Bosch 1660 User Manual

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2610914527 3/03

3/18/03

10:47 AM

Page 1

 

 

IMPORTANT:

IMPORTANT :

IMPORTANTE:

 

Read Before Using

Lire avant usage

Leer antes de usar

 

 

Operating/Safety Instructions

 

 

Consignes de fonctionnement/sécurité

 

 

Instrucciones de funcionamiento

 

 

y seguridad

 

 

 

1660

 

 

 

 

 

1662

 

 

 

 

 

 

 

Consumer Information

 

 

Renseignement des consommateurs

 

 

Información para el consumidor

 

Toll Free Number:

Appel gratuit :

Número de teléfono gratuito:

 

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

 

For English

 

Parlez-vousfrançais?

¿Habla español?

 

See page 2

 

Voir page 16

Ver página 30

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General Safety Rules

 

 

For All Battery Operated Tools

 

 

 

 

 

Read and understand all instructions. Failure to follow all instructions listed

 

! WARNING

 

below, may result in electric shock, fire and/or serious personal injury.

 

 

 

 

SAVE THESE INSTRUCTIONS

Work Area

Keep your work area clean and well lit.

Cluttered benches and dark areas invite accidents.

Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Power tools create sparks which may ignite the dust or fumes.

Keep by-standers,children, and visitors away while operating a power tool.

Distractions can cause you to lose control.

Electrical Safety

Do not abuse the cord. Never use the cord to carry the tool. Keep cord away from heat, oil, sharp edges, or moving parts. Replace damaged cords immediately. Damaged cords may create a fire.

A battery operated tool with integral batteries or a separate battery pack must be recharged only with the specified charger for the battery. A charger that may be suitable for one type of battery may create a risk of fire when used with another battery.

Use battery operated tool only with specifically designated battery pack. Use of any other batteries may create a risk of fire.

Personal Safety

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

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

Avoid accidental starting. Be sure switch is in the locked or off position before inserting battery pack. Carrying tools with your finger on the switch or inserting the battery pack into a tool with the switch on invites accidents.

Remove adjusting keys or wrenches before turning the tool on. A wrench or a key that is left attached to a rotating part of the tool may result in personal injury.

Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enable better control of the tool in unexpected situations.

Use safety equipment. Always wear eye protection. Dust mask, non-skid safety shoes, hard hat, or hearing protection must be used for appropriate conditions.

Tool Use and Care

Use clamps or other practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control.

Do not force tool. Use the correct tool for your application. The correct tool will do 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. A tool that cannot be controlled with the switch is dangerous and must be repaired.

Disconnect battery pack from tool or place the switch in the locked or off position before making any adjustments, changing accessories, or storing the tool.

Such preventive safety measures reduce the risk of starting the tool accidentally. Store idle tools out of reach of children and other untrained persons. Tools are dangerous in the hands of untrained users.

When battery pack is not in use, keep it away from other metal objects like: paper clips, coins, keys, nails, screws, or other

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! DANGER

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small metal objects that can make a connection from one terminal to another.

Shorting the battery terminals together may cause sparks, burns, or a fire.

Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools with sharp cutting edge are less likely to bind and are easier to control.

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

Use only accessories that are recommended by the manufacturer for your

model. Accessories that may be suitable for one tool may create a risk of injury when used on another tool.

Service

Tool service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel may result in a risk of injury.

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

Use of unauthorized parts or failure to follow Maintenance Instructions may create a risk of shock or injury.

Safety Rules for Circular Saws

Keep hands away from cutting area and blade.

Keep your second hand on auxiliary handle, or motor housing. If both hands are holding the saw, they cannot be cut by the blade. Hold the saw firmly to prevent loss of control. Figures in this manual illustrate typical hand support of the saw. NEVER place your hand behind the saw blade since kickback could cause the saw to jump backwards over your hand.

Keep your body positioned to either side of the saw blade, but not in line with the saw blade. KICKBACK could cause the saw to jump backwards. (See “Causes and Operator Prevention of Kickback.”)

Do not reach underneath the work. The guard cannot protect you from the blade below the work. Do not attempt to remove cut material when blade is moving.

Check lower guard for proper closing before each use. Do not operate saw if lower guard does not move freely and close instantly. Never clamp or tie the lower guard into the open position. If saw is accidentally dropped, lower guard may be bent. Raise the lower guard only with the Lower Guard Lift Lever and make sure it moves freely and does not touch the blade or any other part, in all angles and depths of cut.

Check the operation of the lower guard spring. If the guard and the spring are not operating properly, they must be serviced

before use. Lower guard may operate sluggishly due to damaged parts, gummy deposits, or a buildup of debris.Disconnect battery pack from tool. Periodically remove the blade, clean the upper, lower guards and the hub area with kerosene and wipe it dry, or blow it clean with compressed air.

Lower guard should be retracted manually only for special cuts such as “Pocket Cuts” and “Compound Cuts”. Raise lower guard by Lower Guard Lift Lever. As soon as blade enters the material, lower guard must be released. For all other sawing, the lower guard should operate automatically.

Always observe that the lower guard is covering the blade before placing saw down on bench or floor. An unprotected, coasting blade will cause the saw to walk backwards, cutting whatever is in its path. Be aware of the time it takes for the blade to stop after switch is released.

NEVER hold piece being cut in your hands or across your leg. It is important to support the work properly to minimize body exposure, blade binding, or loss of control.

Hold tool by the insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or it own cord. Contact with a "live" wire will also make exposed metal parts of the tool “live” and shock the operator.

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When ripping always use a rip fence or straight edge guide. This improves accuracy of cut and reduces the chance for blade binding.

Always use blades with correct size and shape (diamond vs. round) arbor holes.

Blades that do not match the mounting hardware of the saw will run eccentrically, causing loss of control and will not allow proper vari-torqueengagement.

Never use damaged or incorrect blade washers or bolts. The blade washers and bolt were specially designed for your saw, for optimum performance and safety of operation.

The blade washers and the bolt on your saw have been designed to work as a “VARITORQUE CLUTCH”. Understand the operation and settings of the VARI-TORQUECLUTCH, because the proper setting of the CLUTCH, combined with firm handling of the saw will allow you to control KICKBACK.

Do not run the saw while carrying it at your side. Lower guard may be opened by a contact with your clothing. Accidental contact with the spinning saw blade could result in serious personal injury.

Depending upon use, the switch may not last the life of the saw. If the switch should fail in the “OFF” position, the saw may not start. If it should fail while the saw is running, the saw may not shut off. If either occurs, remove battery pack from saw immediately and do not use until repaired.

This circular saw should not be mounted to a table and converted to a table saw.

Circular saws are not designed or intended to be used as table saws.

CAUSES AND OPERATOR PREVENTION OF

KICKBACK:

Kickback is a sudden reaction to a pinched, bound or misaligned saw blade, causing an uncontrolled saw to lift up and out of the workpiece toward the operator.

When the blade is pinched or bound tightly by the kerf closing down, the blade stalls and the motor reaction drives the unit rapidly back toward the operator.

If the blade becomes twisted or misaligned in the cut, the teeth at the back edge of the blade can dig into the top surface of the wood causing the blade to climb out of the kerf and jump back toward the operator.

Kickback is the result of tool misuse and/or incorrect operating procedures or conditions

and can be avoided by taking proper precautions as given below:

KICKBACK

Maintain a firm grip with both hands on the saw and position your body and arm to allow you to resist KICKBACK forces.

KICKBACK forces can be controlled by the operator, if proper precautions are taken.

When blade is binding, or when interrupting a cut for any reason, release the trigger and hold the saw motionless in the material until the blade comes to a complete stop. Never attempt to remove the saw from the work or pull the saw backward while the blade is in motion or KICKBACK may occur. Investigate and take corrective action to eliminate the cause of blade binding. Wet lumber, green lumber or pressure treated lumber require special attention during cutting operation to prevent KICKBACK. Avoid cutting nails. Inspect for and remove all nails from lumber before cutting.

When restarting a saw in a workpiece, center the saw blade in the kerf and check that saw teeth are not engaged into the material. If saw blade is binding, it may walk up or KICKBACK from the workpiece as the saw is restarted.

Support large panels to minimize the risk of blade pinching and KICKBACK. Large panels tend to sag under their own weight. Supports must be placed under the panel on both sides, near the line of cut and near the edge of the panel. See “Cutting Large Sheets” in this manual.

Do not use dull or damaged blade.

Unsharpened or improperly set blades produce narrow kerf causing excessive friction, blade binding and KICKBACK.

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! WARNING

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Blade depth and bevel adjusting locking knobs must be tight and secure before making cut. If blade adjustment shifts while cutting, it may cause binding and KICKBACK.

Using the saw with an excessive depth of cut setting increases loading on the unit and susceptibility to twisting of the blade in the kerf. It also increases the surface area of the blade available for pinching under conditions of kerf close down.

Use extra caution when making a “Pocket Cut” into existing walls or other blind areas.

The protruding blade may cut objects that can cause KICKBACK.

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-basedpaints,

Crystalline silica from bricks and cement and other masonry products, and

Arsenic and chromium from chemicallytreated 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.

This product is intended to cut wood and wood-likeproducts only. Dust build up around the lower guard and hub from other materials (plastic, masonry or metal) may disable the lower guard operation.

Battery/Charger

Before using battery charger, read all instructions and cautionary markings on

(1) battery charger, (2) battery pack, and

(3) product using battery.

Use only the charger which accompanied your product or direct replacement as listed in the catalog or this manual. Do not substitute any other charger. Use only Bosch approved chargers with your product. See Functional Description and Specifications.

Do not disassemble charger or operate the charger if it has received a sharp blow, been dropped or otherwise damaged in any way. Replace damaged cord or plugs immediately. Incorrect reassembly or damage may result in electric shock or fire.

Do not recharge battery in damp or wet environment. Do not expose charger to rain or snow. If battery case is cracked or otherwise damaged, do not insert into charger. Battery short or fire may result.

Charge only Bosch approved rechargeable batteries. See Functional Description and Specifications. Other types of batteries may burst causing personal injury and damage.

Charge battery pack in temperatures above +40 degrees F (4 degrees C) and below +105 degrees F (41 degrees C). Store tool and battery pack in locations where temperatures do not go below 40

degrees F (4 degrees C) or will no exceed 120 degrees F (49 degrees C). Allow battery pack to return to room temperature before attempting to charge.This is important to prevent serious damage to the battery cells.

Battery leakage may occur under extreme usage or temperature conditions. Avoid contact with skin and eyes. The battery liquid is caustic and could cause chemical burns to tissues. If liquid comes in contact with skin, wash quickly with soap and water, then with lemon juice or vinegar. If the liquid contacts your eyes, flush them with water for a minimum of 10 minutes and seek medical attention.

Place charger on flat non-flammablesurfaces and away from flammable materials whenre-chargingbattery pack.

The charger and battery pack heat during charging. Carpeting and other heat insulating surfaces block proper air circulation which may cause overheating of the charger and battery pack. If smoke or melting of the case are observed unplug the charger immediately and do not use the battery pack or charger.

Use of an attachment not recommended or sold by Bosch may result in a risk of fire, electric shock or injury to persons.

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! WARNING
! WARNING

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Battery Care

When batteries are not in tool or charger, keep them away from metal objects. For example, to

protect terminals from shorting DO NOT place batteries in a tool box or pocket with nails, screws, keys, etc. Fire or injury may result.

To prevent fire or injury ! WARNING when batteries are not in

tool or charger, always place protective cap onto end of battery pack. Protective cap, guards against terminal shorting.

DO NOT PUT BATTERIES INTO FIRE OR EXPOSE TO HIGH HEAT. They may explode.

Battery Disposal

Do not attempt to disassemble the battery or remove any component projecting from

the battery terminals. Fire or injury may result. Prior to disposal, protect exposed terminals with heavy insulating tape to prevent shorting.

NICKEL-CADMIUMBATTERIES

If equipped with a nickel-cadmiumbattery, the battery must be collected, recycled or disposed of in an environmentally sound manner.

“The EPA certified RBRC Battery Recycling Seal on the nickel-cadmium(Ni-Cd)

battery indicates Robert

Bosch Tool Corporation isvoluntarily participating in an industry program to collect and recycle

these batteries at the end of their useful life,

when taken out of service in the United States or Canada. The RBRC program provides a convenient alterative to placing used Ni-Cdbatteries into the trash or the municipal waste stream, which may be illegal in your area.

Please call 1-800-8-BATTERYfor information onNi-Cdbattery recycling and disposal bans/restrictions in your area, or return your batteries to a Skil/Bosch/Dremel Service Center for recycling. Robert Bosch Tool Corporation’s involvement in this program is part of our commitment to preserving our environment and conserving our natural resources.”

NICKEL-METALHYDRIDE BATTERIES

If equipped with a nickel-metalhydride battery, the battery can be disposed of in a municipal solid waste stream.

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Symbols

IMPORTANT: Some of the following symbols may be used on your tool. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to operate the tool better and safer.

Symbol

Name

Designation/Explanation

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

V

Volts

Voltage (potential)

 

 

 

 

A

Amperes

Current

 

 

 

 

 

 

 

 

 

 

 

 

 

Hz

Hertz

Frequency (cycles per second)

 

 

 

W

Watt

Power

 

 

kg

Kilograms

Weight

 

 

 

 

 

 

 

 

 

 

 

 

min

Minutes

Time

 

 

 

 

s

Seconds

Time

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Diameter

Size of drill bits, grinding wheels, etc.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

n0

No load speed

Rotational speed, at no load

.../min

Revolutions or reciprocation per minute

Revolutions, strokes, surface speed,

 

 

 

 

 

 

 

 

 

 

orbits etc. per minute

0

 

 

 

Off position

Zero speed, zero torque...

 

 

 

 

 

 

 

 

 

 

 

1, 2, 3, ...

Selector settings

Speed, torque or position settings.

I, II, III,

 

Higher number means greater speed

 

 

 

 

 

 

 

 

 

 

 

0

 

 

 

 

 

 

Infinitely variable selector with off

Speed is increasing from 0 setting

 

 

 

 

 

 

 

 

 

Arrow

Action in the direction of arrow

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Alternating current

Type or a characteristic of current

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Direct current

Type or a characteristic of current

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Alternating or direct current

Type or a characteristic of current

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Class II construction

Designates Double Insulated

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Construction tools.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Earthing terminal

Grounding terminal

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Warning symbol

Alerts user to warning messages

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Ni-CadRBRC seal

Designates Ni-Cadbattery recycling

 

 

 

 

 

 

 

 

 

 

program

 

 

 

 

 

 

 

 

 

 

 

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

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

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

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

This symbol designates that

this tool complies to NOM Mexican Standards.

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Functional Description and Specifications

Disconnect battery pack from tool or place the switch in the locked or ! WARNING off position before making any assembly, adjustments or changing

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

AUXILIARY

HANDLE

Cordless

Circular Saws

CALIBRATED BEVEL

QUADRANT

BEVEL

ADJUSTMENT

KNOB

ADJUSTABLE

LINE GUIDE

 

BEGINNING OF

FIG. 1

CUT ARROW

 

TRIGGER

BATTERY

 

PACK

 

BATTERY PACK

RELEASE TABS

BLADE WRENCH &

STORAGE AREA

DUST PORT

COVER DEPTH ADJUSTMENT

KNOB

LOWER

GUARD LIFT

LEVER

FOOT

END OF CUT ARROW

LOWER GUARD

SAFETY SWITCH

RELEASE

BUTTON

UPPER GUARD

LOCK

BUTTON

VENTILATION

OPENINGS PUSH 45°STOP SPRING IN DIRECTION OF ARROW

FOR 50°

ALIGNMENT

SCREW

Tool

 

 

 

 

 

 

 

 

Maximum Capacities

 

Model number

1660

 

 

1662

 

 

 

 

Blade

6-1/2"

Voltage rating

24 V

 

 

18 V

 

 

 

 

Depth of cut at 90°

2-1/8"

 

 

 

 

 

No load speed

n0 3,600/min

n0 3,600/min

Depth of cut at 45°

1-5/8"

Charge time

1 hr

 

 

1 hr

 

 

 

Depth of cut at 50°

1-1/2"

Charger

BC004, 6, & BC016

BC003, 4, 6, & BC016

ATTENTION: Use only thin

Voltage rating

120 V

 

60 Hz

120 V

 

 

60 Hz

kerf blades designed for

Battery pack

BAT030 & BAT031

BAT025 & BAT026

Cordless Circular Saws.

BC006 charger requires 12 V DC input

NOTE: ONLY USE CHARGERS LISTED ABOVE

For replacement blades we recommend Bosch Cordless Circular saw blades. Their thin kerf and tooth design deliver the best speed, quality of cut, and reduce battery drain. Use of standard blades will substantially affect the performance and reduce run-time.

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Assembly

ATTACHING THE BLADE

Do not use wrenches with longer handles,

Disconnect battery pack

since it may lead to over tightening of the

! WARNING from tool or place the

blade stud.

switch in the locked or off position before

VARI-TORQUECLUTCH

making any assembly, adjustments or

This clutching action is provided by the friction

changing accessories. Such preventive

of the OUTER WASHER against the BLADE

safety measures reduce the risk of starting

and permits the blade shaft to turn when the

the tool accidentally.

 

 

blade encounters excessive resistance. When

1. Turn BLADE STUD with wrench provided

the BLADE STUD is properly tightened (as

clockwise and remove BLADE STUD and

described in No. 5 of Attaching The Blade), the

OUTER WASHER (Fig. 2). If the shaft moves

blade will slip when it encounters excessive

while attempting to loosen the blade stud

resistance, thus reducing saw’s tendency to

press the lock button (Fig. 1).

 

 

KICKBACK.

2. Retract the lower guard all the way up into

One setting may not be sufficient for cutting all

the upper guard. While retracting the lower

materials. If excessive blade slippage occurs,

guard, check operation and condition of the

tighten the blade stud 1/2 mark more.

LOWER GUARD SPRING.

 

 

OVERTIGHTENING THE BLADE STUD

3. Make sure the saw teeth and arrow on the

NULLIFIES THE EFFECTIVE-NESSOF THE

blade point in the same direction as the arrow

CLUTCH.

on the lower guard.

 

DUST EXTRACTION

4. Slide blade through slot in the foot and

Your tool is equipped is with a dust port for

mount it against the INNER WASHER on the

dust and chip extraction. To use this feature,

shaft. Be sure the large diameter of the OUTER

open dust port cover and attach vacuum hose

washer lays flush against the blade.

(optional accessory) to the dust port, and

5. Reinstall OUTER WASHER and tighten

connect opposite end the hose to a shop

BLADE STUD finger tight. The face of outer

vacuum cleaner.

washer has marks around it that will help you

To prevent personal injury,

properly adjust the blade stud. Press lock

button to lock shaft and TIGHTEN BLADE

! WARNING always position vacuum

STUD COUNTER-CLOCKWISEONE MARK

hose so that it does not interfere with the

ON BLADE WASHER WITH THE WRENCH

lower guard, or the cutting operation at all

PROVIDED.

 

settings.

FIG. 2

 

WRENCH

 

 

MARK

 

 

LOWER

UPPER

 

GUARD

 

SPRING

GUARD

 

 

 

 

 

BLADE

 

 

OUTER WASHER

 

 

OUTER WASHER

 

 

Large Diameter

 

 

Faces Blade

 

 

BLADE

 

 

STUD

LOWER

BLADE

TIGHTEN

GUARD

SHAFT

 

INNER WASHER

Large Diameter

Faces Blade

LOOSEN

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Operating Instructions

DEPTH ADJUSTMENT

Disconnect battery pack from tool. Loosen the depth adjustment knob located on the back side of the upper guard. Hold the foot down with one hand and raise or lower saw by the handle. Tighten knob at the depth

setting desired. Check desired depth (Fig. 3).

Not more than one tooth length of the blade should extend below the material to be cut, for minimum splintering (Fig. 4).

FIG. 3

2

1

0

CALIBRATED DEPTH

BRACKET

DEPTH

ADJUSTMENT

KNOB

BLADE WRENCH

&STORAGE AREA

FIG. 4

ONE TOOTH LENGTH SHOULD PENETRATE WOOD FOR MINIMUM SPLINTERING

SAFETY SWITCH

The safety switch is designed to prevent accidental starts. To operate safety switch, press the release button with your thumb on either side of handle to disengage the lock, then pull the trigger (Fig. 5). When the trigger is released the button will engage the safety switch automatically, and the trigger will no longer operate. (See Switch & General Cuts on page 11.)

FIG. 5

SAFETY SWITCH

RELEASE

BUTTON

90° CUTTING ANGLE CHECK

Disconnect battery pack from tool. Set foot to maximum depth of cut setting. Loosen bevel adjustment knob, set to 0° on quadrant, retighten knob and check for 90° angle between the blade and bottom plane of foot with a square (Fig. 6). Make adjustments by turning the small alignment screw, if necessary (Fig. 7).

FIG. 6

FIG. 7

BEVEL

ADJUSTMENT

KNOB

FOOT 90°

ALIGNMENT

SCREW

TRIGGER

BLADE

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