Bosch GKM 18 V-LI Professional Cordless Circular Saw Instruction Manual

GKM 18 V-LI Professional Cordless Circular Saw
Instruction Manual 

GKM 18 V-LI Professional 

Original instructions 

GKM 18 V-LI

Safety Notes

General Power Tool Safety Warnings
WARNING Read all safety warnings and all 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.
The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.
Work area safety

• Keep the 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. Power tools create sparks that may ignite dust or fumes.
• Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

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. Unmodified plugs and matching outlets will reduce the risk of electric shock.
• Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges, and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
• Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
• Do not abuse the cord. Never use the cord for carrying, pulling, or unplugging the power tool. Keep cord away from heat, oil, sharp edges, and moving parts. Damaged or entangled cords increase the risk of electric shock.
• When operating a power tool outdoors, use an extension cord suitable for outdoor use. The use of a cord suitable for outdoor use reduces the risk of electric shock.
• If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. The use of an RCD reduces the risk of electric shock.

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. A moment of inattention while operating power tools may result in serious personal injury
• Use personal protective equipment. Always wear eye protection. Protective equipment such as dust masks, non-skid safety shoes, hard hats, 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 a power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.
• Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.
• Do not overreach. Keep proper footing and balance at all times. This enables 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. Loose 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. The use of dust collection can reduce dust-related hazards.

Power tool use and care

• Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.
• Do not use the power tool if the switch does not turn it on and off. Any power tool 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. Such 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. 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 tool’s 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. Use of the power tool for operations different from those intended could result in a hazardous situation.

Battery tool use and care

• Recharge only with the charger specified by the manufacturer. A charger that is 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. The use of any other battery packs may create a risk of injury and fire.
• When the 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 the eyes, additionally seek medical help. Liquid ejected from the battery may cause irritation or burns.

Service

• Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

Safety Warnings for Circular Saws Cutting procedures

• DANGER: Keep hands away from the cutting area and the blade. Keep your second hand on the auxiliary handle, or motor housing. If both hands are holding the 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. Less than a full tooth of the blade teeth should be visible below the workpiece.
• Never hold a piece being cut in your hands or across your leg. Secure the workpiece to a stable platform. It is important to support the work properly to minimize body exposure, blade binding, or loss of control.
• Hold the power tool by insulated gripping surfaces only, when performing an operation where the cutting tool may contact hidden wiring. Contact with a “live” wire will also make exposed metal parts of the power tool “live” and could give the operator an electric shock.
• When ripping, always use a rip fence or straight edge guide. This improves the accuracy of the cut and reduces the chance of blade binding.
• Always use blades with the correct size and shape (diamond versus round) of arbor holes. Blades that do not match the mounting hardware of the saw will run eccentrically, causing a loss of control.
• 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.
• Kickback causes and Related Warnings – 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 saw 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 arms 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 backward, but kickback forces can be controlled by the operator, if proper precautions are taken.
• When the 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 actions to eliminate the cause of blade binding.
• When restarting a saw in the workpiece, center the saw blade in the kerf and check those saw teeth are not engaged in the material. If the saw blade is binding, it may walk up or kick back 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.
• Do not use dull or damaged blades. 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 cuts. If blade adjustment shifts while cutting, it may cause binding and kickback.
• Use extra caution when sawing into existing walls or other blind areas. The protruding blade may cut objects that can cause kickback.

Lower guard function

• Check lower guard for proper closing before each use. Do not operate the saw if the lower guard does not move freely and close instantly. Never clamp or tie the lower guard into the open position. If the saw is accidentally dropped, the lower guard may be bent. Raise the lower guard with the retracting handle and make sure it moves freely and does not touch the blade or any other part, at all angles and depths of the 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. The lower guard may operate sluggishly due to damaged parts, gummy deposits, or a build-up of debris.
• The lower guard may be retracted manually only for special cuts such as “plunge cuts and angle cuts”. Raise the lower guard by retracting the handle and as soon as the blade enters the material, release the lower guard. For all other sawing operations, the lower guard should operate automatically.
• Always observe that the lower guard is covering the blade before placing the saw down on the bench or floor. An unprotected, coasting blade will cause the saw to walk backward, cutting whatever is in its path. Be aware of the time it takes for the blade to stop after the switch is released.

Additional safety warnings

• Do not work overhead with the saw. In this manner, you do not have sufficient control over the power tool.
• Use appropriate detectors to determine if utility lines are hidden in the work area or call the local utility company for assistance. Contact with electric lines can lead to fire and electric shock. Damaging a gas line can lead to an explosion. Penetrating a water line causes property damage.
• Do not operate the power tool stationary. It is not designed for operation with a saw table.
• Do not use high-speed steel (HSS) saw blades. Such saw blades can easily break.
• When working with the machine, always hold it firmly with both hands and provide a secure stance. The power tool is guided more securely with both hands.
• Secure the workpiece. A workpiece clamped with clamping devices or in a vice is held more secure than by hand.
• Always wait until the machine has come to a complete stop before placing it down. The tool insert can jam and lead to loss of control over the power tool.
• Do not open the battery. The danger of short-circuiting.
  Protect the battery against heat, e. g., against continuous intense sunlight, fire, water, and moisture. The danger of explosion.
• In case of damage and improper use of the battery, vapors may be emitted. Ventilate the area and seek medical help in case of complaints. The vapors can irritate the respiratory system.
• Use the battery only in conjunction with your Bosch power tool. This measure alone protects the battery against dangerous overload.
• The battery can be damaged by pointed objects such as nails or screwdrivers or by force applied externally. An internal short circuit can occur and the battery can burn, smoke, explode or overheat.

Product Description and Specifications

Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire, and/or serious injury. While reading the operating instructions, unfold the graphics page for the machine and leave it open.

Intended Use
The power tool is intended for sawing ferrous metals up to a cutting depth of 50 mm.
The power tool is not intended for working on wood materials.

Product Features

The numbering of the product features refers to the illustration of the machine on the graphics page.

* Accessories shown or described are not part of the standard delivery scope of the product. A complete overview of accessories can be found in our accessories program.

Technical Data

* depending on the battery pack being used
** Limited performance at temperatures <0 °C
Noise/Vibration Information
Sound emission values are determined according to EN 60745-2-5.
Typically the A-weighted sound pressure level of the product is 75 dB(A). Uncertainty K=3 dB. The noise level when working can exceed 80 dB(A).
Wear hearing protection!
Vibration total values ah (triax vector sum) and uncertainty K determined according to EN 60745: Sawing metal: ah <2.5m/s 2 2 , K=1.5 m/s .
The vibration level given in this information sheet has been measured in accordance with a standardized test given in EN 60745 and may be used to compare one tool with another. It may be used for a preliminary assessment of exposure. The declared vibration emission level represents the main applications of the tool. However, if the tool is used for different applications, with different accessories or insertion tools, or is poorly maintained, the vibration emission may differ. This may significantly increase the exposure level over the total working period.
An estimation of the level of exposure to vibration should also take into account the times when the tool is switched off or when it is running but not actually doing the job. This may significantly reduce the exposure level over the total working period.
Identify additional safety measures to protect the operator from the effects of vibration such as: maintaining the tool and the accessories, keeping the hands warm, and organization of work patterns.
Declaration of Conformity
We declare under our sole responsibility that the product described under “Technical Data” is in conformity with all relevant provisions of the directives 2011/65/EU, 2014/30/EU, 2006/42/EC including their amendments, and complies with the following standards: EN 60745-1, EN 60745-2-5.
Technical file (2006/42/EC) at: Robert Bosch GmbH, PT/ETM9, 70764 Leinfelden-Echterdingen, GERMANY

Robert Bosch GmbH, Power Tools Division 70764 Leinfelden-Echterdingen, GERMANY Leinfelden, 18.11.2014
Note: The battery supplied is partially charged. To ensure the full capacity of the battery, completely charge the battery in the battery charger before using your power tool for the first time. The lithium-ion battery can be charged at any time without reducing its service life. Interrupting the charging procedure does not damage the battery. The lithium-ion battery is protected against deep discharging by the “Electronic Cell Protection (ECP)”. When the battery is empty, the machine is switched off by means of a protective circuit: The inserted tool no longer rotates.

• Do not continue to press the On/Off switch after the machine has been automatically switched off. The battery can be damaged. Observe the notes for disposal.

Removing the battery

The battery 9 is equipped with two locking levels that should prevent the battery from falling out when pushing the battery unlocking button 8 unintentionally. As long as the battery is inserted in the power tool, it is held in position by means of a spring.
To remove battery 9, press the battery unlocking button 8 and pull the battery upward out of the power tool. Do not exert any force.
Battery Charge-control Indication (see figure F)
The three green LEDs of the battery charge-control indicator 25 indicate the charge condition of the battery 9. For safety reasons, it is only possible to check the status of the charge condition when the machine is at a standstill. Press button 24 to indicate the charge condition. This is also possible when battery 9 is removed.

When no LED lights up after pushing button 24, then the battery is defective and must be replaced.
Mounting/Replacing the Saw Blade

• Before any work on the power tool, remove the battery.
• When mounting the saw blade, wear protective gloves. The danger of injury when touching the saw blade.
• Only use saw blades that correspond with the characteristic data given in the operating instructions.
• Use only saw blades with a diameter of min. 130 mm and max. 136 mm.
• Do not under any circumstances use grinding discs as the cutting tool.

Selecting a Saw Blade
An overview of recommended saw blades can be found at the end of this manual.
Removal of the Saw Blade (see figure A)
For changing the cutting tool, it is best to place the machine on the face side of the motor housing.
– Press the spindle lock button 1 and keep it pressed.

• The spindle lock button 1 may be actuated only when the saw spindle is at a standstill. Otherwise, the power tool can be damaged.
  –With the Hex key 5, unscrew the clamping bolt 16 turning in the rotation direction.
  – Tilt back the retracting blade guard 21 and hold firmly.
  – Remove the clamping flange 17 and the saw blade 18 from the saw spindle 20.

Mounting the Saw Blade (see figure A)
For changing the cutting tool, it is best to place the machine on the face side of the motor housing.
– Clean the saw blade 18 and all clamping parts to be assembled.
– Tilt back the retracting blade guard 21 and hold firmly.
–Place the saw blade 18 onto the mounting flange 19. The cutting direction of the teeth (direction of the arrow on the saw blade) and the direction-of-rotation arrow on the retracting blade guard 21 must correspond.
–Mount the clamping flange 17 and screw in the clamping bolt 16 turning in the rotation direction. Observe the correct mounting position of mounting flange 19 and clamping flange 17.
– Press the spindle lock button 1 and keep it pressed.
–Use the hex key 5 to tighten the clamping bolt 16 in the rotation direction. The tightening torque should be 6–9 Nm, which corresponds to hand-tight plus 1/8 turn. Dust/Chip Extraction

• Before any work on the power tool, remove the battery.
• Dust from materials such as lead-containing coatings, minerals, and metal can be harmful to one’s health. Touching or breathing in the dust can cause allergic reactions and/or lead to respiratory infections in the user or bystanders. Certain dust, such as oak or beech dust, are considered carcinogenic, especially in connection with wood-treatment additives (chromate, wood preservative). Materials containing asbestos may only be worked by specialists.
  – Provide for good ventilation of the working place.
  – It is recommended to wear a P2 filter-class respirator.
  Observe the relevant regulations in your country for the materials to be worked.
• Prevent dust accumulation at the workplace. Dust can easily ignite.

Operation

Operating Modes

• Before any work on the power tool, remove the battery.

Adjusting the Cutting Depth (see figure B)

• Adjust the cutting depth to the thickness of the workpiece. Less than a full tooth of the blade teeth should be visible below the workpiece.

Loosen the clamping lever 10. For a smaller cutting depth, pull the saw away from the base plate 13; for a larger cutting depth, push the saw toward the base plate 13. Adjust the desired cutting depth at the cutting-depth scale. Tighten the clamping lever 10 again. The tightening tension of the clamping lever 10 can be readjusted. For this, unscrew the clamping lever 10, screw it back again turned offset by at least 30° in an anticlockwise direction.
Cutting Marks
The cutting mark 12 indicates the position of the saw blade for straight cuts.
For precise cuts, position the circular saw against the workpiece as shown in the figure. It is best to carry out a trial cut
Utility Hook (see figure C)
Your tool is equipped with a utility hook 3 for hanging it, e. g., to a ladder, etc. Simply fold out the utility hook 3 to the required position.

• When the tool is hanging by the utility hook, ensure that the saw blade is protected against unintended contact. The danger of injury.

Fold the utility hook 3 back in again when you are ready to continue working.
Starting Operation
Inserting the battery

• Use only original Bosch lithium-ion batteries with the voltage listed on the nameplate of your power tool. Using other batteries can lead to injuries and pose a fire hazard.

Insert the charged battery 9 into the base of the power tool until the battery is securely locked.
Switching On and Off
To start the machine, first, push the lock-off button for the On/Off switch 6 and then press the On/Off switch 7 and keep it pressed.
To switch off the machine, release the On/Off switch 7.
Note: For safety reasons, the On/Off switch 7 cannot be locked; it must remain pressed during the entire operation.
To save energy, only switch the power tool on when using it.
Run-on Brake
An integrated run-on brake reduces the run-on period of the saw blade after switching off the machine.
Protection Against Deep Discharging
The lithium-ion battery is protected against deep discharging by the “Electronic Cell Protection (ECP)”. When the battery is empty, the machine is switched off by means of a protective circuit: The inserted tool no longer rotates.
Working Advice
Protect saw blades against impact and shock.
Guide the machine evenly and with light feed in the cutting direction. Excessive feed significantly reduces the service life of the saw blade and can cause damage to the power tool.
Sawing performance and cutting quality depend essentially on the condition and the tooth form of the saw blade. Therefore, use only sharp saw blades that are suited for the material to be worked.
Sawing with Parallel Guide (see figure D)
The parallel guide 14 enables exact cuts along a workpiece edge and cutting strips of the same dimension.
Sawing with Auxiliary Guide (see figure E)
For sawing large workpieces or straight edges, a board or strip can be clamped to the workpiece as an auxiliary guide; the base plate of the circular saw can be guided alongside the auxiliary guide.
Recommendations for Optimal Handling of the Battery
Protect the battery against moisture and water. Store the battery only within a temperature range between –20 °C and 50 °C. As an example, do not leave the battery in the car in summer.
Occasionally clean the venting slots of the battery using a soft, clean, and dry brush. A significantly reduced working period after charging indicates that the battery is used and must be replaced. Observe the notes for disposal.

Maintenance and Service

Maintenance and Cleaning

• Before any work on the machine itself (e. g. maintenance, tool change, etc.) as well as during transport and storage, remove the battery from the power tool. There is a danger of injury when unintentionally actuating the On/Off switch.
• For safe and proper working, always keep the machine and ventilation slots clean.

The retracting blade guard must always be able to move freely and retract automatically. Therefore, always keep the area around the retracting blade guard clean. Remove dust and chips by blowing out with compressed air or with a brush.  Non-coated saw blades can be protected against corrosion using a thin layer of acid-free oil. Remove the oil gain before sawing.
Resin and glue residue on the saw blade produces poor cuts. Therefore, clean the saw blade immediately after use.
After-sales Service and Application Service
In all correspondence and spare parts orders, please always include the 10-digit article number given on the type plate of the machine.
Our after-sales service responds to your questions concerning maintenance and repair of your product as well as spare parts. Exploded views and information on spare parts can also be found under:
www.bosch-pt.com
Bosch’s application service team will gladly answer questions concerning our products and their accessories.
Great Britain
Robert Bosch Ltd. (B.S.C.)
P.O. Box 98
Broadwater Park
North Orbital Road
Denham
Uxbridge
UB 9 5HJ
At www.bosch-pt.co.uk you can order spare parts or arrange the collection of a product in need of servicing or repair.
Tel. Service: (0344) 7360109
E-Mail:
Ireland
Origo Ltd.
Unit 23 Magna Drive
Magna Business Park
City West
Dublin 24
Tel. Service: (01) 4666700
Fax: (01) 4666888
Australia, New Zealand, and Pacific Islands
Robert Bosch Australia Pty. Ltd.
Power Tools
Locked Bag 66
Clayton South VIC 3169
Customer Contact Center
Inside Australia:
Phone: (01300) 307044
Fax: (01300) 307045
Inside New Zealand:
Phone: (0800) 543353
Fax: (0800) 428570
Outside AU and NZ:
Phone: +61 3 95415555
www.bosch.com.au
Republic of South Africa
Customer service
Hotline: (011) 6519600
Gauteng – BSC Service Centre
35 Roper Street, New Centre
Johannesburg
Tel.: (011) 4939375
Fax: (011) 4930126
E-Mail:
KZN – BSC Service Centre
Unit E, Almar Centre
143 Crompton Street
Pinetown
Tel.: (031) 7012120
Fax: (031) 7012446
E-Mail:
Western Cape – BSC Service Centre
Democracy Way, Prosperity Park
Milnerton
Tel.: (021) 5512577
Fax: (021) 5513223
E-Mail:
Bosch Headquarters
Midrand, Gauteng
Tel.: (011) 6519600
Fax: (011) 6519880
E-Mail:
Transport
The contained lithium-ion batteries are subject to the Dangerous Goods Legislation requirements. The user can transport the batteries by road without further requirements. When being transported by third parties (e.g.: air transport or forwarding agency), special requirements on packaging and labeling must be observed. For the preparation of the item being shipped, consulting an expert for hazardous material is required.
Dispatch batteries only when the housing is undamaged. Tape or mask off open contacts and pack up the battery in such a manner that it cannot move around in the packaging. Please also observe possibly more detailed national regulations.
Disposal
The machine, rechargeable batteries, accessories, and packaging should be sorted for environmental-friendly recycling. Do not dispose of power tools and batteries/rechargeable batteries into household waste!
Only for EC countries:
According to the European Guideline 2012/19/EU, power tools that are no longer usable, and according to the European Guideline 2006/66/EC, defective or used battery packs/batteries, must be collected separately and disposed of in an environmentally correct manner.

Batteries no longer suitable for use can be directly returned at:
Great Britain
Robert Bosch Ltd. (B.S.C.)
P.O. Box 98
Broadwater Park
North Orbital Road
Denham
Uxbridge
UB 9 5HJ
At www.bosch-pt.co.uk you can order spare parts or arrange the collection of a product in need of servicing or repair.
Tel. Service: (0344) 7360109
E-Mail:

 Battery packs/batteries:
Li-ion:
Please observe the instructions in section “Transport”, page 19.
Subject to change without notice.

Robert Bosch GmbH
Power Tools Division
70764 Leinfelden-Echterdingen
GERMANY
www.bosch-pt.com
1 609 92A 0PX (2014.11) O / 236 EURO