Bosch 1661, 1659 User Manual
BM 2610925945 6-05 6/10/05 10:30 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
1659
1661
Call Toll Free
for Consumer Information
& Service Locations
1-877-BOSCH99 (1-877-267-2499) www.boschtools.com
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BM 2610925945 6-05 6/10/05 10:30 AM Page 2
General Safety Rules
WARNING
!
all of the warnings listed below refers to your mains-operated (corded) power tool or batteryoperated (cordless) power tool.
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
SAVE THESE INSTRUCTIONS
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.
tools create sparks which may ignite the dust
or fumes.
Keep children and bystanders away while
operating a power tool.
cause you to lose control.
Distractions can
Power
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.
and matching outlets will reduce risk of
electric shock.
Avoid body contact with earthed or
grounded surfaces such as pipes,
radiators, ranges and refrigerators.
is an increased risk of electric shock if your
body is earthed or grounded.
Do not expose power tools to rain or wet
conditions.
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.
outdoor use reduces the risk of electric
shock.
Do not use AC only rated tools with a DC
power supply.
work, the electrical components of the AC
rated tool are likely to fail and create a
hazard to the operator.
Water entering a power tool will
Use of a cord suitable for
While the tool may appear to
Unmodified plugs
There
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.
personal protection devices like electrician’s
rubber gloves and footwear will further
enhance your personal safety.
GFCI and
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.
inattention while operating power tools may
result in serious personal injury.
Use safety equipment. Always wear eye
protection.
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-position before
plugging in.
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.
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.
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.
be caught in moving parts.
If devices are provided for the connection
of dust extraction and collection facilities,
ensure these are connected and properly
Safety equipment such as dust
Carrying power tools with your
Loose clothes, jewelry or long hair can
A moment of
This enables
A
-2-
BM 2610925945 6-05 6/10/05 10:30 AM Page 3
used. Use of these devices can reduce dustrelated hazards.
Keep handles dry, clean and free from oil
and grease.
control the power tool.
Slippery hands cannot safely
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.
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.
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.
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.
Many accidents are caused by
Any power tool
Such preventive safety
Use clamps or other practical way to
secure and support the workpiece to a
stable platform.
or against your body is unstable and may
lead to loss of control.
Holding the work by hand
Battery tool use and care
Recharge only with the charger specified
by the manufacturer.
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.
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.
battery may cause irritation or burns.
Ensure the switch is in the off position
before inserting battery pack.
battery pack into power tools that have the
switch on invites accidents.
A charger that is
Use of any other
Liquid ejected from the
Inserting the
Service
Have your power tool serviced by a
qualified repair person using only identical
replacement parts.
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.
This will ensure that the
SAVE THESE INSTRUCTIONS
-3-
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Safety Rules for Circular Saws
WARNING
!
Read all safety warnings and all instructions.
Cutting procedures
!
DANGER
Keep your second hand on auxiliary handle,
or motor housing.
saw, they cannot be cut by the blade.
This product is intended to cut wood and
wood-like products only
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.
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.
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.
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.
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.
pressure treated lumber require special
attention during cutting operation to prevent
kickback.
Hold the saw firmly to prevent loss of
control.
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
Keep hands away from
cutting area and blade.
If hands are holding the
. Dust build up
It is important to support the
Contact with a "live" wire
This improves accuracy
The blade washers and bolt
Wet lumber, green lumber or
Figures in this manual illustrate
running, the saw may not shut off.
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 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.
up or kickback from the workpiece as the saw
is restarted.
-4-
kickback:
If saw blade is binding, it may walk
If either
BM 2610925945 6-05 6/10/05 10:30 AM Page 5
Support large panels to minimize the risk of
blade pinching and kickback.
t
end to sag under their own weight. Supports
m
ust be placed under the panel on both sides,
near the line of cut and near the edge of the
panel.
D
o 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.
cutting, it may cause binding and kickback.
Use extra caution when making a “Plunge
Cut” into existing walls or other blind
areas.
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-TORQUE CLUTCH.
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.
backwards over your hand.
Do not use the saw with an excessive
depth of cut setting.
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.
If blade adjustment shifts while
The protruding blade may cut objects
Kickback could cause the saw to jump
Large panels
The proper
Too much blade
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
L
ower Guard Lift Lever and make sure it
m
oves freely and does not touch the blade or
any other part, in all angles and depths of cut.
C
heck the operation of the lower guard
s
pring. If the guard and the spring are not
operating properly, they must be serviced
before use.
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.
guard should operate automatically.
Always observe that the lower guard is
covering the blade before placing saw
down on bench or floor.
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.
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.
and properly operating guard will reduce the
probability of an accident.
WARNING
!
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
to filter out microscopic particles.
Lower guard may operate
For all other sawing, the lower
An unprotected,
Accidental
Preventive maintenance
Some dust created by
power sanding, sawing,
designed
-5-
BM 2610925945 6-05 6/10/05 10:30 AM Page 6
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.
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.
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.
Charge only Bosch approved rechargeable
batteries.
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
Battery short or fire may result.
See Functional Description and
Do not
Incorrect
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
c
harge.
damage to the battery cells.
Battery leakage may occur under extreme
usage or temperature conditions. Avoid
contact with skin and eyes.
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-flammable
surfaces and away from flammable
materials when re-charging battery 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.
T
his is important to prevent serious
The battery
Battery Care
!
WARNING
away from metal objects.
protect terminals from shorting
place batteries in a tool box or pocket with
nails, screws, keys, etc. Fire or injury may
result.
When batteries are not in
tool or charger, keep them
For example, to
DO
NOT
!
WARNING
tool or charger, always place protective
cap onto end of battery pack.
cap, guards against terminal shorting.
DO NOT PUT BATTERIES INTO FIRE OR
EXPOSE TO HIGH HEAT.
explode.
To prevent fire or injury
when batteries are not in
Protective
They may
-6-
BM 2610925945 6-05 6/10/05 10:30 AM Page 7
Battery Disposal
!
WARNING
remove any component projecting from
the battery terminals.
result. Prior to disposal, protect exposed
terminals with heavy insulating tape to
prevent shorting.
NICKEL-CADMIUM BATTERIES
If equipped with a nickel-cadmium battery, the
battery must be collected, recycled or
disposed of in an environmentally sound
manner.
industry program to collect and recycle these
batteries at the end of their useful life, when
Do not attempt to disassemble the battery or
Fire or injury may
“The EPA certified RBRC
Battery Recycling Seal on the
nickel-cadmium (Ni-Cd)
battery indicates Robert
Bosch Tool Corporation is
voluntarily participating in an
taken out of service in the United States or
Canada. The RBRC program provides a
convenient alterative to placing used Ni-Cd
batteries into the trash or the municipal
waste stream, which may be illegal in your
area.
Please call 1-800-8-BATTERY for information
on Ni-Cd battery 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-metal hydride
battery, the battery can be disposed of in a
municipal solid waste stream.
NICKEL-METAL HYDRIDE BATTERIES
-7-
A
0
A
A
0
A
BM 2610925945 6-05 6/10/05 10:30 AM Page 8
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.
n
0
.../min Revolutions or reciprocation per minute Revolutions, strokes, surface speed,
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
No load speed Rotational speed, at no load
orbits etc. per minute
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
Alternating or direct current Type or a characteristic of current
Class II construction
Earthing terminal Grounding terminal
Warning symbol Alerts user to warning messages
Ni-Cad RBRC seal Designates Ni-Cad battery recycling
Type or a characteristic of current
Designates Double Insulated
Construction tools.
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.
-8-
BM 2610925945 6-05 6/10/05 10:30 AM Page 9
Functional Description and Specifications
!
WARNING
accessories
accidentally.
Disconnect battery pack from tool or place the switch in the locked or
off position before making any assembly, adjustments or changing
. Such preventive safety measures reduce the risk of starting the tool
Cordless
Circular Saws
CALIBRATED
BEVEL QUADRANT
BEVEL
ADJUSTMENT
KNOB
FIG. 1
BATTERY
PACK
BATTERY PACK
RELEASE TABS
TRIGGER
AUXILIARY
HANDLE
DUST PORT
COVER
ADJUSTMENT
LOWER
GUARD LIFT
LEVER
LOWER
GUARD
SAFETY SWITCH
RELEASE
BUTTON
UPPER GUARD
LOCK
BUTTON
DEPTH
KNOB
FOOT
BLADE WRENCH &
STORAGE AREA
VENTILATION
OPENINGS
Model number 1659 1661
Voltage rating 18 V 14.4 V
No load speed
n
0
min n
/
3,600
3,600
0
min
/
Charger BC003,4,6, & BC016 BC001-6 & BC016
Voltage rating
BC130 & BC230
120 V 60 Hz
BC130 & BC230
120 V 60 Hz
Battery pack BAT025 & BAT26 BAT040
Maximum Capacities
Blade 5-3/8"
Depth of cut at 90° 1-5/8"
Depth of cut at 45° 1-1/4"
ATTENTION: Use only thin
kerf blades designed for
Cordless Circular Saws.
BAT160 thru BAT189 BAT140 thru BAT159
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.
-9-
BM 2610925945 6-05 6/10/05 10:30 AM Page 10
Assembly
ATTACHING THE BLADE
!
WARNING
Disconnect battery pack
f
rom tool or place the
switch in the locked or off position before
making any assembly, adjustments or
changing accessories
. Such preventive
safety measures reduce the risk of starting
the tool accidentally.
1. Turn BLADE STUD with wrench provided
clockwise and remove BLADE STUD and
OUTER WASHER (Fig. 2). If the shaft moves
while attempting to loosen the blade stud press
the lock button (Fig. 1).
2. Retract the lower guard all the way up into
the upper guard. While retracting the lower
guard, check operation and condition of the
LOWER GUARD SPRING.
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
mount it against the INNER WASHER on the
shaft. Be sure the large diameter of the OUTER
washer lays flush against the blade.
5. Reinstall OUTER WASHER and tighten
BLADE STUD finger tight. The face of outer
washer has marks on it that will help you
properly adjust the blade stud. Press lock
button to lock shaft and TIGHTEN BLADE
STUD COUNTER-CLOCKWISE ONE MARK
ON BLADE WASHER WITH THE WRENCH
PROVIDED.
Do not use wrenches with longer handles,
since it may lead to over tightening of the blade
s
tud.
This clutching action is provided by the friction
of the OUTER WASHER against the BLADE
and permits the blade shaft to turn when the
blade encounters excessive resistance. When
the BLADE STUD is properly tightened (as
described in No. 5 of Attaching The Blade), the
blade will slip when it encounters excessive
resistance, thus reducing saw’s tendency to
KICKBACK.
One setting may not be sufficient for cutting all
materials. If excessive blade slippage occurs,
tighten the blade stud a fraction of a turn more
(less than 1/8 turn). OVERTIGHTENING THE
BLADE STUD NULLIFIES THE EFFECTIVENESS OF THE CLUTCH.
Your tool is equipped is with a dust port for dust
and chip extraction. To use this feature, open
dust port cover and attach vacuum hose
(optional accessory) to the dust port, and
connect opposite end the hose to a shop
vacuum cleaner.
!
hose so that it does not interfere with the
lower guard, or the cutting operation at all
settings.
VARI-TORQUE CLUTCH
DUST EXTRACTION
WARNING
To prevent personal injury,
always position vacuum
FIG. 2
UPPER
GUARD
LOWER
GUARD
BLADE
SHAFT
INNER WASHER
Large Diameter
Faces Blade
-10-
LOWER
GUARD
SPRING
BLADE
WRENCH
MARK
OUTER WASHER
OUTER WASHER
LOOSEN
Large Diameter
Faces Blade
BLADE
STUD
TIGHTEN
90°
BM 2610925945 6-05 6/10/05 10:30 AM Page 11
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
DEPTH
ADJUSTMENT
KNOB
BLADE
WRENCH &
STORAGE AREA
CALIBRATED DEPTH
BRACKET
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. 4
ONE TOOTH LENGTH SHOULD
PENETRATE WOOD FOR
MINIMUM SPLINTERING
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). If adjustment is
necessary, tilt foot to 45
°, tighten bevel
adjustment wing nut and bend "TAB" with an
adjustable wrench or pliers (Fig. 7).
FIG. 5
SAFETY SWITCH
RELEASE
BUTTON
TRIGGER
-11-
FIG. 6
ADJUSTMENT
FOOT
BEVEL
KNOB
BLADE
FIG. 7
TAB
BM 2610925945 6-05 6/10/05 10:30 AM Page 12
IG. 8
BEVEL ADJUSTMENT
F
Disconnect battery pack from tool. The foot
can be adjusted up to 50° by loosening the
bevel adjustment knob at the front of the saw.
Align to desired angle on calibrated quadrant.
Then tighten bevel adjustment knob (Fig. 8).
Because of the increased amount of blade
engagement in the work and decreased
stability of the foot, blade binding may occur.
QUADRANT
Keep the saw steady and the foot firmly on
the workpiece.
LINE GUIDE
For a straight 90° cut, use right side of notch
in the foot. For 45° bevel cuts, use the left side
(Fig. 9). The cutting guide notch will give an
approximate line of cut. Make sample cuts in
scrap lumber to verify actual line of cut. This
will be helpful because of the number of
FIG. 9
different blade types and thicknesses
available. To ensure minimum splintering on
the good side of the material to be cut, face
the good side down.
90°
VERTICAL
CUTS
ADJUSTMENT
°
45
BEVEL
CUTS
BEVEL
KNOB
To turn tool “ON”, squeeze the trigger switch.
SWITCH
To turn the tool “OFF”, release the trigger
switch, which is spring loaded and will return
to the off position automatically.
Your saw should be running at full speed
BEFORE starting the cut, and turned off only
AFTER completing the cut. To increase switch
life, do not turn switch on and off while cutting.
BRAKE
When the trigger is released it activates the
electrical brake to stop the blade quickly. This
feature is especially useful when making
repetitive cuts.
GENERAL CUTS
Always hold the saw handle with one hand
and the auxiliary handle or housing with the
other.
Always make sure saw foot rests on portion of
work surface that does not drop off.
!
WARNING
Always be sure either
hand does not interfere
with the free movement of the lower
guard.
Maintain a firm grip and operate the switch
with a decisive action. Never force the saw.
Use light and continuous pressure.
!
WARNING
After completing a cut and
the trigger has been
released, be aware of the necessary time it
takes for the blade to come to a complete
stop during coast down. Do not allow the
saw to brush against your leg or side,
since the lower guard is retractable, it
could catch on your clothing and expose
the blade. Be aware of the necessary blade
exposures that exist in both the upper and
lower guard areas.
When cutting is interrupted, to resume cutting:
squeeze the trigger and allow the blade to
reach full speed, re-enter the cut slowly and
resume cutting.
When cutting across the grain, the fibers of
the wood have a tendency to tear and lift.
Advancing the saw slowly minimizes this
effect. For a finished cut, a cross cut blade or
miter blade is recommended.
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BM 2610925945 6-05 6/10/05 10:30 AM Page 13
Disconnect battery pack from tool before
POCKET CUTS
making adjustments. Set depth adjust-ment
according to material to be cut. Tilt saw forward
with cutting guide notch lined up with the line
you’ve drawn. Raise the lower guard, using lift
lever and hold the saw by the front and rear
h
andles (Fig. 10).
With the blade just clearing the material to be
cut, start the motor. Gradually lower the back
end of saw using the front end of the foot as the
hinge point.
WARNING: As blade starts
cutting the material, release the lower guard
immediately.
When the foot rests flat on the
surface being cut, proceed cutting in forward
direction to end of cut.
WARNING: Allow blade
to come to a complete stop before lifting the
saw from cut. Also, never pull the saw
backward since blade will climb out of the
material and KICKBACK will occur.
Turn saw
around and finish the cut in the normal manner,
sawing forward. If corners of your pocket cut are
not completely cut through, use a jigsaw or
hand saw to finish the corners.
FIG. 10
LOWER
GUARD
LIFT
LEVER
Large sheets and long boards sag or bend,
CUTTING LARGE SHEETS
depending on support. If you attempt to cut
without leveling and properly supporting the
p
iece, the blade will tend to bind, causing KICK-
BACK and extra load on the motor (Fig. 11).
Support the panel or board close to the cut, as
shown in (Fig. 12). Be sure to set the depth of
the cut so that you cut through the sheet or
board only and not the table or work bench. The
two-by-fours used to raise and support the work
should be positioned so that the broadest sides
support the work and rest on the table or bench.
Do not support the work with the narrow sides
as this is an unsteady arrangement. If the sheet
or board to be cut is too large for a table or work
bench, use the supporting two-by-fours on the
floor and secure.
FIG. 11
WRONG
FOOT
RIP CUTS
The combination blade provided with your saw
is for both cross cuts and rip cuts. Ripping is
cutting lengthwise with the grain of the wood.
Rip cuts are easy to do with a rip fence (Fig.
13). Rip Fence is available as an accessory (not
included). To attach fence, insert fence through
slots in foot to desired width as shown and
secure with the knob.
FIG. 13
DESIRED
WIDTH
OF CUT
KNOB
RIP
FENCE
When rip cutting large sheets, the rip fence
RIP BOARD GUIDE
may not allow the desired width of cut. Clamp
or nail a straight piece of 1" (25 mm) lumber to
the sheet as a guide (Fig. 14). Use the right
side of the foot against the board guide.
DESIRED
OF CUT
RIP
BOARD
GUIDE
-13-
FIG. 12
RIGHT
FIG. 14
LINE
BM 2610925945 6-05 6/10/05 10:30 AM Page 14
RELEASING AND INSERTING BATTERY PACK
Release battery pack from tool by pressing
on both sides of the battery release tabs and
p
ull downwards. Before inserting battery
pack, remove protective cap from battery
IMPORTANT CHARGING NOTES
1. The battery pack accepts only about 80%
of its maximum capacity with its first few
charge cycles. However, after the first few
charge cycles, the battery will charge to full
capacity.
2. The charger was designed to fast charge
the battery only when the battery
temperature is between 40˚F (4˚C) and
105˚F (41˚C).
3. A substantial drop in operating time per
charge may mean that the battery pack is
nearing the end of its life and should be
replaced.
4. If you anticipate long periods (i.e. a month
or more) of non-use of your tool, it is best to
run your tool down until it is fully discharged
before storing your battery pack. After a long
period of storage, the capacity at first recharge
will be lower. Normal capacity will be restored
in two or three charge/discharge cycles.
pack. To insert battery, align battery and slide
battery pack into tool until it locks into
p
osition. Do not force.
Remember to unplug charger during storage
period.
5. If battery does not charge properly:
in some other electrical device.
light switch which turns power “off” when
lights are turned off.
Clean with cotton swab and alcohol if
necessary.
take or send tool, battery pack and charger
to your local Bosch Service Center. See
“Tools, Electric” in the Yellow Pages for
names and addresses.
Note: Use of chargers or battery packs not
sold by Bosch will void the warranty.
a. Check for voltage at outlet by plugging
b. Check to see if outlet is connected to a
c. Check battery pack terminals for dirt.
d. If you still do not get proper charging,
CHARGING BATTERY PACK (30 MINUTE SINGLE BAY-BC130)
INDICATORS, SYMBOLS AND MEANING
If the indicator lights are “OFF”, the charger
is not receiving power from power supply
outlet.
If the green indicator light is
“ON”, the charger is plugged in
but the battery pack is not
inserted, or the battery pack is fully charged
and is being trickle charged.
If the green indicator light is
“BLINKING”, the battery pack is
being fast-charged. Fastcharging will automatically stop when the
battery pack is fully charged.
If the red indicator light is “ON”,
the battery pack is too hot or
cold for fast-charging. The
charger will switch to trickle charge, until a
suitable temperature is reached, at which
time the charger will switch automatically to
fast-charging.
If the red indicator light is
“BLINKING”, the battery pack
cannot accept a charge or the
contacts of the charger or battery pack are
contaminated. Clean the contacts of the
charger or battery pack only as directed in
these operating instructions or those
supplied with your tool or battery pack.
-14-
BM 2610925945 6-05 6/10/05 10:30 AM Page 15
Plug charger cord into your standard power
outlet. Before inserting battery pack, remove
protective cap, then insert battery pack into
charger (Fig. 15).
The charger’s green indicator light will begin to
“BLINK”. This indicates that the battery is
receiving a fast charge. Fast-charging will
automatically stop when the battery pack is
fully charged.
When the indicator light stops “BLINKING”
(and becomes a steady green light) fast
charging is complete.
The battery pack may be used even though
the light may still be blinking. The light may
require more time to stop blinking depending
on temperature. When you begin the charging
process of the battery pack, a steady red light
BATTERY
PACK
CHARGER
could also mean the battery pack is too hot or
too cold.
The purpose of the green light is to indicate
t
hat the battery pack is fast-charging. It does
n
ot indicate the exact point of full charge. The
light will stop blinking in less time if the battery
pack was not completely discharged.
When charging several batteries in sequence,
the charge time may slightly increase.
When the battery pack is fully charged,
unplug the charger (unless you're charging
another battery pack) and slip the battery
pack back into the tool.
To prevent fire or injury when batteries are
not in tool or charger, always place protective
cap onto end of battery pack.
FIG. 15
PROTECTIVE
CAP
RED LIGHT
GREEN LIGHT
CHARGING BATTERY PACK (30 MINUTE DUAL BAY-BC230)
INDICATORS, SYMBOLS AND MEANING
If the indicator lights are “OFF”, the charger
is not receiving power from power supply
outlet.
If the red indicator light is
“ON”, the battery pack is too
hot or cold for fast-charging.
The charger will switch to trickle charge, until
a suitable temperature is reached, at which
time the charger will switch automatically to
fast-charging.
If the red indicator light is
“BLINKING”, the battery pack
cannot accept a charge or
the contacts of the charger or battery pack
are contaminated. Clean the contacts of the
charger or battery pack only as directed in
these operating instructions or those
supplied with your tool or battery pack.
If the green indicator light is
“BLINKING”, the battery pack
is being fast-charged. Fastcharging will automatically stop when the
battery pack is fully charged.
If the green indicator light is
“ON”, the charger is plugged
in but the battery pack is not
inserted, or the battery pack is fully charged
and is being trickle charged.
-15-
BM 2610925945 6-05 6/10/05 10:30 AM Page 16
Plug charger cord into your standard power
outlet. Before inserting battery pack, remove
protective cap, then insert battery pack into
charger (Fig. 16).
The charger’s green indicator light will begin to
“BLINK”. This indicates that the battery is
receiving a fast charge. Fast-charging will
automatically stop when the battery pack is
fully charged.
When the indicator light stops “BLINKING”
(and becomes a steady green light) fast
charging is complete.
The battery pack may be used even though
the light may still be blinking. The light may
require more time to stop blinking depending
on temperature. When you begin the
charging process of the battery pack, a
BATTERY
PACK
steady red light could also mean the battery
pack is too hot or too cold.
The purpose of the green light is to indicate
that the battery pack is fast-charging. It does
not indicate the exact point of full charge.
The light will stop blinking in less time if the
battery pack was not completely discharged.
When charging several batteries in
sequence, the charge time may slightly
increase.
When the battery pack is fully charged,
unplug the charger (unless you're charging
another battery pack) and slip the battery
pack back into the tool.
To prevent fire or injury when batteries are
not in tool or charger, always place protective
cap onto end of battery pack.
FIG. 16
PROTECTIVE
CAP
CHARGER
RED LIGHT
CHARGING BATTERY PACK (1 HOUR CHARGER)
INDICATORS, SYMBOLS AND MEANING
If the indicator lights are “OFF”, the charger
is not receiving power from power supply
outlet.
If the green indicator light is “ON”,
the charger is plugged in but the
battery pack is not inserted, or the
battery pack is fully charged and is being
trickle charged, or the battery pack is too hot
or cold for fast-charging. The charger will
GREEN LIGHT
switch to trickle charge, until a suitable
temperature is reached, at which time the
charger will switch automatically to fastcharging.
If the green indicator light is
“BLINKING”, the battery pack is
being fast-charged. Fast-charging
will automatically stop when the battery pack
is fully charged.
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BM 2610925945 6-05 6/10/05 10:30 AM Page 17
Plug charger cord into your standard power
outlet. Before inserting battery pack, remove
protective cap, then insert battery pack into
charger (Fig. 17).
The charger’s green indicator will begin to
“BLINK”. This indicates that the battery is
receiving a fast charge. Fast-charging will
automatically stop when the battery pack is
fully charged.
When the indicator light stops “BLINKING”
(and becomes a steady green light) fast
charging is complete.
When you begin the charging process of the
battery pack, a steady green light could also
mean the battery pack is too hot or too cold.
BATTERY
PACK
CHARGER
The purpose of the light is to indicate that the
battery pack is fast-charging. It does not
indicate the exact point of full charge. The
light will stop blinking in less time if the
battery pack was not completely discharged.
When the battery pack is fully charged,
unplug the charger (unless you're charging
another battery pack) and slip the battery
pack back into the tool handle (Fig.17).
To prevent fire or injury when batteries are
not in tool or charger, always place protective
cap onto end of battery pack.
FIG. 17
BATTERY PACK
RELEASE TABS
PROTECTIVE
CAP
INDICATOR
LIGHT
Maintenance
Service
!
WARNING
maintenance performed by unauthorized
personnel may result in misplacing of
internal wires and components which
could cause serious hazard.
mend that all tool service be performed by a
Bosch Factory Service Center or Authorized
Bosch Service Station. SERVICEMEN:
Disconnect tool and/or charger from power
source before servicing.
NO USER SERVICEABLE
PARTS INSIDE. Preventive
We recom
Be alert for battery packs that are nearing
BATTERIES
their end of life.
If you notice decreased
tool performance or significantly shorter
running time between charges then it is time
to replace the battery pack. Failure to do so
can cause the tool to operate improperly or
damage the charger.
Long term battery storage should be in
the discharged state.
Battery packs last
longer and re-charge better when they are
stored discharged. Remember to fully re-
-17-
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