to loss of control. Do not exceed a total combined rating of 15 amps when connecting the router and any accessories such as a light or wet/dry vacuum. The switch has a rating of 15 amps.

Before connecting router to router table switch box, ensure that the router switch is OFF, and that the router table switch box is unplugged. Such precautionary safety measures reduce the risk of unintentional tool operation.

1. Plug the router power cord into one of the electrical

outlets on the back of the switch box (10).

2. Form the excess power cord into a coil.

3. Wrap two pieces of friction tape or strong cord around

the coiled cord at opposite sides of the coil.

4. Allow some slack so that the cord does not become

stretched when it is plugged into the switch box outlets.

5. If desired, at this time plug the power cord from

an accessory, such as a wet/dry vac or light, into the other outlet. Before starting to work, ensure that the power cords from the router, accessories, the switch case, and the extension cord do not and cannot come in contact with the router or any moving parts of the router. Such precautionary safety measures reduce the risk of injury due to loss of control.23 Router Table Operation SWITCH OPERATION (Fig. 18) This section explains the operation and features of the switch box assembly prior to plugging the power cord into a power outlet. The intent is to familiarize the user with the switch operation without actually turning ON the router. The switch box (10) (Fig. 18) incorporates a lockout key (10A) to help prevent unauthorized use by others.

• The lockout key (10A) is the yellow part in the top of the red plastic paddle. The yellow lockout key must be completely inserted into the top of the red plastic paddle and switch box (10) before the paddle can be turned ON.

• The circuit reset button for the switch box (10) is on the bottom right side of the box. Make sure that the extension cord is not plugged into an electrical outlet before proceeding any further.

1. Make sure the yellow lockout key (10A) is completely

inserted in the top of the red plastic paddle. Red plastic paddle (ON/OFF switch) FIG. 18

4. To prevent unauthorized use, the switch can be

disabled by removing the yellow lockout key (10A) completely from the top of the red plastic paddle.

2. To turn the router ON, lift the red plastic paddle up to

3. To turn the router OFF, press the red plastic paddle to

INSTALLING AND USING A WET/DRY

VACUUM Before connecting vacuum to router table switch box, ensure that the vacuum switch is OFF, and that the router table switch box is unplugged. Such precautionary safety measures reduce the risk of unintentional tool operation. Do not exceed a total combined rating of 15 amps when connecting the router and any accessories such as a light or wet/dry vacuum. The switch has a rating of 15 amps. The guard/dust collector assembly has a port for connecting a wet/dry vac hose with a 2

⁄2″ nozzle. To attach, simply push the nozzle into the port while holding the fence assembly in place. Operating the router table without a wet/dry vacuum can result in an excessive buildup of sawdust and wood chips under the fence assembly and guard, reducing the performance of the router table and fence assembly. RECOMMENDATION: To maximize performance, regardless of whether a wet/dry vac is being used, remove the sawdust and wood chips from under the fence assembly and overhead guard as needed. RECOMMENDATION: It is always a good practice to keep the work area clean. As necessary, remove any accumulated sawdust and wood chips from the top of the router table, as well as from the surrounding work area and floor. Never place your fingers near a spinning bit or under the guard when the router is plugged in. Such precautionary safety measures reduce the risk of personal injury. Before proceeding any further, make sure the switch on the router is in the OFF position and the switch lever is in the OFF position. Never leave the router unattended while it is running or before it comes to a complete stop. Before starting to work ensure that the power cords from the router, accessories, the switch case, and the extension cord do not and cannot come in contact with the router or any moving parts of the router. Such precautionary safety measures reduce the risk of injury due to loss of control. The switch power cord can now be plugged into the extension cord.

ROUTER AND SWITCH OPERATION

This section explains operation of the switch with the power cord plugged into the extension cord. The router will turn ON when the red paddle on the switch box is pulled up to the ON position.

1. Position the ON/OFF switch on the router in the ON

position. On certain routers this will require the use of the switch trigger and “LOCK-ON” button. (Consult router ownerʼs manual.) Make sure the switch on the switch case is in the OFF position when doing this.

2. To turn the router ON, pull up the red paddle to the

ON position. See page 23.

3. To turn the router OFF, press the red paddle to the

NOTE: In the event of an overload, the internal switch circuit breaker will trip the switch to the OFF position. This will interrupt power to the router and any accessory plugged into the switch itself. If this occurs, proceed as follows:

1. Push the red plastic paddle to the OFF position and unplug

the switch cord from the wall outlet or extension cord.

2. Turn router switch to OFF position.

3. Remove the workpiece from the router table.

4. Correct the cause of the overload situation. For

example, if too many accessories are plugged into the switch, or combined amperage exceeds the switch rating, remove the accessory. Other causes include the removal of too much stock or use of too high a feed rate.

5. Press the circuit reset button on the bottom of the

6. Plug the switch power cord into the wall outlet or

7. Restart the router as described in the section

ROUTER AND SWITCH OPERATION on this page. If the switch case does not work and you have tried to RESET the circuit reset button as described above:

• Unplug ALL electrical connections.

• Remove the switch from the router table and obtain a replacement switch by calling BOSCH customer service at 1-877-BOSCH99. WHEN THE ROUTER TABLE IS NOT IN USE

1. Make sure the switch is in the OFF position.

2. Remove the lockout key (10A). See page 23.

3. Store the lockout key in a safe location

where it is not available to children and other unauthorized persons.

4. Unplug the switch power cord from the wall outlet or

5. Remove the router bit from the router.

6. Position the router collet assembly below the top of

the router table. NOTE: If the key should become lost or damaged, replacement keys are available by calling BOSCH customer service at 1-877-BOSCH99. Router Table OperationRouter Table Operation INSTALLING THE ROUTER BIT (CUTTER) Disconnect the router from the power supply before making adjustments or changing accessories. Such precautionary safety measures reduce the risk of unintentional tool operation. Install the router bit according to the instructions included with your router. Because of the large variation of router bits, certain router bits may not always operate in the desired manner with this router table. To ensure that the most popular bits will perform satisfactorily, install the bit so that the router collet engages 3/4″ of the router bit shank. If the shank of the router bit bottoms out in the collet, back out the router bit approximately 1/16″ to allow for proper tight- ening. NEVER INSTALL ROUTER BITS WITH LESS THAN 3/4

ASSEMBLING THE FEATHERBOARDS

(Figs. 19–21) NOTE: The top/front side of each featherboard is marked to indicate proper feed direction. Fence Featherboard (Figs. 19 and 20)

⁄2″ carriage bolts (30) through the slotted holes in the featherboard (19). See Fig. 19.

2. Slide a large washer (26) onto each carriage bolt

and thread a small clamping knob (17) three or four turns onto each carriage bolt.

3. To install on the fence, slide a spacer (16) over

the head of each carriage bolt, aligning the tabs on the spacer with the slot in the featherboard (Fig. 20). Then slide the carriage bolt heads into the T-slot on the top of the fence. Tabletop Featherboard (Fig. 21)

⁄2″ carriage bolts (30) through the slotted holes in the featherboard (19).

2. Slide a large washer (26) onto each carriage bolt

and thread a small clamping knob (17) three or four turns onto each carriage bolt.

3. To install the featherboard in the miter channel on

the tabletop, insert the heads of the carriage bolts into the desired pair of keyhole slots on the tabletop (located in the miter channel). Then tighten the clamping knobs securely. FIG. 19 FIG. 20 FIG. 21

Router Table Operation

ROUTING USING FEATHERBOARDS

(Fig. 22) Featherboards are helpful in controlling the workpiece while routing and assist in keeping the workpiece flat on the tabletop. The table featherboard, combined with

he fence featherboard, helps keep the workpiece pressed against the fence and tabletop. The best location for the featherboards varies according to your application, workpiece size, and other factors.

1. Loosely install the featherboard(s) as described

2. Place the workpiece on the router table so that it is

squarely against the fence.

3. Position the featherboard so that the featherboard

is snug against the workpiece and tighten the clamping knobs.

4. The workpiece should move with some resistance

but without requiring a great effort.

5. For wider workpieces, the tabletop featherboard

cannot be used. The second featherboard may also be positioned on the fence, if desired. Additional featherboards, model RA1187, can be purchased from your Bosch retailer. Never let go of the workpiece when routing until the cut has been completed and the workpiece is completely clear of the bit. Such precautionary safety measures reduce the risk of personal injury and/or property damage.

• Featherboards aid in holding the workpiece in position when routing on a router table.

• They are NOT intended to hold the workpiece in place alone when the workpiece is in contact with the bit, or at any other time when the bit is turning. For accuracy in routing and improved control, the workpiece should be held against the router table fence when routing. ADJUSTING THE FENCE FACING (Fig. 23) The right and left fence facings are attached to the front face of the router table fence and can be adjusted inward or outward from the router bit to allow proper clearance for different-sized bits. To provide the best support during routing operations, the fence facings should be as close to the bit as possible without being able to come in contact with the bit (typically about 1/4″ from the bit is a suitable distance).

1. Loosen the two clamping knobs on the backs of

the fence facings and slide the facings inward or outward from the router bit as needed. Always hold the workpiece against the router table fence when routing. Such precautionary safety measures increase the accuracy in routing and improve the control of the workpiece, reducing the risk of personal injury.

2. Once the fence facings are in the desired position,

tighten the clamping knobs SECURELY. DIRECTION OF FEED FIG. 23 FIG. 2227 Router Table Operation

ADJUSTING DEPTH AND HEIGHT OF CUT

1. Select a board that is smooth and straight, with good

2. Mark lines “A” and “B” on the end of the board, as

• Line “A” indicates the desired height of cut.

• Line “B” indicates the desired final depth of cut.

• The area outlined by “A,” “B,” and the edge of the board is the area that will be cut away.

3. Following the instructions that came with your router,

adjust the router height of cut until the top of the router bit lines up with line “A.”

4. If the desired depth of cut can be cut in a single

pass, loosen the fence clamping knobs and move the fence forward or backward until the outermost cutting edge of the router bit is aligned with line “B.” It may be necessary to reposition the guard to provide clear access. NOTE: For deeper cuts, do NOT attempt to make the cut in a single pass. Make multiple shallower passes, progressively moving the fence backward until the desired depth of cut is reached.

5. Use the scales on the tabletop as a guide to align

the fence; then SECURELY tighten both fence clamping knobs. Always make sure that the fence and guard cannot come in contact with the router bit. Failure to do so will result in damage to the router table and can cause personal injury.

6. Once all adjustments have been made,

• The router is SECURELY tightened in the router base.

• The router bit is SECURELY tightened in the router collet, with at least 3/4 ″ shank engagement.

• The router base is SECURELY tightened to the router mounting plate.

7. Remove the board from the table.

NOTE: When making adjustments, use a piece of scrap wood to make trial cuts before making the cut with the actual workpiece.

AREA OFDETAIL 24SCRAP WOOD

B28 Router Table Operation

FULL EDGE CUTTING OR JOINTING

(Figs. 25 and 26) For maximum strength and accuracy, boards that are to be joined together should be smooth and true. The edges should be true to the workpiece surface.

ou can true the edges using the router table with a straight bit. NOTE: Use the jointing shim(s) to provide continuous support for the workpiece as it is fed past the router bit. Always make sure that the fence and guard cannot come in contact with the router bit. Failure to do so will result in damage to the router table and can cause personal injury.

1. Loosen the clamping knobs on the left fence facing.

2. Align the slot in the jointing shim(s) with the holes

in the fence facing, and slide the jointing shim(s) between the fence and the left fence facing (Fig. 25). Use one jointing shim for a 1/16″ offset, or both jointing shims for a 1/8″ offset.

3. Install a straight bit in the router.

4. Position both fence facings so that they clear the bit

5. Tighten the four clamping knobs holding the fence

on the table so that it rests against the left fence facing.

7. Move the fence back until the straight edge lines up

with the cutting edge of the bit and is still in contact with the left fence facing.

10. Adjust the height of the bit so that it will cut the

complete thickness of the workpiece.

12. Remove the board from the table and lower the

overhead guard to the operating position. Tighten the guard clamping knobs SECURELY. NOTE: When making adjustments, use a piece of scrap wood to make trial cuts before making the cut with the actual workpiece.

13. Make sure that both the router and switch box are

OFF; then plug the router into the switch box.

14. While firmly holding a piece of scrap wood against

the fence and down against the router table, feed a piece of scrap wood toward the bit in the direction shown by the arrow in Fig. 26.

15. Using the switch box, turn the router OFF. If any

adjustments are needed, unplug the power cord and repeat steps 6–11 until all adjustments are correct. Once you are satisfied with all settings, make the cut with the actual workpiece. WORKPIECE JOINTING SHIM(S)

IG. 25 FIG. 26Router Table Operation

ROUTER BITS (Figs. 27 and 28) Disconnect the router from the power supply before making adjustments or changing accessories. Such precautionary safety measures reduce the risk of unintentional tool operation. NOTE: If the jointing shim is installed, remove it before proceeding. When using NONPILOTED router bits, the fence is used to set the depth of cut. For deep cuts, do not try to cut the total depth all in one pass. Repeat the cut, taking multiple smaller cuts.

1. Install the desired bit in the router.

2. Follow the instructions on page 27 to set the desired

depth of cut and height of cut (Fig. 27). Make sure that the fence and router are SECURELY in place.

3. Position both fence facings so that they clear the bit

4. Tighten the four clamping knobs holding the fence

5. Position the featherboards, if desired. See

ROUTING USING FEATHERBOARDS on page 26.

6. Remove the board from the table and lower the

overhead guard to the operating position. Tighten the guard clamping knobs SECURELY. NOTE: When making adjustments, use a piece of scrap wood to make trial cuts before making the cut with the actual workpiece.

7. Make sure that both the router and switch box are

OFF; then plug the router into the switch box.

8. While firmly holding a piece of scrap wood against

the fence and down against the router table, feed a piece of scrap wood toward the bit in the direction shown by the arrow in Fig. 28.

9. Using the switch box, turn the router OFF. If any

adjustments are needed, unplug the power cord and repeat steps 2–8 until all adjustments are correct. Once you are satisfied with all settings, make the cut with the actual workpiece. WORKPIECE FENCE FACING ROUTER BIT

BITS (Figs. 29 and 30) Disconnect the router from the

ower supply before making adjustments or changing accessories. Such precautionary safety measures reduce the risk of unintentional tool operation. NOTE: If the jointing shim is installed, remove it before proceeding.

1. Install the desired piloted bit in the router.

2. Follow the instructions on page 27 to set the desired

height of cut (Fig. 29). Make sure that the router is SECURELY in place.

3. Adjust the router table fence back just enough that

the pilot on the router bit will control the depth of cut. The router bit pilot should just barely protrude past the fence facings. Tighten the fence clamping knobs SECURELY.

4. Position both fence facings so that they clear the bit

5. Tighten the four clamping knobs holding the fence

6. Remove the board from the table and lower the

overhead guard to the operating position. Tighten the guard clamping knobs SECURELY. NOTE: When making adjustments, use a piece of scrap wood to make trial cuts before making the cut with the actual workpiece.

7. Make sure that both the router and switch box are

OFF; then plug the router into the switch box.

8. While firmly holding a piece of scrap wood against

the fence and down against the router table, feed a piece of scrap wood toward the bit in the direction shown by the arrow in Fig. 30.

9. Using the switch box, turn the router OFF. If any

adjustments are needed, unplug the power cord and repeat steps 2–8 until all adjustments are correct. Once you are satisfied with all settings, make the cut with the actual workpiece. PILOTED ROUTER BIT

(Figs. 31 and 32) Disconnect the router from the power supply before making adjustments or changing accessories. Such precautionary safety measures reduce the risk of unintentional tool operation. NOTE: If the jointing shim is installed, remove it before proceeding. When performing these routing operations, the use of featherboards and a push shoe is recommended. For best results and maximum accuracy, the side of the workpiece that will be against the fence must be square and straight. If you are using a wet/dry vac, it should be connected to the vac port on the back of the table cabinet.

1. Install the desired end-cutting bit in the router.

2. Follow the instructions on page 27 to set the desired

depth of cut (location of cut) and height of cut (Fig. 31). Make sure that the fence and router are SECURELY in place. IMPORTANT: For deep cuts, do not try to cut the total depth (controlled by the router bit height) all in one pass. Repeat the cut, taking smaller cuts until the desired depth is reached.

3. Position both fence facings so that they provide

continuous support of the workpiece.

4. Tighten the four clamping knobs holding the fence

5. Position the featherboards, if desired. See

ROUTING USING FEATHERBOARDS on page 26.

6. Remove the board from the table and lower

the overhead guard to the operating position. Tighten the guard clamping knobs SECURELY. NOTE: When making adjustments, use a piece of scrap wood to make trial cuts before making the cut with the actual workpiece.

7. Make sure that both the router and switch box are

OFF; then plug the router into the switch box.

8. While firmly holding a piece of scrap wood against

the fence and down against the router table, feed a piece of scrap wood toward the bit in the direction shown by the arrow in Fig. 32.

9. Using the switch box, turn the router OFF. If any

adjustments are needed, unplug the power cord and repeat steps 2–8 until all adjustments are correct. Once you are satisfied with all settings, make the cut with the actual workpiece. FENCE FACING END CUTTING ROUTER BIT

IG. 31 FIG. 3232 Router Table Operation The starter pin (20) is used instead of the fence for operations that involve routing curves in the workpiece. It should be used only with bits that have pilot bearings. Thread the starter pin into the threaded hole in the mounting plate and tighten securely with a slotted screwdriver (Fig. 33). Attach the starter pin guard (21) to the mounting plate by threading a #10-32 x 3/8″ truss-head machine screw (22) through the hole in the guard post and into the threaded hole in the mounting plate. Align the guard with the hole in the mounting plate so it is over the bit and securely fasten the guard in place.

• Always use the starter pin 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. 34).

• 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 bitʼs pilot bearing. Use starter pin guard for this type of operation. Do not attempt to rout very small workpieces. Keep fingers clear of spinning bit. FIG. 33 USING THE STARTER PIN FOR EDGE FORMING OF CURVES USING A MITER GAUGE (not supplied) The aluminum miter gauge slot may be used with most stationary table saw miter gauges that measure 3/4″ wide x 3/8″ deep. NOTE: For ALL routing operations requiring the use of the miter gauge with the fence, BE SURE to align the fence using the scales on the top of the router table before making any cuts. Miters can be cut by loosening the knob on the protractor head, turning the protractor head up to 60° in either direction and retightening the protractor head knob. MITERGAUGE FIG. 35 FIG. 34 STARTER PIN

Tool’s Ampere RatingCord Size in A.W.G.Wire Sizes in mm2 3-6 6-8