Bosch 1660, 1662 User Manual

Operating/Safety Instructions

Consignes de fonctionnement/sécurité
Instrucciones de funcionamiento

y seguridad

1660

1662

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 16 Ver página 30

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

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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

-2-

Work Area

Keep your work area clean and well lit.

Cluttered benches and dark areas invite
accidents.

Do not operate power tools in explosive
atmospheres, such as in the presence of
flammable liquids, gases, or dust. Power

tools create sparks which may ignite the
dust or fumes.

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

Distractions can cause you to lose control.

Electrical Safety

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

fire.

A battery operated tool with integral
batteries or a separate battery pack must
be recharged only with the specified
charger for the battery. A charger that may

be suitable for one type of battery may
create a risk of fire when used with another
battery.

Use battery operated tool only with
specifically designated battery pack. Use

of any other batteries may create a risk of
fire.

Personal Safety

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

operating power tools may result in serious
personal injury.

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

or long hair can be caught in moving parts.

Avoid accidental starting. Be sure switch
is in the locked or off position before
inserting battery pack. Carrying tools with

your finger on the switch or inserting the
battery pack into a tool with the switch on
invites accidents.

Remove adjusting keys or wrenches
before turning the tool on. A wrench or a

key that is left attached to a rotating part of
the tool may result in personal injury.

Do not overreach. Keep proper footing
and balance at all times. Proper footing

and balance enable better control of the tool
in unexpected situations.

Use safety equipment. Always wear eye
protection. Dust mask, non-skid safety

shoes, hard hat, or hearing protection must
be used for appropriate conditions.

Tool Use and Care

Use clamps or other practical way to
secure and support the workpiece to a
stable platform. Holding the work by hand

or against your body is unstable and may
lead to loss of control.

Do not force tool. Use the correct tool for
your application. The correct tool will do

the job better and safer at the rate for which
it is designed.

Do not use tool if switch does not turn it
on or off. A tool that cannot be controlled

with the switch is dangerous and must be
repaired.

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

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

idle tools out of reach of children and
other untrained persons. Tools are

dangerous in the hands of untrained users.

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

!

WARNING

General Safety Rules

For All Battery Operated Tools

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-3-

Safety Rules for Circular Saws

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

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

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

tools with sharp cutting edge are less likely
to bind and are easier to control.

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

caused by poorly maintained tools.

Use only accessories that are recom­mended by the manufacturer for your

model. Accessories that may be suitable for

one tool may create a risk of injury when
used on another tool.

Service

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

maintenance performed by unqualified
personnel may result in a risk of injury.

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

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

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.

!

DANGER

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When ripping always use a rip fence or
straight edge guide. This improves accuracy

of cut and reduces the chance for blade
binding.

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

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

Never use damaged or incorrect blade
washers or bolts. The blade washers and bolt

were specially designed for your saw, for
optimum performance and safety of operation.

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

Do not run the saw while carrying it at your
side. Lower guard may be opened by a
contact with your clothing. Accidental

contact with the spinning saw blade could
result in serious personal injury.

Depending upon use, the switch may not
last the life of the saw. If the switch should
fail in the “OFF” position, the saw may not
start. If it should fail while the saw is
running, the saw may not shut off. If either

occurs, remove battery pack from saw
immediately and do not use until repaired.

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

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

CAUSES AND OPERATOR PREVENTION OF

KICKBACK:

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

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

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

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

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

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.

-4-

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:

• Lead from lead-based paints,

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

• Arsenic and chromium from chemically­treated lumber.

Your risk from these exposures varies,
depending on how often you do this type of
work. To reduce your exposure to these
chemicals: work in a well ventilated area,
and work with approved safety equipment,
such as those dust masks that are specially
designed to filter out microscopic particles.

This product is intended to cut wood and
wood-like products only. Dust build up

around the lower guard and hub from other
materials (plastic, masonry or metal) may
disable the lower guard operation.

-5-

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-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.

Battery/Charger

!

WARNING

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-6-

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
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.

!

WARNING

Battery Care

Do not attempt to disas­semble the battery or

remove any component projecting from
the battery terminals. Fire or injury may

result. Prior to disposal, protect exposed
terminals with heavy insulating tape to
prevent shorting.

NICKEL-CADMIUM BATTERIES

If equipped with a nickel-cadmium battery,
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 is

voluntarily 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-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.”

NICKEL-METAL HYDRIDE BATTERIES

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

!

WARNING

Battery Disposal

!

WARNING

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-7-

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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-8-

Functional Description and Specifications

FOOT

LOWER

GUARD LIFT

LEVER

AUXILIARY

HANDLE

BEVEL

ADJUSTMENT

KNOB

CALIBRATED BEVEL

QUADRANT

Disconnect battery pack from 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.

!

WARNING

DUST PORT

COVER

DEPTH

ADJUSTMENT

KNOB

Cordless

Circular Saws

UPPER GUARD

LOWER GUARD

ADJUSTABLE

LINE GUIDE

LOCK

BUTTON

PUSH 45°STOP SPRING IN

DIRECTION OF ARROW

FOR 50°

FIG. 1

BATTERY PACK
RELEASE TABS

BATTERY

PACK

ALIGNMENT

SCREW

SAFETY SWITCH

RELEASE

BUTTON

TRIGGER

BLADE WRENCH &

STORAGE AREA

VENTILATION

OPENINGS

END OF CUT ARROW

BEGINNING OF

CUT ARROW

Tool Maximum Capacities

Model number 1660 1662 Blade 6-1/2"
Voltage rating 24 V 18 V Depth of cut at 90° 2-1/8"
No load speed n

0

3,600/min n0 3,600/min Depth of cut at 45° 1-5/8"

Charge time 1 hr 1 hr Depth of cut at 50° 1-1/2"
Charger BC004, 6, & BC016 BC003, 4, 6, & BC016 ATTENTION: Use only thin

Voltage rating 120 V 60 Hz 120 V 60 Hz kerf blades designed for
Battery pack BAT030 & BAT031 BAT025 & BAT026 Cordless Circular Saws.

BC006 charger requires 12 V DC input

NOTE: ONLY USE CHARGERS LISTED ABOVE

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

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-9-

Assembly

ATTACHING THE BLADE

Disconnect battery pack

from 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 around 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 stud.

VARI-TORQUE CLUTCH

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 1/2 mark more.
OVERTIGHTENING THE BLADE STUD
NULLIFIES THE EFFECTIVE-NESS OF THE
CLUTCH.

DUST EXTRACTION

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.

To prevent personal injury,

always position vacuum
hose so that it does not interfere with the
lower guard, or the cutting operation at all
settings.

!

WARNING

FIG. 2

TIGHTEN

LOOSEN

BLADE

STUD

LOWER
GUARD

SPRING

OUTER WASHER

Large Diameter

Faces Blade

INNER WASHER

Large Diameter

Faces Blade

BLADE

LOWER
GUARD

BLADE
SHAFT

UPPER

GUARD

!

WARNING

WRENCH

OUTER WASHER

MARK

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-10-

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).

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.)

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).

DEPTH ADJUSTMENT

Operating Instructions

0

2

1

90°

FIG. 3

FIG. 4

FIG. 5

FIG. 7

FIG. 6

ONE TOOTH LENGTH SHOULD

PENETRATE WOOD FOR

MINIMUM SPLINTERING

DEPTH

ADJUSTMENT

KNOB

CALIBRATED DEPTH

BRACKET

BLADE WRENCH

& STORAGE

AREA

SAFETY SWITCH

RELEASE

BUTTON

ALIGNMENT

SCREW

BEVEL

ADJUSTMENT

KNOB

BLADE

TRIGGER

FOOT

BM 2610914527 3/03 3/18/03 10:47 AM Page 10

BEVEL ADJUSTMENT

Disconnect battery pack from tool. The foot
can be adjusted up to 45° 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). For 50° loosen bevel adjustment
knob, depress 45° stop spring (Fig. 9), align
foot to 50 mark on quadrant and tighten knob.
Because of the increased amount of blade
engagement in the work and decreased
stability of the foot, blade binding may occur.
Keep the saw steady and the foot firmly on
the workpiece.

-11-

ADJUSTABLE LINE GUIDE

For a straight 90° cut you can use the left or
right side of notch in the foot. For 45° bevel
cuts, use the right side (Fig 9). The guide can
be adjusted to allow for variation in blade
thicknesses for whichever side of the blade
the user would prefer to cut the line on.

TO ATTACH: Disconnect battery pack from
tool. Align hole in adjustable line guide with
hole in foot and secure with screw provide.

TO ADJUST: Loosen but don’t remove, the
adjustment screw enough so the guide can
move freely. Set a straightedge flat on the
preferred side of the blade, lining up both the
edge of the straightedge and the edge of the
guide where the 0° mark is located.

SWITCH

To turn tool “ON”, squeeze the trigger 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.

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.

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.

!

WARNING

!

WARNING

45º

0º

FIG. 9

45°

BEVEL CUTS

90°

VERTICAL

CUTS

GUIDE

ADJUSTMENT

SCREW

ADJUSTABLE LINE

GUIDE

FIG. 8

BEVEL

ADJUSTMENT

KNOB

QUADRANT

PUSH 45°STOP

SPRING IN

DIRECTION OF

ARROW FOR 50°

45°STOP

SPRING

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-12-

POCKET CUTS

Disconnect battery pack from tool before
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
handles (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.

CUTTING LARGE SHEETS

Large sheets and long boards sag or bend,
depending on support. If you attempt to cut
without leveling and properly supporting the
piece, the blade will tend to bind, causing KICK­BACK 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.

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). To attach fence, insert fence through slots
in foot to desired width as shown and secure
with the knob.

RIP BOARD GUIDE

When rip cutting large sheets, the rip fence
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.

FIG. 10

FIG. 11

FIG. 12

FIG. 13

FIG. 14

WRONG

RIGHT

FOOT

LOWER

GUARD

LIFT

LEVER

RIP

FENCE

KNOB

DESIRED

WIDTH

OF CUT

DESIRED

LINE

OF CUT

RIP

BOARD

GUIDE

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CHARGING BATTERY PACK (1 HOUR CHARGER)

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 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.

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.15).

To prevent fire or injury when batteries are
not in tool or charger, always place
protective cap onto end of battery pack.

INDICATOR

LIGHT

CHARGER

BATTERY

PACK

PROTECTIVE

CAP

FIG. 15

RELEASING AND INSERTING BATTERY PACK

Release battery pack from tool by pressing
on both sides of the battery release tabs and
pull downwards. Before inserting battery
pack, remove protective cap from battery

pack. To insert battery, align battery and
slide battery pack into tool until it locks into
position. Do not force.

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).

BATTERY PACK
RELEASE TABS

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-14-

Maintenance

Service

NO USER SERVICEABLE

PARTS INSIDE. Preventive
maintenance performed by unauthorized
personnel may result in misplacing of
internal wires and components which
could cause serious hazard. We recom-

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.

BATTERIES

Be alert for battery packs that are nearing
their end of life. Battery packs typically last

from 500 to 1000 charges. 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 re­charge battery packs before using after

prolonged storage.

TOOL LUBRICATION

Your Bosch tool has been properly
lubricated and is ready for use.

D.C. MOTORS

The motor in your tool has been engineered
for many hours of dependable service. To
maintain peak efficiency of the motor, we
recommend it be examined every six
months. Only a genuine Bosch replacement
motor specially designed for your tool
should be used.

BEARINGS

Bearings which become noisy (due to heavy
load or very abrasive material cutting) should
be replaced at once to avoid overheating and
motor failure.

Cleaning

To avoid accidents, always
disconnect the tool and/or

charger from the power supply before
cleaning. 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 opening.

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

!

CAUTION

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. Remember to unplug charger during
storage period.

5. If battery does not charge properly:
a. Check for voltage at outlet by

plugging in some other electrical device.

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