BOSCH GSA 120 Professional Reciprocating Saw Instruction Manual

: June 3, 2024
: Bosch

Table of Contents

BOSCH GSA 120 Professional Reciprocating Saw
Safety Instructions
Product Description and Specifications
Assembly
Operation
Maintenance and Service
References
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BOSCH GSA 120 Professional Reciprocating Saw

Safety Instructions

General Power Tool Safety Warnings

WARNING Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all in- structions listed below 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 (cord-less) 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 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 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 carry-ing, 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 a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. 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 a dust mask, non-skid safety shoes, hard hat or hearing protection used for appropriate conditions will reduce personal injuries.
Prevent unintentional starting. Ensure the switch is in the off-position before connecting to 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 and clothing 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 dust collection can re-duce dust-related hazards.
Do not let familiarity gained from the frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe in-jury within a fraction of a second.

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 remove the battery pack, if detachable, 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 and accessories. 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 ac-count the working conditions and the work to be per-formed. Use of the power tool for operations different from those intended could result in a hazardous situation.
Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

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 instructions for reciprocating saws

Hold the power tool by insulated gripping surfaces, when performing an operation where the cutting accessory may contact hidden wiring or its own cord. Cutting accessory contacting a “live” wire may make exposed metal parts of the power tool “live” and could give the operator an electric shock.
Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the workpiece by hand or against your body leaves it unstable and may lead to loss of control.
Keep hands away from the sawing area. Do not reach under the workpiece. Contact with the saw blade can lead to injuries.
Hold the power tool firmly with both hands and make sure you have a stable footing. The power tool can be more securely guided with both hands.
Only bring the power tool into contact with the workpiece when switched on. Otherwise, there is a danger of kickback if the cutting tool jams in the workpiece.
Ensure that the footplate is always resting on the workpiece while sawing. The saw blade can jam and lead to loss of control over the power tool.
When the cut is completed, switch off the power tool and then pull the saw blade out of the cut only after it has come to a standstill. In this manner you can avoid kickback and can place down the power tool securely.
Always wait until the power tool has come to a complete stop before placing it down. The application tool can jam and cause you to lose control of the power tool.
Use only undamaged saw blades that are in perfect condition. Bent or dull saw blades can break, negatively influence the cut, or lead to kickback.
Do not brake the saw blade to a stop by applying side pressure after switching off. The saw blade can be damaged, break or cause kickback.
Ensure that the material is securely clamped. Do not support the workpiece using your hands or feet. Do not touch any objects or the floor with the saw while it is running. There is a risk of kickback.
Use suitable 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 or may cause an electric shock.

Products sold in GB only:
Your product is fitted with a BS 1363/A approved electric plug with an internal fuse (ASTA approved to BS 1362). If the plug is not suitable for your socket outlets, it should be cut off and an appropriate plug fitted in its place by an authorized customer service agent. The replacement plug should have the same fuse rating as the original plug. The severed plug must be disposed of to avoid a possible shock hazard and should never be inserted into a mains socket elsewhere.

Product Description and Specifications

Read all the safety and general instructions. Failure to observe the safety and general instructions may result in electric shock, fire and/or serious injury.

Please observe the illustrations at the beginning of this operating manual.

Intended Use
The power tool is suitable for sawing wood, plastic, metal and building materials on a firm surface. It is suitable for straight and curved cuts. When using designated suitable bi-metal saw blades, flush cutting is also possible. The saw blade recommendations are to be observed.

Product features
The numbering of the product features refers to the diagram of the power tool on the graphics page.

Saw blade
Base plate
Saw blade receptacle
Caps for carbon brushes
On/off switch locking mechanism
On/off switch
Hex key
Handle (insulated gripping surface)
SDS lever for saw blade clamping and release
Carbon brush

BOSCH-GSA-120-Professional-Reciprocating-Saw-fig-9

The specifications apply to a rated voltage [U] of 230 V. These specifications may vary at different voltages and in country-specific models.

Assembly

Pull the plug out of the socket before carrying out any work on the power tool.

Inserting/changing the saw blade

When fitting or changing the saw blade, wear protective gloves. Blades are sharp and can become hot when used for prolonged periods of time.
While replacing the saw blade, ensure that the saw blade receptacle is free of material residue, e.g. wood or metal chips.
Take care that there are no sheared-off pieces of the shank in the saw blade receptacle.

Selecting the saw blade
You will find an overview of recommended saw blades at the end of these operating instructions. Only use saw blades with a 1/2″ universal shank. The saw blade should not be longer than required for the intended cut. The shank thickness of the saw blade has to be 0.8–1.8 mm.

Inserting the saw blade (see figure A)
Press the SDS lever (9) forward and guide the saw blade (1) behind the clamping plate into the saw blade receptacle (3). Release the SDS lever (9).

Check that it is seated securely by pulling the saw blade. A loose saw blade can fall out and lead to injuries.
For particular jobs, the saw blade (1) can also be flipped 180° (teeth point upwards) and refitted.

Removing the saw blade (see figure B)

Let the saw blade cool down before removing it. There is a risk of injury when touching the hot saw blade. Press the SDS lever (9) forward and pull out the saw blade (1). Release the SDS lever (9).

Dust/Chip Extraction
Dust from materials such as lead-containing coatings, some wood types, minerals and metal can be harmful to one health. Touching or breathing in the dust can cause allergic reactions and/or lead to respiratory infections of the user or bystanders. Certain dust, such as oak or beech dust, is considered carcinogenic, especially in connection with wood-treatment ad-ditives (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.
Avoid dust accumulation at the workplace. Dust can easily ignite.

Operation

Products that are only sold in AUS and NZ: Use a residual current device (RCD) with a nominal residual current of 30 mA or less.

Starting Operation

Pay attention to the mains voltage. The voltage of the power source must match the voltage specified on the rating plate of the power tool. Power tools marked with 230 V can also be operated with 220 V.

Switching on/off

To switch on the power tool, press the on/off switch (6). To lock the on/off switch (6), press and hold it while also pressing the locking mechanism (5).
To switch off the power tool, release the on/off switch (6). If the on/off switch (6) is locked, press the switch first and then release it.

Controlling the stroke rate
You can variably adjust the stroke rate of the power tool when it is on by pressing in the on/off switch (6) to varying extents. Applying light pressure to the on/off switch (6) results in a low stroke rate. Applying increasing pressure to the switch increases the stroke rate. The required stroke rate is dependent on the material and the work conditions and can be determined using practical tests. It is recommended that you reduce the stroke rate when placing the saw blade on the workpiece and when sawing plastic and aluminium. During prolonged periods of use at a low stroke rate, the power tool may heat up significantly. Remove the saw blade and let the power tool run at the maximum stroke rate for around three minutes to cool down.

Working Advice

Pull the plug out of the socket before carrying out any work on the power tool.
Switch the power tool off immediately if the saw blade becomes blocked.

Tips

When sawing lightweight materials, take into account the statutory provisions and recommendations of the material manufacturers.

Before sawing into wood, chipboard, building materials, etc., check for any foreign objects such as nails, screws, etc. and use a suitable saw blade. Switch on the power tool and guide it towards the workpiece you wish to work on. Place the base plateÂ (2) on the surface of the workpiece and saw through the material applying even pressure and feed. Switch the power tool off once you have finished your work. Switch the power tool off immediately if the saw blade jams. Widen the sawing gap slightly with a suitable tool and pull the power tool out.

Swivelling base plate (see figureÂ C)
Thanks to its mobility, the base plateÂ (2) adopts the required angle position of the surface.

Plunge cutting (see figures E“F)

Plunge cuts may only be applied to soft materials, such as wood, gypsum board, etc. Do not plunge cut metal materials.

For plunge cutting, use only short saw blades. Place the power tool so that the edge of the base plateÂ (2) rests on the workpiece, without the saw bladeÂ (1) touching the workpiece, and switch it on. When using power tools with stroke rate control, select the maximum stroke rate. Press the power tool firmly against the workpiece and allow the saw blade to plunge slowly into the workpiece. As soon as the base plateÂ (2) rests fully on the workpiece, continue sawing along the required cutting line. For particular jobs, the saw bladeÂ (1) can also be fitted after being turned 180Â° in order to operate the power tool the other way around.

Flush sawing (see figure D)
Protruding components such as water pipes, for example, can be cut directly at the wall using elastic bi-metal saw blades.3

Ensure that the saw blade is always longer than the diameter of the workpiece. There is a risk of kickback.

Place the saw blade directly against the wall and bend it slightly by applying lateral pressure to the power tool until the base plate is flush with the wall. Switch on the power tool and saw through the workpiece applying consistent lateral pressure.

Coolant/lubricant
As the material heats up along the cutting line when cutting metal, you should apply coolant or lubricant.

Maintenance and Service

Maintenance and Cleaning

Pull the plug out of the socket before carrying out any work on the power tool.
To ensure safe and efficient operation, always keep the power tool and the ventilation slots clean.

In order to avoid safety hazards, if the power supply cord needs to be replaced, this must be done by Bosch or by an after-sales service centre that is authorised to repair Bosch power tools.
Carefully clean the saw blade receptacle with a soft cloth. To do so, remove the saw blade from the power tool. Keep the saw blade receptacle operational using suitable lubricants. If the power tool becomes very dirty, this can lead to serious faults. For this reason, do not cut materials which generate large quantities of dust from below or overhead.

Replacing the carbon brushes (see figure G)
Check the length of the carbon brushes around every 2â€“3 months and replace both carbon brushes if required. Never replace only a single carbon brush.

Note: Only use carbon brushes supplied by Bosch and inten-ded specifically for your product.

Unscrew the caps (4) using a suitable screwdriver.
Replace the spring-loaded carbon brushes (10) and screw the caps back on.

After-Sales Service and Application Service
Our after-sales service responds to your questions concerning the maintenance and repair of your product as well as spare parts. You can find explosion drawings and information on spare parts at: www.bosch-pt.com
The Bosch product use advice team will be happy to help you with any questions about our products and their accessories. In all correspondence and spare parts orders, please always include the 10‑digit article number given on the nameplate of the product.

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