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The collet chuck is made up of two component parts as illustrated (Fig. 5); check to see that the collet is properly seated in the collet chuck nut and lightly thread the collet chuck back onto the armature shaft. Replace worn or damaged collet chucks immediately. FIG. 4 SHAFT WRENCH COLLET WRENCH 2" in diameter as they will not fit through the sub-base. !WARNING Cutter diameter must be at least 1/4” smaller than opening for the bit and cutter. !CAUTION To prevent damage to tool, do not tighten collet without a bit. NOTE: The bit shank and chuck should be clean and free of dust, wood, residue and grease before assembling. REMOVING THE ROUTER BIT 1. Use the shaft and collet chuck wrenches as described earlier, and turn the collet chuck assembly in a counter-clockwise direction. 2. Once the collet chuck assembly is loosened continue to turn the collet chuck assembly until it pulls the collet free from its taper, and the router bit can be removed. NOTE: The collet chuck is self-extracting; it is NOT necessary to strike the collet chuck to free the router bit. COLLET COLLET NUT FIG. 5 COLLET CHUCK -9 BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 10 REMOVING MOTOR FROM BASE To remove motor from non-plunge bases: (Fig. 6) 1. Hold router in horizontal position, open base clamp lever, depress coarse adjustment lever, and pull motor upwards until it stops. 2. Turn motor counter-clockwise, and gently pull it free of base. To remove motor from plunge base: (Fig. 7) 1. Hold router in horizontal position, open base clamp lever, and pull motor upwards until it stops. 2. Turn motor counter-clockwise, and gently pull it free of base. INSTALLING MOTOR IN BASE The motor can be installed with the switch positioned on the right or left of the base from the operator's side (and the cord facing the opposite side of the router). Install the motor so that the switch is in the location you find to be the most easily accessible from the handles. The switch should be easier to turn "OFF" than "ON" in case of an emergency. To install motor in non-plunge base: 1. Release the base clamp lever. 2. Line up the arrow on the base with arrow on the motor. (Fig. 8) •To position switch on the right side of the base, line up the base’s arrow with motor housing’s arrow that is below the cord. •To position switch on the left, line up the base’s arrow with motor housing’s arrow that is below the switch. 3. While pressing the coarse adjustment lever, slide motor into base until resistance in felt. (The base’s guide pin is now engaged into slot on motor.) 4. Continue to press coarse adjustment lever, and turn the motor clockwise until it stops. 5. Push the motor into the base until it reaches the approximate desired depth. 6. Release the coarse adjustment lever and slide the motor forward or back as needed until the coarse adjustment system’s “catch” springs into the coarse adjustment detent notch. 7. Set final height position as described below in “Operating Instructions”. To install motor in plunge base: 1. Release the base clamp lever. 2. Line up the arrow on the base with arrow on the motor. (Fig. 8) •To position switch on the right side of the base, line up the base’s arrow with arrow on the motor housing that is below the cord. BASE CLAMP LEVER FIG. 6 COARSE ADJUSTMENT LEVER ALIGNMENT ARROWS COARSE ADJUSTMENT NOTCHES MOTOR BASE FIG. 8 BASE CLAMP LEVER FIG. 7 -10 BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 11 •To position switch on the left, line up the 4. Turn the motor clockwise until it stops. base’s arrow with arrow on the motor 5. Push the motor into the base as far as it housing that is below the switch. will go. 3. Slide motor into base until resistance in 6. Fasten the base clamp lever. felt. (The base’s guide pin is now engaged into slot on motor.) INSTALLING TEMPLET GUIDE ADAPTER Place templet guide adapter over the holes in the center of the sub-base, and align the two threaded holes in the bottom of adapter with the countersunk holes in sub-base. Fasten adapter with the screws provided. Note that the adapter is reversible, so the release lever may be positioned as desired. (Fig. 9) TEMPLET GUIDE ADAPTER MOUNTING SCREWS FIG. 9 CHIP DEFLECTOR !WARNING Always wear eye protection. The chip deflector is not intended as a safety guard. The chip deflectors help keep dust and chips out of your face, it will not stop objects larger than dust thrown from the bit. To remove chip shield from bases, press inward on tabs until it releases from base and remove. To attach, place deflector into position as shown in (Fig. 10). Then flex sides of deflector while pushing until it snaps into place. The plunge base’s chip shield can also be flipped out. FIG. 10 210IN50403020100MM -11 BM 2610925542 07-06.qxp 7/24/06 12:06 PM Page 12 Operating Instructions A B FINE ADJUSTMENT DIAL BASE CLAMP LEVER COARSE ADJUSTMENT LEVER INDICATOR RING FIG. 11 CAST INDICATOR MARKS Bosch routers are designed for speed, accuracy and convenience in performing cabinet work, ...

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