Bosch Power Tools CS5 User Manual

BM 1619P06013 06-07 6/14/07 3:42 PM 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
CS5
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& Service Locations
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BM 1619P06013 06-07 6/14/07 3:42 PM Page 2
General Safety Rules
R
WARNING
!
all of the warnings listed below refers to your mains-operated (corded) power tool or battery­operated (cordless) power tool.
ead all instructions. Failure to follow all instructions listed below may
r
esult in electric shock, fire and/or serious injury.
T
he 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.
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
Damaged or
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.
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 used.
related hazards.
Safety equipment such as dust
Carrying power tools with your
Loose clothes, jewelry or long hair can
Use of these devices can reduce dust-
-2-
A moment of
A wrench
This enables
BM 1619P06013 06-07 6/14/07 3:42 PM Page 3
Keep handles dry, clean and free from oil and grease.
c
ontrol 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.
T
he 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.
Many accidents are caused by
Any power tool
Such preventive safety
Keep cutting tools sharp and clean.
Properly maintained cutting tools with sharp c
utting edges are less likely to bind and are
easier to control.
Use the power tool, accessories and tool bits etc., in accordance with these instructions and in the manner intended for the particular type of power tool, taking into account the working conditions and the work to be performed.
Use of the power tool for operations different from those intended could result in a hazardous situation.
Use clamps or other practical way to secure and support the workpiece to a stable platform.
or against your body is unstable and may lead to loss of control.
Holding the work by hand
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.
gasoline, carbon tetrachloride, ammonia, etc. may damage plastic parts.
Certain cleaning agents such as
This will ensure that the
SAVE THESE INSTRUCTIONS
Safety Rules for Circular Saws
!
WARNING
!
DANGER
Keep your second hand on auxiliary handle, or motor housing.
holding the saw, they cannot be cut by the blade.
Adjust the cutting depth to the thickness of the workpiece.
blade teeth should be visible below the workpiece.
Read all safety warnings and all instructions.
Cutting procedures
Keep hands away from cutting area and blade.
If hands are
Less than a full tooth of the
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
It is important to support the
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wiring or it own cord. Contact with a "live" wire will also make exposed metal parts of the tool “live” and shock the operator.
When ripping always use a rip fence or straight edge guide.
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.
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.
Figures in this manual illustrate
This improves accuracy
The blade washers and bolt
Wet lumber, green lumber or
If either
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:
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.
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.
If saw blade is binding, it may walk
Large panels
If blade adjustment shifts while
The protruding blade may cut objects
The proper
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Never place your hand behind the saw
Kickback could cause the saw to jump
blade.
b
ackwards over your hand.
Do not use the saw with an excessive depth of cut setting.
exposure increases the likelihood of the blade t
wisting in the kerf and increases the surface area of the blade available for pinching that leads to kickback.
Too much blade
VARI-TORQUE
CLUTCH
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 may operate
If saw is
Lower guard should be retracted manually only for special cuts such as “Plunge Cuts” a
nd “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 designed to filter out microscopic particles.
For all other sawing, the lower
An unprotected,
Accidental
Preventive maintenance
Some dust created by power sanding, sawing,
-5-
0
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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.
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 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
This symbol designates that this tool is listed by Underwriters Laboratories.
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 the Canadian Standards Association.
This symbol designates that
this tool is listed by
Underwriters Laboratories,
and listed to Canadian
Standards by Underwriters
Laboratories.
-6-
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Functional Description and Specifications
WARNING
!
Disconnect the plug from the power source before making any assembly, adjustments or changing accessories
measures reduce the risk of starting the tool accidentally.
Circular Saw
FIG. 1
TRIGGER SWITCH
LOCK LEVER
AUXILIARY
HANDLE
BEVEL SCALE
BEVEL
ADJUSTMENT
LEVER
QUADRANT
. Such preventive safety
UPPER GUARD
LOWER GUARD
LIFT LEVER
FOOT
LOWER GUARD
CALIBRATED DEPTH
BRACKET
Maximum Capacities
Model CS5 Blade 7-1/4" Blade arbor hole Depth of cut at 90° 2-7/16" Depth of cut at 45° 1-13/16"
5/8" Round
VENTILATION
OPENINGS
DEPTH ADJUSTMENT
LEVER
BLADE WRENCH &
STORAGE AREA
NOTE: For tool specifications refer to the nameplate on your tool.
-7-
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Assembly
5
A
TTACHING THE BLADE
!
WARNING
Disconnect the plug from
the power source before making any assembly, adjustments or changing accessories
. Such preventive safety measures reduce the risk of starting the tool accidentally.
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 lever (Fig. 2).
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 INNER and OUTER washers lay flush against the blade.
. Reinstall OUTER WASHER. First tighten BLADE STUD finger tight, then TIGHTEN BLADE STUD 1/8 TURN (45˚) WITH THE WRENCH PROVIDED.
Do not use wrenches with longer handles, since it may lead to over tightening of the blade stud.
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.
VARI-TORQUE CLUTCH
LOCK LEVER
LOWER GUARD
INNER WASHER
Large Diameter
Faces Blade
UPPER GUARD
-8-
LOWER GUARD LIFT LEVER
LOWER GUARD SPRING
BLADE SHAFT
BLADE
OUTER WASHER
Large Diameter
Faces Blade
Loosen
FIG. 2
BLADE
STUD
Tighten
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Operating Instructions
D
isconnect plug from power source. Loosen the depth adjustment lever located in the housing of saw. Hold the foot down with one hand and raise or lower saw by the handle.
FIG. 3
DEPTH ADJUSTMENT
CALIBRATED DEPTH
BRACKET
DEPTH
ADJUSTMENT
LEVER
FOOT
BLADE WRENCH
& STORAGE AREA
90° CUTTING ANGLE CHECK
Disconnect plug from power source. 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. 5). Make adjustments by turning the small alignment screw, if necessary.
Tighten lever at the depth setting desired. C
heck 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. 4
ONE TOOTH LENGTH SHOULD
PENETRATE WOOD FOR
MINIMUM SPLINTERING
FIG. 5
BEVEL
ADJUSTMENT
LEVER
90°
ALIGNMENT
SCREW
FOOT
BLADE
Disconnect plug from power source. The foot
BEVEL ADJUSTMENT
can be adjusted up to 56° by loosening the bevel adjustment lever at the front of the saw. Align to desired angle on calibrated quadrant. Then tighten bevel adjustment lever (Fig. 6).
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.
-9-
FIG. 6
BEVEL
ADJUSTMENT
LEVER
QUADRANT
45º
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For a straight 90° cut, use left side of notch in the foot. For 45°-56° bevel cuts, use the right side (Fig. 7). The cutting guide notch will give a
n 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.
!
WARNING
The torque from the motor can cause the tool to twist.
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.
Always hold the saw handle with one hand and the auxiliary handle or housing with the other.
!
WARNING
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
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.
LINE GUIDE
SWITCH When starting the tool, hold it with both hands.
GENERAL CUTS
Always be sure either hand does not interfere with the
After completing a cut and the trigger has been
90°
VERTICAL
CUTS
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.
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 will cause the lower guard to become sluggish and may not close fully and quickly after cutting these materials.
!
WARNING
materials or environments.
may produce sparks that could ignite flammable materials and cause explosion hazards.
!
WARNING
feed 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.
45°
BEVEL
CUTS
Do not cut metal or masonry with this circular
Do not cut with abrasive wheels around flammable
Abrasive cutting
Do not use Wet Diamond cutting off wheel or water
FIG. 7
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Disconnect the plug from the power source 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, u
sing lift lever and hold the saw by the front and
rear handles (Fig. 8). 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.
the surface being cut, proceed cutting in forward direction to end of cut.
WARNING
!
the saw from cut. backward since blade will climb out of the material and KICKBACK will occur.
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. 9).
Support the panel or board close to the cut, as shown in (Fig. 10). Be sure to set the depth of
PLUNGE CUTS
As blade starts cutting the material, release the lower
When the foot rests flat on
Allow blade to come to a complete stop before lifting
Also, never pull the saw
CUTTING LARGE SHEETS
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. 8
FOOT
LINE GUIDE
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.
LOWER GUARD
LIFT LEVER
FIG. 9
WRONG
FIG. 10
RIGHT
-11-
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R
T
he 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. 11). 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 thumb screw (not included).
IP CUTS
FIG. 11
THUMB SCREW
RIP
FENCE
DESIRED WIDTH
OF CUT
R
W
hen 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. 12).
Use the right side of the foot against the board guide.
IP BOARD GUIDE
FIG. 12
RIP BOARD
GUIDE
DESIRED LINE
OF CUT
Maintenance
Service
WARNING
!
personnel may result in misplacing of internal wires and components which could cause serious hazard.
recommend that all tool service be performed by a Bosch Factory Service Center or Authorized Bosch Service Station.
Your Bosch tool has been properly lubricated and is ready to use. It is recommended that tools with gears be regreased with a special gear lubricant at every brush change.
The brushes and commutator in your tool have been engineered for many hours of dependable service. To maintain peak efficiency of the motor, we recommend every two to six months the brushes be examined. Only genuine Bosch replacement brushes specially designed for your tool should be used.
Preventive maintenance performed by unauthorized
We
TOOL LUBRICATION
CARBON BRUSHES
After about 300-400 hours of operation, or at every second brush change, the bearings should be replaced at Bosch Factory Service Center or Authorized Bosch Service Station. Bearings which become noisy (due to heavy load or very abrasive material cutting) should be replaced at once to avoid overheating or motor failure.
BEARINGS
Cleaning
WARNING
!
the power supply before cleaning or performing any maintenance.
be cleaned most effectively with compressed dry air.
cleaning tools with compressed air.
Ventilation openings and switch levers must be kept clean and free of foreign matter. Do not attempt to clean by inserting pointed objects through openings.
Always wear safety goggles when
-12-
To avoid accidents always disconnect the tool from
The tool may
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