Bosch 1660 User Manual
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General Safety Rules
For All Battery Operated Tools
Read and understand all instructions. Failure to follow all instructions listed
below, may result in electric shock, fire and/or serious personal injury.
SAVE THESE INSTRUCTIONS
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.
Distractions can cause you to lose control.
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.
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,
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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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.
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
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
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 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:
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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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:
•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
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
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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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.
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.
If equipped with a
“The EPA certified RBRC Battery Recycling Seal on the
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
If equipped with a
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IMPORTANT: Some of the following symbols may be used on your tool. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to operate the tool better and safer.
Frequency (cycles per second)
Size of drill bits, grinding wheels, etc.
No load speed
Rotational speed, at no load
Revolutions or reciprocation per minute
Revolutions, strokes, surface speed,
orbits etc. per minute
Zero speed, zero torque...
1, 2, 3, ...
Speed, torque or position settings.
I, II, III,
Higher number means greater speed
Infinitely variable selector with off
Speed is increasing from 0 setting
Action in the direction of arrow
Type or a characteristic of current
Type or a characteristic of current
Alternating or direct current
Type or a characteristic of current
Class II construction
Designates Double Insulated
Alerts user to warning messages
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.
BLADE WRENCH &
COVER DEPTH ADJUSTMENT
END OF CUT ARROW
OPENINGS PUSH 45°STOP SPRING IN DIRECTION OF ARROW
Depth of cut at 90°
No load speed
Depth of cut at 45°
Depth of cut at 50°
BC004, 6, & BC016
BC003, 4, 6, & BC016
ATTENTION: Use only thin
kerf blades designed for
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
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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
switch in the locked or off position before
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).
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
blade point in the same direction as the arrow
on the lower guard.
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
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
hose so that it does not interfere with the
ON BLADE WASHER WITH THE WRENCH
lower guard, or the cutting operation at all
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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).
ONE TOOTH LENGTH SHOULD PENETRATE WOOD FOR MINIMUM SPLINTERING
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.)
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).