Bosch 1661 User Manual

934.55 Kb

BM 2610925945 6-056/10/05

10:30 AM Page 1





Read Before Using

Lire avant usage

Leer antes de usar

Operating/Safety Instructions

Consignes de fonctionnement/sécurité

Instrucciones de funcionamiento y seguridad







Call Toll Free

Pour renseignement des

Llame gratis para

for Consumer Information

consommateurs et centres

obtener información

& Service Locations

de service, appelez au

para el consumidor y


numéro gratuit :

ubicaciones de servicio


For English


¿Habla español?

See page 2

Voir page 19

Ver página 36

BM 2610925945 6-056/10/05 10:30 AM Page 2

General Safety Rules

! WARNING Read all instructions. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.The term “power tool” in

all of the warnings listed below refers to your mains-operated(corded) power tool or batteryoperated (cordless) power tool.


Work area safety

Keep 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 which may ignite the 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 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 or 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. Use of a cord suitable for outdoor use reduces the risk of electric shock.

Do not use AC only rated tools with a DC power supply. While the tool may appear to work, the electrical components of the AC rated tool are likely to fail and create a hazard to the operator.

If operating the power tool in damp locations is unavoidable a Ground Fault Circuit Interrupter (GFCI) must be used to supply the power to your tool. GFCI and personal protection devices like electrician’s rubber gloves and footwear will further enhance your personal safety.

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 safety equipment. Always wear eye protection. Safety equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.

Avoid accidental starting. Ensure the switch is in the off-positionbefore plugging in.Carrying power tools with your finger on the switch or plugging in 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


BM 2610925945 6-056/10/05 10:30 AM Page 3

used. Use of these devices can reduce dustrelated hazards.

Keep handles dry, clean and free from oil and grease. Slippery hands cannot safely control the power tool.

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 for which it was designed.

Do not use the power tool if the switch does not turn it 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 tools 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 and in the manner intended for the particular type of power tool, 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.

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.

Battery tool use and care

Recharge only with the charger specified by the manufacturer. A charger that is suitable for one type of battery pack may create a risk of fire when used with another battery pack.

Use battery tools only with specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire.

When battery pack is not in use, keep it away from other metal objects like paper clips, coins, keys, nails, screws, or other small metal objects that can make a connection from one terminal to another.

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

Under abusive conditions, liquid may be ejected from the battery, avoid contact. If contact accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the battery may cause irritation or burns.

Ensure the switch is in the off position before inserting battery pack. Inserting the battery pack into power tools that have the switch on invites accidents.


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.

Develop a periodic maintenance schedule for your tool. When cleaning a tool be careful not to disassemble any portion of the tool since internal wires may be misplaced or pinched or safety guard return springs may be improperly mounted. Certain cleaning agents such as gasoline, carbon tetrachloride, ammonia, etc. may damage plastic parts.



BM 2610925945 6-056/10/05 10:30 AM Page 4

Safety Rules for Circular Saws

! WARNING Read all safety warnings and all instructions.

Cutting procedures



Keep hands away from

cutting area and blade.



Keep your second hand on auxiliary handle, or motor housing. If hands are holding the saw, they cannot be cut by the blade.

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.

Do not reach underneath the workpiece.

The guard cannot protect you from the blade below the workpiece.

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

Hold power 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.

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) of arbor holes.

Blades that do not match the mounting hardware of the saw will run eccentrically, causing loss of control.

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.

Inspect the condition and quality of the wood and remove all nails from lumber before cutting. Wet lumber, green lumber or pressure treated lumber require special attention during cutting operation to prevent kickback.

Hold the saw firmly to prevent loss of control. Figures in this manual illustrate typical hand support of the saw.

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, unplug the 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.

Kickback and related warnings

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:

Maintain a firm grip with both hands on the saw and position your body and arm to allow you to resist kickback forces. Position your body to either side of the blade, but not in line with the blade.

Kickback could cause the saw to jump backwards, but 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.

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.


BM 2610925945 6-056/10/05 10:30 AM Page 5

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.

Do not use dull or damaged blade.

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

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

Use extra caution when making a “Plunge Cut” into existing walls or other blind areas. The protruding blade may cut objects that can cause kickback.

The blade washers and the bolt on your saw have been designed to work as a clutch to reduce the intensity of a kickback. Understand the operation and settings of the VARI-TORQUECLUTCH.The proper setting of the clutch, combined with firm handling of the saw will allow you to control kickback.

Never place your hand behind the saw blade. Kickback could cause the saw to jump backwards over your hand.

Do not use the saw with an excessive depth of cut setting. Too much blade exposure increases the likelihood of the blade twisting in the kerf and increases the surface area of the blade available for pinching that leads to kickback.


Lower guard function

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.

Lower guard should be retracted manually only for special cuts such as “Plunge Cuts” and “Compound Cuts”. Raise lower guard by lower guard Lift lever and 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.

Do not run the tool 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.

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. Preventive maintenance and properly operating guard will reduce the probability of an accident.

! WARNING 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.


BM 2610925945 6-056/10/05 10:30 AM Page 6


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.

Battery Care

When batteries are not in ! WARNING tool or charger, keep them

away from metal objects. For example, to protect terminals from shorting DO NOTplace 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.



BM 2610925945 6-056/10/05 10:30 AM Page 7

Battery Disposal

Do not attempt to disas- ! WARNING semble 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 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.”


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


BM 2610925945 6-056/10/05 10:30 AM Page 8


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.







Voltage (potential)







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





Off position

Zero speed, zero torque...

1, 2, 3, ...

Selector settings

Speed, torque or position settings.



Higher number means greater speed







Infinitely variable selector with off

Speed is increasing from 0 setting








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

















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.


BM 2610925945 6-056/10/05 10:30 AM Page 9

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.




Circular Saws






FIG. 1

























Model number






Voltage rating

18 V









No load speed

n0 3,600/min


BC003,4,6, & BC016


BC130 & BC230

Voltage rating

120 V

60 Hz

Battery pack

BAT025 & BAT26


BAT160 thru BAT189


14.4 V n0 3,600/min

BC001-6& BC016 BC130 & BC230 120 V60 Hz


BAT140 thru BAT159

Maximum Capacities




Depth of cut at 90°


Depth of cut at 45°


ATTENTION: Use only thin kerf blades designed for Cordless Circular Saws.

BC006 charger requires 12 V DC input


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.


BM 2610925945 6-056/10/05 10:30 AM Page 10



Do not use wrenches with longer handles,

Disconnect battery pack

since it may lead to over tightening of the blade

! 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 press

resistance, thus reducing saw’s tendency to

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 a fraction of a turn more



(less than 1/8 turn). OVERTIGHTENING THE

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 dust

mount it against the INNER WASHER on the

and chip extraction. To use this feature, open

shaft. Be sure the large diameter of the OUTER

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

vacuum cleaner.

BLADE STUD finger tight. The face of outer

! WARNING To prevent personal injury,

washer has marks on it that will help you

properly adjust the blade stud. Press lock

always position vacuum

button to lock shaft and TIGHTEN BLADE

hose so that it does not interfere with the


lower guard, or the cutting operation at all






FIG. 2






























Large Diameter



Faces Blade














Large Diameter

Faces Blade