BOSCH 1591EVS (01) PDF Document

Failure to follow all instructions may result in electric shock, fire, and/or serious injury. The term “power tool” in all warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

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. Power tools create sparks which may ignite the 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 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 or 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. Use of a cord suitable for outdoor use reduces the risk of electric shock.

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

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 safety equipment. Always wear eye protection. Safety equipment such as dust 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. Carrying 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. 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. Use of these devices can reduce dust-related hazards.

Proper use and care will ensure your tool operates better and safer.

• 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 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 it. 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.

• Keep handles dry, clean and free from oil and grease. Slippery hands cannot safely control the power tool.

• Use clamps or other practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control.

• Empty dust container frequently, especially when sanding wood with polyurethane, varnish, shellac or similarly coated surface. Fine particles of sanding dust may self ignite and cause fire.

• Hold tool by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord. Contact with a “live” wire will make exposed metal parts of the tool “live” and shock the operator.

• Do not drill, fasten or break into existing walls or other blind areas where electrical wiring may exist. If this situation is unavoidable, disconnect all fuses or circuit breakers feeding this worksite.

• Keep hands away from cutting area. Do not reach under the material being cut. The proximity of the blade to your hand is hidden from your sight.

• Keep hands from between the gear housing and saw blade holder. The reciprocating blade holder can pinch your fingers.

• Do not use dull or damaged blades. A bent blade can break easily or cause kickback.

• Before starting to cut, turn tool “ON” and allow the blade to come to full speed. The tool can chatter or vibrate if the blade speed is too slow at the beginning of a cut and possibly kickback.

• Secure material before cutting. Never hold it in your hand or across legs. Small or thin material may flex or vibrate with the blade, causing loss of control.

• Make certain all adjusting screws and the blade holder are tight before making a cut. Loose adjusting screws and holders can cause the tool or blade to slip and loss of control may result.

• When removing the blade from the tool, avoid contact with skin and use proper protective gloves when grasping the blade or accessory. Accessories may be hot after prolonged use.

• Model number: 1591EVS

• Voltage rating: 120 V ~ 50-60Hz

• Amperage rating: 6.4 A

• No load speed: n₀ 500-2,800/min

• Stroke length: 1″

• Wood: 5-3/8″

• Aluminium: 3/4″

• Steel: 3/8″

• Stainless steel: 1/8″

The BOSCH 1591EVS is equipped with the “One Touch” tool-less blade changing system.

Blade Installation:

1. Insert the saw blade (teeth in cutting direction) until it latches in the plunger.

2. When inserting the saw blade, the back of the blade must rest in the groove of the guide roller.

Note: If the saw blade cannot be inserted into the plunger because the slots of the blade holder are not positioned correctly or the precision control guides are shut, push the blade ejector lever briefly to the front and release it.

Blade Removal:

1. To change the saw blade, push the ejector lever to the center stop.

2. This action releases the precision control guides and ejects the saw blade. Hold the tool so that the blade is safely ejected.

The precision control guides were designed to improve the vertical cut accuracy of the saw blade.

To use this feature, simply press the precision control button to close the guides. The saw blade is then guided laterally by the precision control guides, which enables precision cuts. The precision control guides can be used for all applications, including bevel cuts. Precision control is recommended for cuts in thick wood, as it maintains the cutting angle and reduces the run-out of the saw blade.

A vacuum hose adapter tube and dust shroud (optional accessory) can be attached for dust and chip extraction. The vacuum hose adapter tube serves as the connector to the vacuum hose.

ATTENTION: The vacuum hose adapter must only be used with the dust shroud when connected to a vacuum.

To use this feature, attach the vacuum hose adapter tube to the footplate. When inserting the adapter tube, ensure that the plastic post of the adapter tube engages into the corresponding hole on the housing. For vacuuming, a Bosch Air Sweep vacuum hose (optional accessory) can be directly connected to the vacuum hose adapter tube. For maximum vacuum dust pick up, the dust shroud must be attached.

Attaching Non-Marring Overshoe:

Your tool is equipped with a protective plastic overshoe that protects finer surfaces. To attach, hook the overshoe over the front of the metal footplate and snap it into place at the rear of the footplate.

Anti-Splinter Insert:

To minimize splintering of the top surface of the material being cut, place the anti-splinter insert in the blade opening of the footplate. The insert can be placed in two positions:

• For narrow saw blades, place the insert completely to the front of the opening.

• For wider saw blades, place the insert completely to the rear of the opening.

Note: This insert will only work with blades that have ground sides such as T301CD, T101B, T101D, and T101DP.

Slide On-Off Switch:

The BOSCH 1591EVS is switched “ON” by the switch button located at the side of the motor housing. The switch locks in the “ON” position for continuous operation.

• TO TURN THE TOOL “ON”: slide the switch button forward.

• TO TURN THE TOOL “OFF”: slide the switch button backward.

Variable Speed Dial:

The jigsaw is equipped with a variable speed dial. The blade stroke rate may be adjusted during cutting by presetting the dial on or between any one of the six numbers.

The best speed for an application is determined by experience. Generally, slower speeds are for denser materials and faster speeds are for softer materials. Note that using the jigsaw at low speed settings for extended periods may cause the motor temperature to rise.

Constant Response Circuitry:

The internal electronic feedback system provides a “soft start” to reduce stress from a high torque start. It also maintains the selected speed under load for maximum efficiency.

Maximum cutting efficiency can be obtained by adjusting the blade orbit selector lever to suit the material being cut. Test cuts in scrap material should be performed first to determine the best setting.

• Setting O: For hard materials such as metals or thin sheet metals. Can be used with knife blades, grit edge blades, rasp work, and down cutting blades.

• Setting 1: For soft materials where cleaner cutting or delicate scrolling work is performed.

• Setting 2: For medium density materials such as harder woods or particle board.

• Setting 3: For soft materials such as wood, plastics, etc., and when fast cutting is more important than a clean cut.

Chip Blower:

The jigsaw has a two-position chip blower to keep the cutting line clear. Adjust the lever as follows:

• BLOWER SWITCHED ON: For working with wood, plastic, and similar materials that produce large amounts of sawdust.

• BLOWER SWITCHED OFF: For working with metals, when using cooling agents, or with the dust collection accessory.

Footplate Angle Adjustment:

The footplate can be tilted up to 45º in either direction for angle cuts.

1. Open the footplate lock lever.

2. Slide the footplate slightly forward towards the front of the tool.

3. Rotate the footplate to the desired angle. Detent slots hold the footplate at 45º, with position marks for 15º, 22.5º, and 30º.

4. After positioning, close the footplate lock lever to securely tighten the adjustment.

Note: If you have difficulty adjusting the footplate after releasing the lock lever, rotate the tension wheel in the “-” direction. If the lock lever does not securely tighten, open the lever and rotate the tension wheel in the “+” direction until the desired tension is achieved.

Flush Cutting Adjustment:

To make a perpendicular cut close to a vertical surface, the footplate can be repositioned. Note that only 90º cuts are possible in this position, and the optional cutting guide and anti-splinter insert cannot be used.

1. Open the footplate lock lever.

2. Move the footplate back into the 0º alignment slot.

3. Close the footplate lock lever.

Plunge cutting is useful for making rough openings in softer materials without drilling a starting hole. Plunge cutting with a scroll blade is not recommended. Do not attempt to plunge cut into hard materials such as steel.

1. Draw the lines for the opening.

2. Hold the saw firmly and tilt it forward so the toe of the saw foot rests on the workpiece, with the blade well clear of the work.

3. Start the motor, and then very gradually lower the blade.

4. When the blade touches, continue pressing down on the toe of the saw foot, slowly pivoting the saw like a hinge until the blade cuts through and the foot rests flat on the work.

5. Saw ahead on the cutting line.

The circle and parallel cutting guide is an optional accessory used for fast and accurate straight and circle cutting.

Parallel Cutting:

1. Insert the bar of the guide through the lock knob clamp, then through the slots in the footplate from either side, with the edge guide facing DOWN.

2. Hook the lock knob clamp onto the edge of the footplate, adjust the fence to the desired width, and securely tighten the lock knob clamp.

Circle Cutting:

1. Before attaching the guide, draw a circle and predrill a 13/64” center hole in the workpiece.

2. Drill or plunge cut near the circle’s edge, turn the saw off, and disconnect the power.

3. Attach the guide to the saw with the edge guide facing UP.

4. Remove the guide pin from the end of the guide, push it through the hole in the guide, and then into the center hole of the workpiece.

5. Measure the distance from the selected hole to the blade to be equal to the circle radius.

6. Insert the plug into the power source, hold the saw firmly, and slowly push the saw forward. To make a hole, cut from inside the circle; to make wheels or discs, cut from the outside.

Cutting Tip: Cut slowly so the blade stays straight. Place small wedges in the cut to keep the inner circle from spreading near the end of the cut.

Cleaning:

Always disconnect the tool from the power supply before cleaning. The tool can be cleaned most effectively with compressed dry air. Always wear safety goggles when cleaning 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. Certain cleaning agents and solvents like gasoline, carbon tetrachloride, and ammonia can damage plastic parts.

Tool Lubrication:

Your Bosch tool has been properly lubricated. It is recommended that tools with gears be regreased with a special gear lubricant at every brush change.

Carbon Brushes:

To maintain peak motor efficiency, it is recommended that the brushes be examined every two to six months. Only genuine Bosch replacement brushes designed for your tool should be used.

Bearings:

After about 300-400 hours of operation, or at every second brush change, the bearings should be replaced. Bearings that become noisy due to heavy load or abrasive material should be replaced at once to avoid overheating or motor failure.

If an extension cord is necessary, a cord with adequate size conductors capable of carrying the necessary current must be used. This will prevent excessive voltage drop, loss of power, or overheating. Grounded tools must use 3-wire extension cords with 3-prong plugs and receptacles. NOTE: The smaller the gauge number, the heavier the cord.

Proper interpretation of these symbols will allow you to operate the tool better and safer.