BOSCH 1638 User guide

Operating/Safety Instructions

Consignes de fonctionnement/sécurité
Instrucciones de funcionamiento

y seguridad

IMPORTANT: IMPORTANT : IMPORTANTE:

Read Before Using Lire avant usage Leer antes de usar

For English Parlez-vous français? ¿Habla español?
See page 2 Voir page 9 Ver página 16

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.

1638

B115 5

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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

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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

Double Insulated tools are equipped with
a polarized plug (one blade is wider than
the other.) This plug will fit in a polarized
outlet only one way. If the plug does not
fit fully in the outlet, reverse the plug. If it
still does not fit, contact a qualified
electrician to install a polarized outlet. Do
not change the plug in any way. Double

Insulation eliminates the need for the
three wire grounded power cord and
grounded power supply system. Before

plugging in the tool, be certain the outlet
voltage supplied is within the voltage marked
on the nameplate. Do not use “AC only”
rated tools with a DC power supply.

Avoid body contact with grounded surfaces
such as pipes, radiators, ranges and
refrigerators. There is an increased risk of

electric shock if your body is grounded. If
operating the power tool in damp locations is
unavoidable, a Ground Fault Circuit Interrupter
must be used to supply the power to your
tool. Electrician’s rubber gloves and footwear
will further enhance your personal safety.

Don't 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
to carry the tools or pull the plug from an
outlet. Keep cord away from heat, oil, sharp
edges or moving parts. Replace damaged
cords immediately. Damaged cords increase

the risk of electric shock.

When operating a power tool outside, use
an outdoor extension cord marked "W-A"
or "W." These cords are rated for outdoor use

and reduce the risk of electric shock. Refer to
“Recommended sizes of Extension Cords” in
the Accessory section of this manual.

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. Keep
handles dry, clean and free from oil and
grease.

Avoid accidental starting. Be sure switch is
“OFF” before plugging in. Carrying tools with

your finger on the switch or plugging in tools
that have 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 enables 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

!

WARNING

Power Tool Safety Rules

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Rotary Cutter Safety Rules

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”. Any tool that cannot be

controlled with the switch is dangerous and
must be repaired.

Disconnect the plug from the power source
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.

Maintain tools with care. Keep cutting tools
sharp and clean. Properly maintained tools,

with sharp cutting edges are less likely to bind
and are easier to control. Any alteration or
modification is a misuse and may result in a
dangerous condition.

Check for misalignment or binding of
moving parts, breakage of parts, and any
other condition that may affect the tools
operation. If damaged, have the tool

serviced before using. Many accidents are

caused by poorly maintained tools. Develop a
periodic maintenance schedule for your tool.

Use only accessories that are recom­mended by the manufacturer for your
model. Accessories that may be suitable for

one tool, may become hazardous when used
on another tool.

Service

Tool service must be performed only by
qualified repair personnel. Service or

maintenance performed by unqualified
personnel could result in a risk of injury. For
example: internal wires may be misplaced or
pinched, safety guard return springs may be
improperly mounted.

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
electric shock or injury. Certain cleaning
agents such as gasoline, carbon tetrachloride,
ammonia, etc. may damage plastic parts.

Hold tool by insulated gripping surfaces
when performing an operation where the
cutting tool may contact hidden wiring or
its own cord. Contact with a "live" wire will

make exposed metal parts of the tool "live"
and shock the operator. If cutting into

existing walls or other blind areas where
electrical wiring may exist is unavoidable,
disconnect all fuses or circuit breakers
feeding this worksite.

Always make sure the work surface is
free from nails and other foreign objects.

Cutting into a nail can cause the bit and the
tool to jump and damage the bit.

Never hold the workpiece in one hand and
the tool in the other hand when in use.
Never place hands near or below cutting
surface. Clamping the material and guiding

the tool with both hands is safer.

Never lay workpiece on top of hard
surfaces, like concrete, stone, etc...

Protruding cutting bit may cause tool to
jump.

Always wear safety goggles and dust
mask. Use only in well ventilated area.

Using personal safety devices and working
in safe environment reduces risk of injury.

After changing the bits or making any
adjustments, make sure the collet nut and
any other adjustment devices are
securely tightened. Loose adjustment

device can unexpectedly shift, causing loss
of control, loose rotating components will be
violently thrown.

Never start the tool when the bit is
engaged in the material. The bit cutting

edge may grab the material causing loss of
control of the cutter.

Always hold the tool with two hands
during start-up. The reaction torque of the

motor can cause the tool to twist.

The direction of feeding the bit into the
material is very important and it relates to
the direction of bit rotation. When
viewing the tool from the top, the bit
rotates clockwise. Feed direction of

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cutting must be counter-clockwise.

NOTE: inside and outside cuts will require
different feed direction, refer to section on
feeding the router. Feeding the tool in the
wrong direction, causes the cutting edge of
the bit to climb out of the work and pull the
tool in the direction of this feed.

Never use dull or damaged bits. Sharp
bits must be handled with care. Damaged

bits can snap during use. Dull bits require
more force to push the tool, possibly
causing the bit to break.

Never touch the bit during or immediately
after the use. After use the bit is too hot to

be touched by bare hands.

Never lay the tool down until the motor
has come to a complete standstill. The

spinning bit can grab the surface and pull
the tool out of your control.

Never use bits that have a cutting
diameter greater than the opening in the
base.

Do not use the tool for drilling purposes.

This tool is not intended to be used with drill
bits.

Always use the tool with the depth guide
securely attached and positioned flat
against material being cut. The guide

securely positioned on the material improves
the stability and control of your tool.

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-based paints,

• Crystalline silica from bricks and cement

and other masonry products, and

• Arsenic and chromium from chemically-

treated 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.

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!

WARNING

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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.

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.

n

0

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

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-Cad RBRC seal Designates Ni-Cad battery recycling

program

Symbols

0

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
complies
to NOM
Mexican
Standards.

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

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Functional Description and Specifications

B115 5

ON/OFF SLIDE

SWITCH

SHAFT LOCK

EXHAUST

AIR VENTS

INTAKE

AIR VENTS

DEPTH GUIDE

DEPTH GUIDE
LOCKING KNOB

DEPTH GUIDE

BRACKET w/CLIC

COLLET NUT

Disconnect the plug from the power source before making any
assembly, adjustments or changing accessories. Such preventive

safety measures reduce the risk of starting the tool accidentally.

!

WARNING

Operating Instructions

SLIDE "ON/OFF" SWITCH

This tool is switched "ON" by the slide
switch located on the front of the motor
housing.

TO TURN THE TOOL "ON" slide the switch
button up.

TO TURN THE TOOL "OFF" slide the switch
button down or "0" position.

Hold the tool with both

hands while starting, since
torque from the motor can cause the tool to
twist.

INSTALLING BITS

The bits are held by a collet system. Use
either the 1/8" or 1/4" collet depending on
the size of the bit shank.

Do Not Use .118" shank bits in the 1/8"
collet use only BOSCH "SC" series bits or
similar bits with 1/8" (.125") or 1/4" (.250")
shanks.

The bit flutes are sharp and
should be handled with

caution.

Depress and hold the shaft-lock in and
rotate the collet nut and shaft until the shaft­lock engages and holds the shaft. Use the
standard equipment wrench to loosen nut
(counter-clockwise). Remove the old bit (if
there is one) insert the new bit as far as
possible, but not so far that the bit flutes
engage the collet (leave approximately 1/8"
of shank exposed). Re-engage the shaft­lock and tighten the nut (clockwise) by hand
and then with the wrench until bit is held
securely.

DEPTH GUIDE ADJUSTMENT

Use the depth guide to adjust the depth of
cut. Simply loosen (counter clockwise) the
knob a little (approximately 1/8 turn) and
slide the depth guide in or out to the desired
depth of cut (about 1/8" greater than
material thickness) and retighten the knob
(clockwise).

NOTE: For tool specifications refer to nameplate on your tool.

!

WARNING

Rotary Cutter

!

WARNING

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REMOVING AND INSTALLING THE "CLIC"

DEPTH GUIDE ASSEMBLY

The depth guide assembly consists of the
depth guide, locking knob and bracket.
Twist the whole assembly counter clockwise
approximately 1/8 of a turn. Then pull the
whole assembly straight off of the tool. To
re-attach the assembly, align the notched
area of the depth guide bracket with the
protrusion on the spring which is attached to
the tool collar. Then push the assembly over
the collar and twist it clockwise about 1/8
turn until the spring clicks in place.

Disconnect the plug from

the power source before
making any assembly, adjustments or
changing accessories. Such preventive

safety measures reduce the risk of starting
the tool accidentally. Make certain that the
collet nut is securely tightened before
turning the tool on.

MAKING DRYWALL CUT OUTS

After assembling the bit into the tool as
described earlier, it will be necessary to
review the instructions provided below and
make some practice cut-outs with this tool
before attempting an actual job. The best
method is to take some scrap pieces and
nail or screw them in place over wall studs
which have an electrical box or other feature
in place. A few such exercises will give you
the necessary practice to make clean,
professional cutouts around whatever is
behind the drywall you are installing.

Do not attempt to use this

tool to make cut-outs
around any fixture or opening which has
live electrical wires, or on any wall which
may have live electrical wiring behind it,
as the bit could conduct current to the
tool, creating an electrocution hazard for
the operator. Shut off breakers or remove

fuses to disconnect the circuit. Always hold
the tool by its thermoplastic housing, and
always wear eye protection when operating
this device.

•Step 1: Be certain that the box or fixture
which requires a cut-out is firmly mounted
and all wires or other obstructions around
the opening are pushed back out of the way.
The drywall cut-out bit uses the outer edge
of the box or fixture as a guide, so it is
important that there is nothing in the way
which can prevent it from guiding completely
around the opening. For the purposes of this
instruction manual, the procedure discussed
will be to make a cut-out around a standard
2 1/8" x 3 3/4" electrical box.

•Step 2: Before fastening the drywall sheet,
make a mark close to the center of the
opening in the box on the side of the drywall
facing you. You may then begin to screw or
nail the sheet to the wall, but do not install
fasteners closer then about 15" to the box,
or the sheet will likely bulge and crack
before you cut the opening.

•Step 3: Holding the tool firmly switch the
tool to the "ON" position as described
earlier.

•Step 4: Holding the tool firmly with both
hands, push the bit through the drywall at
the mark you made in step 2. Guide the bit
to the right until you feel it make contact with
the inside edge of the box. Then retract the
bit slightly, (do not pull entirely out) to allow
it to penetrate through the drywall and
contact the outside edge of the box by
continuing to move the tool slightly to the
right as you cut.

•Step 5: Keeping the bit in contact with the
outside of the box, move the tool counter­clockwise to create the opening. When
rounding a corner, keep applying light
pressure towards the center of the box while
moving the bit steadily and smoothly around
the whole box until the entire cut has been
completed. Slide the switch to the "OFF"
position, and pull the bit free of the drywall.
You may then remove the piece you have
cut, and you will have a smooth opening.
The rest of the screws or nails may now be
put in place on the drywall sheet, and the
task is completed.

The motor may stall if

improperly used or over­loaded. Reduce the pressure or feed rate to
prevent possible damage to the tool. Do not
attempt to start the tool when the bit is
engaged in the workpiece. Always be sure
the collet nut is tightened securely before
use.

MAKING CUT-OUTS IN MATERIALS

OTHER THAN DRYWALL

Your tool is capable of cutting many types of
building materials in addition to drywall.
There are several different bits available for
use on these materials. Most materials can
be cut with the "wood" bit, however the
"carbide" burr bits must be used for hard,
abrasive materials such as ceramic WALL
tile (will not work on ceramic FLOOR grade
tile), cement board, plaster etc.

To make cut-outs, insert and adjust the
proper bit according to previous instructions.
Hold the tool firmly and turn it on. Place the
depth guide at about a 45º angle against the

!

WARNING

!

WARNING

!

CAUTION

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Service

Preventive maintenance

performed by unauth­orized personnel may result in misplacing
of internal wires and components which
could cause serious hazard. We

recommend that all tool service be
performed by a Bosch Factory Service
Center or Authorized Bosch Service Station.

TOOL LUBRICATION

Your Bosch tool has been properly
lubricated and is ready to use. It is
recommended that tools with gears be
regreased with a special gear lubricant at
every brush change.

CARBON BRUSHES

The brushes and commutator in your tool
have been engineered for many hours of
dependable service. To maintain peak
efficiency of the motor, we recommend
every two to six months the brushes be
examined. Only genuine Bosch replacement
brushes specially designed for your tool
should be used.

BEARINGS

After about 300-400 hours of operation, or at
every second brush change, the bearings
should be replaced at Bosch Factory Service
Center or Authorized Bosch Service Station.
Bearings which become noisy (due to heavy
load or very abrasive material cutting) should
be replaced at once to avoid overheating or
motor failure.

Cleaning

To avoid accidents always

disconnect the tool from
the power supply before cleaning or
performing any maintenance. The tool may

be cleaned most effectively with
compressed dry air. Always wear safety

goggles when cleaning tools with
compressed air.

Ventilation openings and switch levers must
be kept clean and free of foreign matter. Do
not attempt to clean by inserting pointed
objects through openings.

Certain cleaning agents

and solvents damage
plastic parts. Some of these are: gasoline,

carbon tetrachloride, chlorinated cleaning
solvents, ammonia and household
detergents that contain ammonia.

!

WARNING

!

WARNING

Maintenance

!

CAUTION

If an extension cord is

necessary, a cord with
adequate size conductors that is capable
of carrying the current necessary for your
tool must be used. This will prevent

excessive voltage drop, loss of power or
overheating. Grounded tools must use 3­wire extension cords that have 3-prong
plugs and receptacles.

NOTE: The smaller the gauge number, the
heavier the cord.

RECOMMENDED SIZES OF EXTENSION CORDS

120 VOLT ALTERNATING CURRENT TOOLS

Tool’s

Ampere

Rating

Cord Size in A.W.G.

Wire Sizes in mm

2

3-6
6-8

8-10
10-12
12-16

18 16 16 14 .75 .75 1.5 2.5
18 16 14 12 .75 1.0 2.5 4.0
18 16 14 12 .75 1.0 2.5 4.0
16 16 14 12 1.0 2.5 4.0 —
14 12 — — — — — —

25 50 100 150 15 30 60 120

Cord Length in Feet Cord Length in Meters

!

WARNING

Accessories

work surface and tilt the tool to an upright
position with the bit entering the scrap
portion of the area being cut. Move the bit to
the line you wish to follow and cut in a
clockwise position. Cutting at a slow even
rate will make following a line easier and will
put less stress on the bit.

NOTE: When cutting on a vertical surface,
avoid ending your cut at the bottom of the
hole. If possible, start and end your cut at
the top so the scrap part will not drop onto
the rotating bit. Turn the tool off and remove
it from the cut out hole.

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