Bosch CCS180 User Manual

BM 2610001787 07-08 7/24/08 10:42 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

CCS180

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BM 2610001787 07-08 7/24/08 10:42 AM Page 2

General Power Tool Safety Warnings

WARNING

The term “power tool” in all of the warnings listed below refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

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.

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.

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.

cords increase the risk of electric shock.

When operating a power tool outdoors, use an extension cord suitable for outdoor use.

Use of a cord suitable for outdoor use

reduces the risk of electric shock.

If operating the power tool in damp locations is unavoidable use a Ground Fault Circuit Interrupter (GFCI) protected supply.

a GFCI reduce the risk of electric shock.

GFCI and personal protection devices like electrician’s rubber gloves and footwear will further enhance your personal safety.

ead all safety warnings and instructions. Failure to follow the warnings

and instructions may result in electric shock, fire and/or serious injury.

SAVE ALL WARNINGS AND INSTRUCTIONS

FOR FUTURE REFERENCE

Work area safety

Power

Distractions can

Electrical safety

Unmodified plugs

There is an increased risk

Water entering a power tool will

Damaged or entangled

Use of

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.

While the tool may appear to

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.

while operating power tools may result in serious personal injury.

Use personal protective equipment. Always wear eye protection.

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

Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source and / or battery pack, picking up or carrying the tool.

power tools with your finger on the switch or plugging in power tools that have the switch on invites accidents.

Remove any adjusting key or wrench before turning the power tool on.

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.

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.

clothes, jewelry or long hair can be caught in moving parts.

If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used.

Use of dust collection can reduce dust-

related hazards.

A moment of inattention

Protective equipment

A wrench or a

This enables better

Carrying

Loose

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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.

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.

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.

preventive safety measures reduce the risk of starting the power tool accidentally.

Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool.

dangerous in the hands of untrained users.

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

Many accidents are caused by poorly maintained power tools.

Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.

Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed.

power tool for operations different from those intended could result in a hazardous situation.

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

Holding the work by hand or against

Any power tool that

The correct

Such

Power tools are

Use of the

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

Battery tool use and care

Ensure the switch is in the off position before inserting battery pack.

battery pack into power tools that have the switch on invites accidents.

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 power 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.

Liquid ejected from the

Inserting the

A charger that is

Use of any other

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.

cleaning agents such as gasoline, carbon tetrachloride, ammonia, etc. may damage plastic parts.

This will ensure that the

Certain

SAVE ALL WARNINGS AND INSTRUCTIONS

FOR FUTURE REFERENCE

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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.

Do not reach underneath the workpiece.

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

Adjust the cutting depth to the thickness of the workpiece.

blade teeth should be visible 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 running, the saw may not shut off.

Keep hands away from cutting area and blade.

If hands are holding the

Less than a full tooth of the

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

If either

occurs, unplug the saw immediately and do not use until repaired.

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

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

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.

. Dust build up

Kickback and related warnings

Causes and operator prevention of kickback:

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

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

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

Kickback is the result of tool misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below:

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

Kickback could cause the saw to jump backwards, but kickback forces can be controlled by the operator, if proper precautions are taken.

When blade is binding, or when interrupting a cut for any reason, release the trigger and hold the saw motionless in the material until the blade comes to a complete stop. Never attempt to remove the saw from the work or pull the saw backward while the blade is in motion or kickback may occur.

Investigate and take corrective action to eliminate the cause of blade binding.

When restarting a saw in a workpiece, center the saw blade in the kerf and check

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KICKBACK

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that saw teeth are not engaged into the material.

up or kickback from the workpiece as the saw is restarted.

Support large panels to minimize the risk of blade pinching and kickback.

tend to sag under their own weight. Supports must be placed under the panel on both sides, near the line of cut and near the edge of the panel.

Do not use dull or damaged blade.

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

Blade depth and bevel adjusting locking levers must be tight and secure before making cut.

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 saw blade is binding, it may walk

Large panels

If blade adjustment shifts while

The protruding blade may cut objects

The proper

Kickback could cause the saw to jump

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.

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.

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.

lower 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 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.

Lower guard may operate

For all other sawing, the

An unprotected,

Accidental

Preventive maintenance

Some dust created by power sanding, sawing,

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If saw is

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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.

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 +32 degrees F (0 degrees C) and below

Incorrect reassembly or damage

Battery short or fire may result.

See Functional Description and

Do not

+113 degrees F (45 degrees C). Store tool and battery pack in locations where temperatures will not exceed 120 degrees F (49 degrees C).

serious 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. 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 will result in a risk of fire, electric shock or injury to persons.

This is important to prevent

The battery

Battery Care

WARNING

away from metal objects.

protect terminals from shorting place batteries in a tool box or pocket with

When batteries are not in tool or charger, keep them

For example, to

NOT

nails, screws, keys, etc. Fire or injury may result.

DO NOT PUT BATTERIES INTO FIRE OR EXPOSE TO HIGH HEAT.

explode.

They may

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Battery Disposal

WARNING

remove any component projecting from the battery terminals.

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

If equipped with a lithium-ion battery, the battery must be collected, recycled or disposed of in an environmentally sound manner.

Do not attempt to disassemble the battery or

Fire or injury may result.

LITHIUM-ION BATTERIES

“The EPA certified RBRC Battery Recycling Seal on the lithium-ion (Li-ion) 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 Li-ion 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 Li-ion 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.”

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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.

.../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 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

Li-ion RBRC seal Designates Li-ion battery recycling

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 by the Intertek Testing

This symbol designates that this tool is listed by the Canadian Standards Association, to United States and Canadian Standards.

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

This symbol

designates that this tool complies to NOM Mexican Standards.

Services, to United States and Canadian Standards.

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Functional Description and Specifications

WARNING

isconnect battery pack from tool before making any assembly,

adjustments or changing accessories

reduce the risk of starting the tool accidentally.

Cordless Circular Saw

. Such preventive safety measures

CALIBRATED BEVEL

QUADRANT

ADJUSTMENT

FIG. 1

BLADE WRENCH &

STORAGE AREA

BATTERY PACK

RELEASE BUTTON

AUXILIARY

HANDLE

BEVEL

KNOB

FOOT

UPPER GUARD

TRIGGER SWITCH

RUBBERIZED

GRIP

BATTERY

PACK

LOWER

GUARD LIFT

LEVER

LOWER GUARD

SAFETY SWITCH

RELEASE BUTTON

LOCK

BUTTON

DEPTH ADJUSTMENT

LEVER

Model No. CCS180 Voltage rating 18 V No load speed n

3,900/min

Battery pack BAT609 & BAT618

Charger BC630 & BC660

Voltage rating

120 V 60 Hz

VENTILATION

OPENINGS

Maximum Capacities

Blade 6-1/2" Depth of cut at 0° 2" Depth of cut at 45° 1-9/16" Depth of cut at 50° 1-3/8"

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

ALIGNMENT

SCREW

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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Assembly

ATTACHING THE BLADE

WARNING

isconnect battery pack

from tool 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 upper

UPPER GUARD

guard has marks around it that will help you p

roperly adjust the blade stud. Press lock button to lock shaft and TIGHTEN BLADE STUD COUNTER-CLOCKWISE TWO MARKS ON UPPER GUARD 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 one mark more. OVERTIGHTENING THE BLADE STUD NULLIFIES THE EFFECTIVE-NESS OF THE CLUTCH.

FIG. 2

LOWER GUARD

BLADE SHAFT

LOWER GUARD SPRING

INNER WASHER

Large Diameter Faces Blade

-10-

BLADE

WRENCH

LOOSEN

MARK

OUTER

WASHER

OUTER WASHER

Large Diameter

Faces Blade

BLADE STUD

TIGHTEN

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Operating Instructions

DEPTH ADJUSTMENT

Disconnect battery pack from tool. Loosen the depth adjustment lever located on the right side of the tool. Hold the foot down with one hand and raise or lower saw by the handle.

Tighten lever 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

CALIBRATED DEPTH

BRACKET

DEPTH

ADJUSTMENT

LEVER

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 12.)

FIG. 5

SAFETY SWITCH

RELEASE BUTTON

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 lever, set to 0° on quadrant, retighten lever 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 from bottom side of foot, if necessary (Fig. 7).

FIG. 6

BEVEL

ADJUSTMENT

KNOB

FIG. 7

TRIGGER

-11-

FOOT

BLADE

ALIGNMENT

SCREW

BM 2610001787 07-08 7/24/08 10:42 AM Page 12

Disconnect battery pack from tool. The foot

BEVEL ADJUSTMENT

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. Keep the saw steady and the foot firmly on the workpiece.

LINE GUIDE

For a straight 90° cut, use left side of notch in the foot. For 45° & 50° bevel cuts, use the right 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 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.

FIG. 8

QUADRANT

90°

VERTICAL

CUTS

45° & 50°

BEVEL

CUTS

BEVEL

ADJUSTMENT

KNOB

FIG. 9

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.

When the trigger is released it activates the electrical brake to stop the blade quickly. This feature is especially useful when making repetitive 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

free movement of the lower guard.

SWITCH

BRAKE

GENERAL CUTS

Always be sure either hand does not interfere with the

Maintain a firm grip and operate the switch with a decisive action. Never force the saw. Use light and continuous pressure.

WARNING

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.

After completing a cut and the trigger has been

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CUTTING MASONRY/METAL

This tool is not recommended for usage with metal or masonry cut-off wheels.

WARNING

saw.

The dust from metal or masonry cutting

ill cause the lower guard to become sluggish and may not close fully and quickly after cutting these materials.

WARNING

Disconnect battery pack from tool before making adjustments. Set depth adjustment 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

guard immediately.

on the surface being cut, proceed cutting in forward direction to end of cut.

WARNING

the saw from cut. Also, never pull the saw

Do not cut metal or masonry with this circular

Do not cut with abrasive wheels around flammable

PLUNGE CUTS

As blade starts cutting the material, release the lower

When the foot rests flat

Allow blade to come to a complete stop before lifting

materials or environments.

may produce sparks that could ignite flammable materials and cause explosion hazards.

WARNING

eed devices with this circular saw.

Masonry cutting waste will enter the lower guard system, harden and cause the guard to become inoperable. Use of water in masonry cutting applications with an electric circular saw will cause electric shock hazards.

backward since blade will climb out of the material and KICKBACK will occur.

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.

Do not use Wet Diamond cutting off wheel or water

Abrasive cutting

Turn

FIG. 10

LOWER GUARD

LIFT

LEVER

FOOT

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 piece, 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

FIG. 11

WRONG

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. 12

RIGHT

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The combination blade provided with your saw

RIP CUTS

is for both cross cuts and rip cuts. Ripping is cutting lengthwise with the grain of the wood. R

ip 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.

FIG. 13

DESIRED

WIDTH

OF CUT

KNOB

RIP

FENCE

WARNING

After attaching or adjusting

the rip fence, be sure the rip fence does not touch or interfere with the free movement of the lower guard or contact the saw blade.

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 t

he sheet as a guide (Fig. 14). Use the right

ide of the foot against the board guide.

FIG. 14

DESIRED

LINE

OF CUT

RIP

BOARD

GUIDE

INSERTING AND RELEASING BATTERY PACK

Set Forward/Reversing lever to the center (off position). Slide charged battery pack into the housing until the battery pack locks into position (Fig. 1).

Your tool is equipped with a secondary locking latch to prevent the battery pack from completely falling out of the handle, should it become loose due to vibration.

IMPORTANT CHARGING NOTES

1. The charger was designed to fast charge the battery only when the battery temperature is between 32˚F (0˚C) and 113˚F (45˚C). If the battery pack is too hot or too cold, the charger will not fast charge the battery. (This may happen if the battery pack is hot from heavy use). When the battery temperature returns to between 32˚F (0˚C) and 113˚F (45˚C), the charger will automatically begin charging.

To remove the battery pack, press the battery pack release button and slide the battery pack forward.

Press the battery pack release button again and slide the battery pack completely out of tool housing (Fig. 1).

2. 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.

3. Remember to unplug charger during storage period.

4. If battery does not charge properly:

a. Check for voltage at outlet by plugging in

some other electrical device.

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BM 2610001787 07-08 7/24/08 10:42 AM Page 15

b. Check to see if outlet is connected to a light switch which turns power “off” when lights are turned off.

. Check battery pack terminals for dirt. Clean with cotton swab and alcohol if necessary.

CHARGER INDICATORS, SYMBOLS AND MEANING (Model BC630)

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

the battery pack is fully charged.

charging will automatically stop when the battery pack is fully charged.

Plug charger cord into your standard power outlet.

With no battery pack inserted, the charger’s green indicator light will go ON. This indicates the charger is receiving power and the charger is ready for operation.

When you insert the battery pack into the charger. The charger’s green indicator light will begin to “BLINK”. This indicates that the battery is receiving a fast charge (Fig. 15).

When the indicator light stops “BLINKING” (and becomes a steady green light) fast charging is complete. The battery pack is fully charged and can be removed from the charger.

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.

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.

battery pack is not inserted, or

If the green indicator light is “BLINKING”, the battery pack is being fast-charged. Fast-

CHARGING BATTERY PACK (Model BC630

d. If you still do not get proper charging, take or send tool, battery pack and charger to your local Bosch Service Center. See “Tools, Electric” in the Yellow Pages for names and a

ddresses.

Note: Use of chargers or battery packs not sold by Bosch will void the warranty.

If the red indicator light is “ON”, the battery pack is too hot or cold

automatically switch to fast-charging once a suitable temperature is reached.

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.

When you begin the charging process of the battery pack, a steady red light could also mean the battery pack is too hot or too cold.

Fast charging is only possible when the temperature range of the battery pack is between 32˚F (0˚C) and 113˚F (45˚C). When needed, the internal fan of the charger will turn on to aid the charging process and speed.

As soon as the battery pack reaches the correct temperature range, the battery charger will automatically switch to fast charging.

If the red indicator light is “BLINKING”, the battery pack cannot accept a charge.

• Check to make sure the battery pack is

inserted into the charger properly.

• Clean the contacts of the charger or battery

pack (e. g. by inserting and removing the battery several times) or replace the battery pack, as required.

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.

for fast-charging. The charger will

If the red indicator light is “BLINKING”, the battery pack cannot accept a charge or the

)

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BM 2610001787 07-08 7/24/08 10:42 AM Page 16

FIG. 15

BATTERY

PACK

CHARGER

RED LIGHT

GREEN LIGHT

CHARGER INDICATORS, SYMBOLS AND MEANING (Model BC660)

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,

the battery pack is too hot or cold for fastcharging. The charger will automatically switch

CHARGING BATTERY PACK (Model BC660)

Plug charger cord into your standard power outlet.

With no battery pack inserted, the charger’s green indicator light will go ON. This indicates the charger is receiving power and the charger is ready for operation.

When you insert the battery pack into the charger, the charger’s green indicator light will begin to “BLINK”. This indicates that the battery is receiving a fast charge (Fig. 16).

When the indicator light stops “BLINKING” (and becomes a steady green light) fast charging is complete. The battery pack is fully charged and can be removed from the charger.

to fast-charging once a suitable temperature is reached.

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.

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.

As soon as the battery pack reaches the correct temperature range, the battery charger will automatically switch to fast charging.

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.

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BM 2610001787 07-08 7/24/08 10:42 AM Page 17

If the green indicator light is “ON”, the battery pack cannot accept a charge.

• Check to make sure the battery pack is inserted into the charger properly.

FIG. 16

GREEN LIGHT

• Clean the contacts of the charger or battery pack (e. g. by inserting and removing the battery several times) or replace the battery pack, as required.

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.

BATTERY

PACK

CHARGER

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.

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

performance or significantly shorter running time between charges then it is time to replace the battery pack. Failure to do so can

NO USER SERVICEABLE PARTS INSIDE. Preventive

We recom-

BATTERIES

If you notice decreased tool

cause the tool to operate improperly or damage the charger.

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.

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