Bosch 0 607 595 100 manual

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  • Brand: Bosch
  • Product: Cutting machine
  • Model/name: 0 607 595 100
  • Filetype: PDF
  • Available languages: Dutch, English, German, French, Spanish, Italian, Swedish, Portuguese, Danish, Norwegian, Finnish, Turkish

Table of Contents

Page: 0
Production Tools www.boschproductiontools.com
1
0 607 595 100
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2 609 929 157 • (04.08) T
1 GENERAL SAFETY RULES
FOR PNEUMATIC TOOLS
Read and understand all in-
structions. Failure to follow all in-
structions listed below may result in
electric shock, fire, and/or serious personal injury.
Save these instructions.
The terminology “Pneumatic Tool” or “Tool” used in
the following text refers to the so-called air tool in these
operating instructions.
Work area
Keep work area clean and well lit. Cluttered and
dark areas invite accidents.
Do not operate tools in explosive atmospheres,
such as in the presence of flammable liquids, gas-
es, or dust. During operation of the tool, its accessory
can create sparks that may ignite the dust or fumes.
Keep bystanders, children, and visitors away
while operating a tool. Distractions can cause you to
lose control.
Pneumatic safety
Use compressed air of Quality Class 5 in accord-
ance with DIN ISO 8573-1 and a separate mainte-
nance unit near the tool. The compressed air sup-
plied should be free of foreign material and moisture to
protect the tool from damage, contamination, and rust.
Check the connections and air supply lines. All
maintenance units, couplers, and hoses should con-
form to the product specifications in terms of pressure
and air volume. Too low a pressure impairs the func-
tioning of the tool; too high a pressure can result in
physical damage and personal injury.
Protect the hoses from kinks, restrictions, sol-
vents, and sharp edges. Keep the hoses away
from heat, oil, and rotating parts. Immediately
replace a damaged hose. A defective air supply line
may result in a wild compressed air hose and can
cause personal injury. Raised dust or chips may
cause serious eye injury.
Make sure that hose clamps are always tight-
ened firmly. Loose or damaged hose clamps may re-
sult in uncontrolled air escape.
Personal safety
Stay alert, watch what you are doing, and use
common sense when operating a tool. Do not
use tool while tired or under the influence of
drugs, alcohol, or medication. A moment of inat-
tention while operating tools may result in serious per-
sonal injury.
Use safety equipment. Always wear eye protec-
tion. Safety equipment such as a dust mask, non-
skid safety shoes, a hard hat, or hearing protection
used for appropriate conditions will reduce personal
injuries.
Avoid accidental starting. Be sure switch is off
before connecting to the air supply. Carrying tools
with your finger on the switch or connecting tools to
the air supply with the switch on invites accidents.
Remove adjusting keys before turning the tool
on. A key that is left attached to a rotating part of the
tool may result in personal injury.
Do not overreach. Keep proper footing and bal-
ance at all times. Proper footing and balance ena-
bles better control of the 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 dust extraction and collection devices are in-
stalled, ensure these are connected and properly
used. Use of these devices can reduce dust-related
hazards.
Do not directly inhale the exhaust air. Avoid ex-
posing the eyes to exhaust air. The exhaust air of
the air tool may contain water, oil, metal particles, or
contaminants that may cause personal injury.
Pneumatic tool use and care
Use clamps or other practical way to secure and
support the workpiece to a stable platform. Hold-
ing the work by hand or against your body is unstable
and may lead to loss of control.
Do not force tool. Use the correct tool for your
application. The correct tool will do the job better
and safer at the rate for which it is designed.
Do not use tool if switch does not turn it ON or
OFF. Any tool that cannot be controlled with the
switch is dangerous and must be repaired.
Disconnect the air hose from the air supply be-
fore making any adjustments, changing acces-
sories, or storing the tool. Such preventive safety
measures reduce the risk of starting the tool acciden-
tally.
Store idle air tools out of the reach of children
and do not allow persons unfamiliar with the air
tool or these instructions to operate the air tool.
Air tools are dangerous in the hands of untrained us-
ers.
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2 609 929 157 • (04.08) T
Maintain air tools. Check for misalignment or
binding of moving parts, breakage of parts, and
any other condition that may affect the operation
of the air tool. If damaged, have the air tool re-
paired before use. Many accidents are caused by
poorly maintained air tools.
Keep the tool bits clean. Well cared for tool bits are
easier to use and can be controlled better.
Use the air tool, accessories, and tool bits, etc.,
in accordance with these instructions and in the
manner intended for the particular type of air
tool, taking into account the working conditions
and the work to be performed. Use of the air tool
for operations different from those intended could re-
sult in a hazardous situation.
Service
Have your air tool serviced by a qualified repair
person using only identical replacement parts.
This will ensure that the safety of the air tool is main-
tained.
2 SPECIFIC SAFETY RULES
FOR AIR FOAM RUBBER CUTTERS
Avoid contact with a live wire. The
tool is not insulated and contact with
a live wire may result in electric shock.
Use suitable detectors to find hidden utility lines
or call the local utility company for assistance.
Contact with electric lines can lead to fire or electrical
shock. Damaging a gas line can result in an explosion.
Penetrating a water pipe will cause property damage
or an electrical shock.
When removing a saw blade, avoid contact with
skin and use proper protective gloves when
grasping the blade or accessory. Saw blades and
accessories may become hot during prolonged use.
Never use bent or damaged saw blades. Bent or
dull saw blades may break or kick back.
Check that the saw blades are seated firmly in
the tool before you connect the tool to the air
supply. Saw blades that are not clamped properly in
the appropriate holder may slip out and can cause
damage to the workpiece or injury to you or others.
Position the tool on the workpiece only when the
tool is switched on. Otherwise, there is the danger
of a kickback when the teeth bind in the workpiece.
Keep your hands away from the cutting area. Do
not reach underneath the workpiece. Contact
with the saw blade may result in injury.
Take care during cutting to insure that the foot-
plate 6 lies completely on the workpiece. A foot-
plate that does not lie completely on the surface may
result in breakage of the saw blade.
After cutting has been completed, switch off the
air tool and withdraw the saw blade from the cut
only when the saw blade has come to a complete
stop. In this way, you avoid a kickback and can put
down the air tool safely.
Do not brake the saw blade by applying side
pressure against it after the tool is switched off.
The saw blade may be damaged, may break, or may
kick back.
Some dust created by power
sanding, sawing, grinding, drill-
ing, and other construction ac-
tivities contains chemicals known to cause can-
cer, 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 fil-
ter out microscopic particles.
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SYMBOLS
Important notice: Some of the following symbols could have meaning for the use of your tool. Please take note
of the symbols and their meaning. The correct interpretation of the symbols will help you to use the tool in a
better and safer manner.
Symbol Name Meaning
W
Hp
Watt
Horsepower
Power
Nm
ft-lbs
Newton-meter
Foot-pounds
Unit of energy, torque
kg
lbs
Kilograms
Pounds
Mass, weight
mm
in
Millimeter
Inches
Length
min/s Minutes/seconds Time
bar/psi Bar/pounds per square inch Air pressure
l/s
cfm
Liter per second
Cubic feet/minute
Air consumption
°C/°F Degrees Celsius/Degrees
Fahrenheit
Temperature
dB Decibel Unit of relative loudness
Ø Diameter Size of drill bits, grinding wheels, etc.
min-1
/n0 Revolutions per minute/no load
speed
Rotational speed at no load
.../min Revolutions or reciprocations per
minute
Revolutions, strokes, surface speed, orbits, etc.
per minute
0 Off position Zero speed, zero torque
Left rotation/right rotation Direction of drive rotation
/■/UNF Hex socket drive/square drive/
Unified National Fine
Type of tool holder
Arrow Action in the direction of arrow
Warning symbol Alerts user to warning messages.
Symbol for directions Gives instructions for correct handling – for exam-
ple, read operating instructions or wear safety
glasses.
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3 FUNCTION
1 Hose nipple
2 On/Off switch (Paddle style switch)
3 Housing
4 Base of the saw blade guide
5 Saw blade guide
6 Footplate
7 Saw blade set (Tool bit)
8 Knurled nut with lock washer
9 Face plate
Not all the accessories illustrated or described are in-
cluded in standard delivery.
Intended Use
The tool is intended for cutting synthetic foams, foam
rubber, and similar materials.
Declaration of Conformity
We declare under our sole responsibility that this pro-
duct is in conformity with the following standards or
standardization documents: EN 792, according to the
provisions of the directive 98/37/EC.
Robert Bosch GmbH, Geschäftsbereich Elektrowerkzeuge
1
2
3
4
5
6
7
8
9
Dr. Egbert Schneider
Senior Vice President
Engineering
Dr. Eckerhard Strötgen
Head of Product
Certification
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2 609 929 157 • (04.08) T
Noise/Vibration Information
Measured sound values determined in accordance
with EN ISO 15744.
Measured vibration values determined in accordance
with EN 28662 and EN ISO 8662.
Typically, the A-weighted sound pressure level of the
product is 75 dB(A).
Measuring inaccuracy K = 3 dB.
The noise level when working can exceed 85 dB(A).
Wear ear protection!
The hand-arm acceleration is typically below 2.5 m/s2
.
Measuring inaccuracy K = 1.2 m/s2
.
Product Specifications
4 MOUNTING
The saw blades and the saw blade guide have to be
ordered separately. The tool is delivered unassembled
and has to be assembled on side.
Be sure to use the same length of saw blades
with the same matching saw blade guide. For ex-
ample, a saw blade set with a maximum cutting depth
capacity of 70 mm (2–3/4") can ONLY be installed in
a saw blade guide of 70 mm (2–3/4").
Disconnect the air hose from the air supply before
making any adjustments, changing accessories,
or storing the tool. Such preventive safety measures
reduce the risk of starting the tool accidentally.
Installing the Saw Blade Guide
Unscrew the slotted screws 10 from the housing 3.
Choose the appropriate saw blade guide according to
the thickness of the material to be cut (see Accesso-
ries). Join the base 4 of the saw blade guide 5 to the
housing 3.
Insure that the cylindrical pins 11 are seated in the cor-
responding holes of the base 4. Screw the base 4 of
the saw blade guide 5 to the housing 3 using the two
slotted screws 10.
Air Foam Rubber Cutter
Part number 0 607 595 100
Stroke rate min-1
3800
Power output W
Hp
120
0.16
Maximum cutting
depth capacity
mm
in
300
12
Rated pressure bar/psi 6.3/91
Connecting thread G 1/4"
Hose inner diameter mm
in
10
3/8"
Air consumption under load l/s
cfm
5.5
11.7
Weight in accordance with
EPTA-Procedure 01/2003
kg
lbs
1.2
2.6
10
3
11
10
3
11
4
5
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2 609 929 157 • (04.08) T
Installing the Saw Blades
Unscrew the two knurled nuts 8 nd remove them to-
gether with the lock washers and the faceplate 9.
Choose the saw blade set 7 that matches the saw
blade guide 5 (see Accessories). Two serrated saw
blades move side by side in opposite directions within
the saw blade guide.
Put the saw blade set 7 together. Take care that the
unground sides of the saw blades are placed against
each other (and the printing on the saw blades is read-
able.
Insert the saw blade set 7 with the lengthwise slots into
the guide pin 12 of the saw blade guide 5.
Push the saw blades into the saw blade guide 5 and
slide them in individually as far as the respective stop
14 of the drive block.
The cross-slots of the saw blades should fit into the
catch pins of the drive blocks 13. The saw blades 7
should lie, as shown in the picture above, between the
drive blocks.
Tightly screw back on the face plate 9 with the knurled
nuts 8 and the lock washers.
Check that the saw blades are seated firmly in
the tool before you connect the tool to the air
supply. Saw blades that are not clamped properly in
the appropriate holder may slip out and can cause
damage to the workpiece or injury to you or others.
Installing the Footplate
Press the footplate 6 onto the saw blade guide 5.
Firmly tighten the clamping screw 15.
8
9
5
12
12
7
7
14
5
13
15
6
5
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2 609 929 157 • (04.08) T
Connection to the Air Supply
The air tool is designed for an operating pressure of
6.3 bar (91 psi). For maximum performance, the inner
diameter of the hose is 10 mm with connection
threads of G 1/4". To maintain full performance, use
only hoses with a maximum length of 4 m.
The supplied air must be free of foreign material and
moisture to protect the air tool from damage, contam-
ination, and rust.
The use of a compressed air maintenance unit is
necessary.
This ensures optimum functioning of compressed air
tools. Observe the operating instructions of the main-
tenance unit.
All fittings, connecting lines, and hoses must be di-
mensioned for the required air pressure and volume.
Avoid restrictions in the air supply resulting from, e.g.,
pinching, kinking, or stretching!
In case of doubt, measure the pressure with a pres-
sure gauge at the air inlet with the tool switched on.
Connection of the Air Supply to the Air Tool
Screw the hose nipple 1 into the connector at the air
inlet 17.
Loosen the hose clamps 18 of the air inlet hose 19
with a maximum length of 4 m and attach the air inlet
hose over the hose nipple 1 by firmly tightening the
hose clamp.
Always connect the air inlet hose 19 first to the
tool, then to the maintenance unit.
Slip the air inlet hose 19 over the coupling nipple 20
and attach the air inlet hose by firmly tightening the
hose clamp 18.
Screw a quick hose connector 21 into the air outlet of
the maintenance unit 22. Quick hose connectors
make possible a quick connection and, when uncou-
pled, they shut off the air supply automatically.
Take care that you do not start the tool accidentally
when you insert the coupling nipple 20 into the coupler
21.
5 OPERATING INSTRUCTIONS
Putting into Operation
The air tool operates optimally with a pressure of
6.3 bar (91 psi) measured at the air inlet with the tool
running.
Switching On/Off
In the event of an interruption of the air supply
or reduced operating pressure, switch off the
tool. Check the operating pressure and start
again when the pressure returns to normal.
Switching on:
Press the lever switch 2 and keep it
pressed down during the operation.
Switching off:
Release the lever switch 2.
Working Instructions
Disconnect the air hose from the air supply be-
fore making any adjustments, changing acces-
sories, or storing the tool. Such preventive safety
measures reduce the risk of starting the tool acciden-
tally.
Excess loads that cause the tool to stall or reduce
speed will not damage the motor.
In the event of an interruption of the air supply
or reduced operating pressure, switch off the
tool. Check the operating pressure and start
again when the pressure returns to normal.
17
1
18
19
20
21
22
2
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2 609 929 157 • (04.08) T
Guide Plate with Rollers
The foam rubber cutter can be used with or without
the footplate 6. The footplate, furnished with rollers
16, allows the cutter to be guided in an easy and
straigt manner. Take care that there are no ob-
structions on the surface being cut.
In order to make freeform cuts and to make cutouts,
the footplate can be removed.
Removing the Footplate
Unscrew the clamping screw 15. Pull the footplate 6
from the saw blade guide 5.
Cutting
Work with a moderate rate of feed when you want to
make precise cuts, especially in the case of soft foams
and similar materials. Do not stretch and press the ma-
terial too strongly during cutting.
Note that too high a feed rate reduces the output ca-
pacity substantially and shortens the life of the saw
blades. Sharp tool bits provide good cutting power
and protect the tool.
When you want to make cutouts, remove the footplate
6 (see Removing the Footplate). Use a knife or a pair
of scissors to pierce a hole in the cutout to be made,
so that you can plunge in the saw blade guide. Make
the cutout with a moderate rate of feed.
Use only saw blades and saw blade guides that
are appropriate for the thickness of the material.
Only in this way can you achieve exact cuts.
Be sure to use the same length of saw blades
with the same matching saw blade guide. For ex-
ample, a saw blade set with a maximum cutting depth
capacity of 70 mm (2–3/4") can ONLY be installed in
a saw blade guide of 70 mm (2–3/4").
Changing the Saw Blades
When removing a saw blade, avoid contact with
skin and use proper protective gloves when
grasping the blade or accessory. Saw blades and
accessories may become hot during prolonged use.
Unscrew the two knurled nuts 8 nd remove them to-
gether with the lock washers and the faceplate 9.
Pull the saw blades 7 first out of the catch pins 13 be-
tween the drive blocks and then out of the saw blade
guide 5 at the guide pin 12.
Replace the saw blades with new, flawless saw blades
of the same size (see Installing the Saw Blades). If you
want to cut a different thickness of material, you also
have to change the saw blade guide.
Changing the Saw Blade Guide
Unscrew the slotted screws 10 from the housing 3.
Replace the saw blade guide 5 with a different one and
attach the new saw blade guide to the housing (see In-
stalling the Saw Blade Guide).
15
16
5
6
8
9
13
7
5
12
12
7
10
3
5
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2 609 929 157 • (04.08) T
Sharpening the Saw Blades
You can sharpen the saw blades yourself. Required
for this is the saw blade sharpener 24 and the whet-
stone 25 (see Accessories).
Always sharpen the saw blades in pairs. Unscrew the
screws on the sharpener 24, so that you can clamp
the saw blades in the holder 23. The beveled sides of
the teeth have to be oriented toward the top (un-
ground side of the saw blades toward the bottom, so
that the writing on the saw blades is readable). Firmly
screw the saw blades in the holder 23.
Pass the whetstone 25 evenly over the bevels of the
two saw blades. Several motions with the whetstone
suffice to give the saw blades sharp points once again.
The saw blades have to be thoroughly cleaned before
they are reinstalled.
6 MAINTENANCE AND SERVICE
Maintenance
Disconnect the air hose from the air supply be-
fore making any adjustments, changing acces-
sories, or storing the tool. Such preventive safety
measures reduce the risk of starting the tool acciden-
tally.
Should the tool fail in spite of careful manufacturing
and testing procedures, have the repairs performed by
an authorized customer service location for Bosch
power tools.
For inquiries and spare parts ordering, please include
the 10-digit order number on the nameplate of the
tool.
Clean the screen of the air inlet
regularly. For this purpose, un-
screw the hose nipple 1 and re-
move dust and dirt particles from
the screen. Then firmly remount
the hose nipple.
Water and dirt particles in the com-
pressed air cause rust formation and
lead to clogging of vanes, valves, etc.
To prevent this, a few drops of motor oil
should be placed in the air inlet 17. Re-
connect the tool to the air supply and
let the tool run for 5–10 s while catching the oil that
runs out with a rag. If the air tool is not used for a
longer time, this procedure should always be
performed.
All Bosch air tools that do not belong to the CLEAN se-
ries (a special kind of air motor that functions with oil-
free compressed air), require a small amount of lubri-
cating oil be mixed into the flow of compressed air.
The compressed air oiler required for this is located at
the compressed air maintenance unit connected to
the tool (you may obtain further details on this from a
compressor manufacturer).
You should use SAE 10 or SAE 20 motor oil for direct
lubrication of the tool or for admixture at the mainte-
nance unit (compressor).
Clean the saw blades 7 and the saw blade guide 5
every 8-10 hours of operation. Remove deposits in
the saw blade guide by using the scraper 26 included
in standard delivery.
The motor vanes should be routinely inspected by
trained personnel and, if necessary, replaced.
Have maintenance and repair work performed
only by qualified specialists. In this manner, it can
be ensured that the safety of the tool is maintained.
Any Bosch customer service center can perform this
work quickly and reliably.
Dispose of lubricants and cleaning agents in an
environment-friendly manner. Comply with the
legal regulations.
23
24
25
1
5
26
7
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2 609 929 157 • (04.08) T
Accessories
The foam rubber cutter can be equipped with saw
blades 7 and matching saw blade guide 5 for materials
of different thickness. You may obtain saw blades and
the respective matching saw blade guide for a max-
imum cutting depth of 70, 130, 200, and 300 mm or
2–3/4", 5", 8", and 12" at your dealer.
Your dealer can also supply you with the saw blade
sharpener 24 and the whetstone 25 as well as the
proper screwdriver 27 for installing the saw blade
guide. In addition, the footplate 6 and the scraper 26
are available there as replacement parts.
Information about the complete quality accessory pro-
gram can be found on the Internet at
www.bosch-pt.com and
www.boschproductiontools.com or at your dealer.
Service
Robert Bosch GmbH is responsible for the delivery of
the tool in accordance with the sales contract within
the framework of the legal/country-specific regula-
tions. For claims with respect to the tool, please con-
tact the following location:
Fax . . . . . . . . . . . . . . . . . . . . . +49 (711) 7 58 24 36
www.boschproductiontools.com
Disposal
Tool, accessories, and packaging should be sorted for
environment-friendly recycling.
The plastic components are labeled for categorized
recycling.
If your tool can no longer be used, deliver it to a recy-
cling center or return it to a dealer – for example, an
authorized Bosch service center.
Specifications subject to change without notice
5
26
27
25
24
6
7
FoamC_bu_2609929157_t.fm Seite 10 Dienstag, 10. August 2004 12:36 12

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