BOSCH GKF 600 Professional Palm Router Instruction Manual

Instruction Manual

GKF 600 Professional

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Safety Notes

General Power Tool Safety

Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire, and/or serious injury.
Save all warnings and instructions for future reference.
The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.
Work area safety
▶ Keep the work area clean and well-lit. Cluttered or dark areas invite accidents.
▶ Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Power tools create sparks that may ignite dust or fumes.
▶ Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

Electrical safety

▶ Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce the risk of electric shock.
▶ Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges, and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
▶ Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
▶ Do not abuse the cord. Never use the cord for carrying, pulling, or unplugging the power tool. Keep cord away from heat, oil, sharp edges, and moving parts. Damaged or entangled cords increase the risk of electric shock.
▶ When operating a power tool outdoors, use an extension cord suitable for outdoor use. The use of a cord suitable for outdoor use reduces the risk of electric shock.
▶   If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. The use of an RCD reduces the risk of electric shock.

Personal safety
▶ Stay alert, watch what you are doing, and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol, or medication. A moment of inattention while operating power tools may result in serious personal injury.
▶ Use personal protective equipment. Always wear eye protection. Protective equipment such as dust masks, non-skid safety shoes, hard hats, or hearing protection used for appropriate conditions will reduce personal injuries.
▶ Prevent unintentional starting. Ensure the switch is in the off-position before connecting to a power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.
▶ Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.
▶ Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. Dress properly.
▶ Do not wear loose clothing or jewelry. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts.
If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. The use of dust collection can reduce dust-related hazards.

Power tool use and care
▶ Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate at which it was designed. ▶ Do not use the power tool if the switch does not turn on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
▶  Disconnect the plug from the power source and/or the battery pack from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.
▶ Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.
▶ Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
▶  Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
▶  Use the power tool, accessories and tool bits, etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.
Service
▶  Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

Safety Warnings for Routers
▶ Hold power tool by insulated gripping surfaces, because the cutter may contact its own cord. Cutting a “live” wire may make exposed metal parts of the power tool “live” and shock the operator.
▶ Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by your hand or against the body leaves it unstable and may lead to loss of control.
▶ The allowable speed of the router bit must be at least as high as the maximum speed listed on the power tool. Accessories that rotate faster than permitted can be destroyed.
▶ Router bits or other accessories must fit exactly in the tool holder (collet) of your machine. Routing bits that do not fit precisely in the tool holder of the machine rotate irregularly, vibrate heavily, and can lead to loss of control.
▶ Apply the machine to the workpiece only when switched on. Otherwise, there is a danger of kickback when the cutting tool jams into the workpiece.
▶ Never cut over metal objects, nails, or screws. The router bit can become damaged and lead to increased vibrations.
▶ Use suitable detectors to determine if utility lines are hidden in the work area or call the local utility company for assistance. Contact with electric lines can lead to fire and electric shock. Damaging a gas line can lead to an explosion. Penetrating a water line causes property damage or may cause an electric shock.
▶ Do not use blunt or damaged router bits. Blunt or damaged router bits cause increased friction, can become jammed, and lead to imbalance.
▶   Always wait until the machine has come to a complete stop before placing it down. The tool insert can jam and lead to loss of control over the power tool.

Products sold in GB only: Your product is fitted with a BS 1363/A approved electric plug with an internal fuse (ASTA approved to BS 1362).
If the plug is not suitable for your socket outlets, it should be cut off and an appropriate plug fitted in its place by an authorized customer service agent. The replacement plug should have the same fuse rating as the original plug.
The severed plug must be disposed of to avoid a possible shock hazard and should never be inserted into the main socket elsewhere.
Products sold in AUS and NZ only: Use a residual current device (RCD) with a rated residual current of 30 mA or less.

Product Description and Specifications

Read all safety warnings and all instructions.
Failure to follow the warnings and instructions may result in electric shock, fire, and/or serious injury.
While reading the operating instructions, unfold the graphics on a page for the machine and leave it open.
Intended Use
The machine is intended for routing grooves, edges, profiles, and elongated holes as well as for copy routing in wood, plastic, and light building materials while resting firmly on the workpiece.

Product Features
The numbering of the components shown refers to the representation of the power tool on the graphic pages.

1 Motor unit
2 Routing base
3 Thumbwheel for depth-of-cut fine adjustment
4 Router bit
5 Tightening nut with collet
6 Guide plate
7 Base plate
8 Scale for depth-of-cut
9 Spindle lock button
10 Clamping lever
11 On/Off switch
12 Handle (insulated gripping surface)
13 Collet
14 Tool holder
15 Open-end spanner (17 mm)| 16 Knurled screw for attachment of side stop
17 Parallel guide
18 Wing bolt for the parallel guide
19 Roller guide
20 Wing bolt for locking of the horizontal alignment
21 Wing bolt for horizontal alignment of the roller guide
22 Roller
23 Base cover sleeve
24 Tilt base
25 Wing bolt for angle adjustment
26 Scale for routing angle adjustment
27 Handle of the guide plate
28 Extraction hood
29 Extraction adapter
30 Side-handle subbase*
31 Nut for adjustment of the tensioning force
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*Accessories shown or described are not part of the standard delivery scope of the product. A complete overview of accessories can be found in our accessories program.

Technical Data

3 601 FOA 17.
Rated power input| W| 600| 600
No-load speed| min-1| 33000| 33000
Tool holder| mm
inch| 6/8
–| –
¼
Weight according to EPTA-Procedure 01/2003| kg| 1.5| 1.5
Protection class| ** /II| /II
° The** values given are valid for a nominal voltage [U] of 230 V. For different voltage and models for specific countries. these values can vary.
Please observe the article number on the type plate of your machine. The trade names of the individual machines may vary.

Noise/Vibration Information
Measured sound values were determined according to EN 60745. Typically the A-weighted noise levels of the product are Sound pressure level 84 dB(A); Sound power level 95 dB(A). Uncertainty K =3 dB.
Wear hearing protection!
Vibration total values ah (triax vector sum) and uncertainty K determined according to EN 60745: ah =4.5 m/s²  , K=1.5 m/s². The vibration emission level given in this information sheet has been measured in accordance with a standardized test given in EN 60745 and may be used to compare one tool with another. It may be used for a preliminary assessment of exposure.
The declared vibration emission level represents the main applications of the tool. However, if the tool is used for different applications, with different accessories, or poorly maintained, the vibration emission may differ. This may significantly increase the exposure level over the total working period.
An estimation of the level of exposure to vibration should also take into account the times when the tool is switched off or when it is running but not actually doing the job. This may significantly reduce the exposure level over the total working period.
Identify additional safety measures to protect the operator from the effects of vibration such as: maintaining the tool and the accessories, keeping hands warm, organize work patterns.

Declaration of Conformity
We declare under our sole responsibility that the product described under “Technical Data” is in conformity with the following standards or standardization documents:  60745 according to the provisions of the directives 2011/65/EU, 2004/108/EC, 2006/42/EC.
Technical file (2006/42/EC) at:
Robert Bosch GmbH, PT/ETM9, D-70745 Leinfelden-Echterdingen

– Unscrew the tightening nut 5 with an open-end spanner 15

Dr. Egbert Schneider
Senior Vice President
Engineering
| Dr. Eckerhard Strötgen
Engineering Director
PT/ESI

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Robert Bosch GmbH, Power Tools Division
D-70745 Leinfelden-Echterdingen
26.10.2011

Assembly

Changing the Tool
▶ Before any work on the machine itself, pull the mains plug.
▶ It is recommended to wear protective gloves when inserting or replacing router bits.
Disassembling the Routing Base (see figure A)
Before a router bit can be inserted, the routing base 2 must first be removed from motor unit 1.
– Open the clamping lever 10 and turn the routing base 2 so that the mark is in line with the symbol on the motor unit 1.
– Pull the motor unit upward to the stop.
– Turn the motor unit in an anticlockwise direction to the stop and pull it out of the routing base.

Replacing the Collet (see figure B)
Depending on the routing tool being used, the tightening nut with the collet 5 may need to be replaced before inserting the router bit.
When the right collet for your router bit is already mounted, follow the work steps as described under “Inserting a Router Bit”.
The collet 13 must have somewhat played when seated in the tightening nut. The tightening nut 5 must assemble easily.
Should the tightening nut or collet be damaged, replace it immediately.
– Push the spindle lock button 9 and keep it pressed. If required, rotate the motor spindle by hand until it locks. turning in an anticlockwise direction.
– Release the spindle lock button.
– If required, clean all parts to be mounted prior to assembling, using a soft brush or by blowing out with compressed air.
– Start the new tightening nut on tool holder 14.
– Hand-tighten the tightening nut.
▶ Do not tighten the tightening nut of the collet without a router bit inserted. Otherwise, the collet can be damaged.

Inserting a Router Bit (see figures C–D)
Depending on the application, router bits are available in the most different designs and qualities.
Router bits made of high-speed steel (HSS) are suitable for the machining of soft materials, e. g. softwood, and plastic.
Carbide tipped router bits (HM) are particularly suitable for hard and abrasive materials, e. g. hardwood and aluminum.
Original router bits from the extensive Bosch accessories program are available at your specialist shop.
Only use clean router bits that are in perfect condition.

– Push the spindle lock button 9 and keep it pressed. If required, rotate the motor spindle by hand until it locks.
– Loosen the tightening nut 5 with the open-end spanner by turning in an anticlockwise direction 15.
– Insert the router bit into the collet. The shank of the router bit must be immersed at least 20 mm into the collet.
– Retighten the tightening nut by turning in a clockwise direction.
– Release the spindle lock button.
▶ Do not tighten the tightening nut of the collet without a router bit inserted. Otherwise, the collet can be damaged.

Mounting the Routing Base (see figure E)
For routing, the routing base 2 must be mounted on motor unit 1 again.
– Release clamping lever 10 , if tightened.
– Bring the two double arrows on the motor unit and the routing base 2 into alignment.
– Push the motor unit into the routing base and turn the motor unit in a clockwise direction until the mark points against the symbol.
– Push the motor unit further into the routing base.
– After mounting is completed, turn the mark on the routing base to the symbol on the motor unit.
– Lock the clamping lever.
▶ After mounting, always check if the motor unit is seated tightly in the routing base.

If required, change the pre-tension of the clamping lever 10 (see “Readjusting the Clamping Lever”, page 17).
Dust/Chip Extraction
Dust from materials such as lead-containing coatings, some wood types, minerals, and metal can be harmful to one’s health. Touching or breathing in the dust can cause allergic reactions and/or lead to respiratory infections in the user or bystanders.
Certain dust, such as oak or beech dust, are considered carcinogenic, especially in connection with wood-treatment additives (chromate, wood preservative). Materials containing asbestos may only be worked by specialists.
– As far as possible, use a dust extraction system suitable for the material.
– Provide for good ventilation of the working place.
– It is recommended to wear a P2 filter-class respirator.
Observe the relevant regulations in your country for the materials to be worked on.

Operation

Adjusting the Depth-of-cut (see figure F)
▶ The adjustment of the depth-of-cut may only be carried out when the router is switched off.
For coarse adjustment of the depth-of-cut, proceed as follows:
– Place the machine with the router bit mounted on the workpiece to be machined.
– Release clamping lever 10 , if tightened.
– Turn the routing base 2 so that the mark points against the symbol and slowly lower the motor unit until the router bit touches the workpiece.
– Lock the clamping lever.
– Read the measuring value off the scale 8 and note it down (zeroing). Add the desired depth-of-cut to this value.
– Open the clamping lever and adjust the motor unit to the calculated scale value.
– Turn the routing base so that the mark points against the symbol and lock the clamping lever again.
– Check the carried out depth-of-cut adjustment with a trial cut and correct it, if necessary.
For fine adjustment of the depth-of-cut, proceed as follows:
– With the clamping lever 10 open, turn the routing base so that the mark points against the symbol.
– Adjust the desired depth-of-cut with thumbwheel 3.
– Lock the clamping lever.

Starting Operation

▶ Observe correct mains voltage! The voltage of the power source must agree with the voltage specified on the nameplate of the machine. Power tools marked with 230 V can also be operated with 220 V.
Switching On and Off
To start the machine, set the On/Off switch 11 to me.
To switch off the machine, set the On/Off switch 11 to 0.
Working Advice
▶ Protect router bits against shock and impact.
Shaping or Molding Applications (see figure G)
For shaping or molding applications without the use of a parallel guide, the router bit must be equipped with a pilot or a ball bearing.
– Guide the switched-on power tool from the side toward the workpiece until the pilot or the ball bearing of the router bit faces against the workpiece edge to be machined.
– Guide the machine alongside the workpiece edge. Ensure rectangular support. Excessive pressure can damage the edge of the workpiece.
Routing with Parallel Guide (see figure H)
For edge-parallel cuts, mount the parallel guide 17.
– Fasten the parallel guide 17 to the routing base 2 with the knurled screw 16.
– Adjust the desired depth setting with wing bolt 18 on the parallel guide.
– Guide the switched-on power tool with uniform feed and lateral pressure on the parallel guide alongside the workpiece edge.
Routing with Roller Guide (see figure I)
The roller guide 19 is used for routing edges with router bits without a pilot or ball bearing.
– Fasten the roller guide to the routing base 2 with knurled screw 16.
– Guide the machine with uniform feed alongside the workpiece edge.
Lateral Clearance: In order to change the amount of material removal, the lateral clearance between the workpiece and the guide roller 22 of the roller guide 19 can be adjusted.
– Loosen wing bolt 20 , adjust the desired lateral clearance by turning wing bolt 21 and tighten wing bolt 20 again.
Height: Adjust the vertical alignment of the roller guide depending on the router bit in use and the thickness of the material to be worked.
– Loosen knurled screw 16 on the roller guide, move the roller guide to the desired position and tighten the knurled screw again. Mounting the Base Cover Sleeve (see figure J) Intensive use of the power tool will cause the routing base to become hot. In this case, a base cover sleeve (accessory) can be mounted for the protection of the hands.
– Remove the clamping lever 10.
– Place the base cover sleeve 23 on the routing base 2 from above.
– Reassemble the clamping lever again in such a manner that the motor unit 1 is held securely in the routing base when the clamping lever is locked.
Routing with Tilt Base (see figures K–M)
The tilt base 24 is particularly suitable for flush routing of laminated edges at hard-to-reach locations, for routing special angles as well as for beveling edges. When beveling edges using the tilt base, the router bit must be equipped with a pilot or a ball bearing. For mounting of the tilt base, follow the work steps in the section “Mounting the Routing Base” (page 16) accordingly. To achieve precise angles, the tilt base 24 is equipped with adjustment notches in steps of 7.5°. The complete adjustment range is 75° (45° toward the front and 30° toward the rear).
– Loosen both wing bolts 25.
– Adjust the requested value using the scale 26 and tighten the wing bolts 25 again.

Changing the Guide Plate (see figure N)
The side-handle subbase 30 can be mounted in place of the guide plate 6. It offers an additional handle 12 as well as a connection possibility for dust extraction.
– Unscrew the four pan head screws on the bottom side of the guide plate 6 and remove the guide plate.
– Screw the side-handle subbase 30 to the base plate with the fastening screws provided.
In order to connect dust extraction, an extraction adapter 29 must be mounted to the side-handle subbase 30.
– Screw the extraction adapter to the guide plate with the two screws provided.
– Connect an extraction hose (Ø 35 mm) to the mounted extraction adapter.
– To ensure optimum dust extraction, the extraction adapter should be cleaned regularly.
When working edges, additionally use the extraction hood 28.
– Mount the extraction hood between the side-handle sub base 30 and the extraction adapter 29.
– Remove the extraction hood again for working smooth face surfaces.
The machine can be plugged directly into the receptacle of a Bosch all-purpose vacuum cleaner with remote starting control. The vacuum cleaner starts automatically when the machine is switched on.
The vacuum cleaner must be suitable for the material being worked. When vacuuming dry dust that is especially detrimental to health or carcinogenic, use a special vacuum cleaner.
Readjusting the Clamping Lever (see figure O)
When motor unit 1 is no longer tightly seated in the routing base, the tensioning force of the clamping lever 10 must be readjusted.
– Open the clamping lever.
– Turn nut 31 approx. 45° in a clockwise direction with an open-end spanner (size 8 mm).
– Tighten the clamping lever again.
– Check if the motor unit is clamped securely. Do not overtighten the nut.

Maintenance and Service

Maintenance and Cleaning
▶ Before any work on the machine itself, pull the mains plug.
▶ For safe and proper working, always keep the machine and ventilation slots clean.
If the replacement of the supply cord is necessary, this has to be done by Bosch or an authorized Bosch service agent in order to avoid a safety hazard.
If the machine should fail despite the care taken in manufacturing and testing procedures, repair should be carried out by an after-sales service center for Bosch power tools.
In all correspondence and spare parts orders, please always include the 10-digit article number given on the type plate of the machine.
After-sales Service and Customer Assistance Our after-sales service responds to your questions concerning maintenance and repair of your product as well as spare parts. Exploded views and information on spare parts can also be found at: www.bosch-pt.com
Our customer service representatives can answer your questions concerning possible applications and adjustments of products and accessories.

Great Britain
Robert Bosch Ltd. (B.S.C.)
P.O. Box 98
Broadwater Park
North Orbital Road
Denham
Uxbridge
UB 9 5HJ
Tel. Service: +44 (0844) 736 0109
Fax: +44 (0844) 736 0146
E-Mail: boschservicecentre@bosch.com

Ireland
Origo Ltd.
Unit 23 Magna Drive
Magna Business Park
City West
Dublin 24
Tel. Service: +353 (01) 4 66 67 00
Fax: +353 (01) 4 66 68 88

Australia, New Zealand, and Pacific Islands
Robert Bosch Australia Pty. Ltd.
Power Tools
Locked Bag 66
Clayton South VIC 3169
Customer Contact Center
Inside Australia:
Phone: +61 (01300) 307 044
Fax: +61 (01300) 307 045
Inside New Zealand:
Phone: +64 (0800) 543 353
Fax: +64 (0800) 428 570
Outside AU and NZ:
Phone: +61 (03) 9541 5555
www.bosch.com.au
Republic of South Africa
Customer service
Hotline: +27 (011) 6 51 96 00
Gauteng – BSC Service Centre
35 Roper Street, New Centre
Johannesburg
Tel.: +27 (011) 4 93 93 75
Fax: +27 (011) 4 93 01 26
E-Mail: bsctools@icon.co.za

KZN – BSC Service Centre
Unit E, Almar Centre
143 Crompton Street
Pinetown
Tel.: +27 (031) 7 01 21 20
Fax: +27 (031) 7 01 24 46
E-Mail: bsc.dur@za.bosch.com
Western Cape – BSC Service Centre
Democracy Way, Prosperity Park
Milnerton
Tel.: +27 (021) 5 51 25 77
Fax: +27 (021) 5 51 32 23
E-Mail: bsc@zsd.co.za
Bosch Headquarters
Midrand, Gauteng
Tel.: +27 (011) 6 51 96 00
Fax: +27 (011) 6 51 98 80
E-Mail: rbsa-hq.pts@za.bosch.com
Disposal
The machine, accessories, and packaging should be sorted for environmental- friendly recycling.
Do not dispose of power tools into household waste!

Only for EC countries:

According to the European Guideline 2002/96/EC for Waste Electrical and Electronic Equipment and its implementation into national  right, power tools that are no longer usable must be collected separately and disposed of in an environmentally correct manner.

Subject to change without notice

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Robert Bosch GmbH
Power Tools Division
70745 Leinfelden-Echterdingen
Germany
www.bosch-pt.com
2 610 007 835 (2011.11) O / 179 UNI

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