BOSCH GST Professional 90 E Jigsaw with Bar Handle Instruction Manual

: October 27, 2023
: Bosch

Table of Contents

Safety instructions
Product Description and Specifications
Technical Data
Assembly
Operation
Maintenance and Service
References
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BOSCH GST Professional 90 E Jigsaw with Bar Handle Instruction Manual

Instructions

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 instructions 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 mainsoperated (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 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 power source and/or battery pack, picking up or carrying the tool.
Carrying power tools with your finger on the switch or energising 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 jewellery. Keep your hair and clothing away from moving parts. Loose clothes, jewellery 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 reduce dust-related hazards.
Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury 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 he 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 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.
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 jigsaws

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.
Only bring the power tool into contact with the workpiece when switched on. Otherwise there is danger of kickback if the cutting tool jams in the workpiece.
Ensure that the footplate always rests securely while sawing. A jammed saw blade can break or lead to kickback.
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.
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 explosion. Penetrating a water line causes property damage or may cause an electric shock.

Products sold in GB only:

Your product is fitted with an BS 1363/A approved electric plug with 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 authorised 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 intended for making separating cuts and cut-outs in wood, plastic, metal, ceramic plates and rubber while resting firmly on the workpiece. It is suitable for straight and curved cuts with mitre/bevel angles of up to 45°. Note the saw blade recommendations.

Product Features

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

On/off switch locking mechanism (GST 90 BE)
On/off switch
Stroke rate preselection thumbwheel
Hex key
Base plate
Sawdust blower device switch
Pendulum action adjusting lever
SDS lever for saw blade release
Guide roller
Saw bladeA)
Shock protection guard
Handle (insulated gripping surface)
Saw blade receptacle
Anti-splinter guardA)
Hood for dust extraction
Extraction outlet
Extraction hoseA)
Scale for mitre/bevel angles
Base plate screw
Guide for parallel guide
Locking screw for parallel guideA)
Parallel guide with circle cutterA)
Circle cutter centring tipA)

A) Accessories shown or described are not included with the product as standard. You can find the complete selection of accessories in our accessories range.

Technical Data

Jigsaw		GST 90 E	GST 90 BE
Article number		3 601 E8G 0	3 601 E8F 0..
Stroke rate control		●	●
Rated power input	W	650	650
No-load stroke rate n0	min−1	500–3100	500–3100
Stroke	mm	26	26
Max. cutting depth
– In wood	mm	90	90
– In aluminium	mm	20	20
– In steel (unalloyed)	mm	10	10
Max. cutting angle (left/right)	°	45	45
Weight according to EPTA-Procedure 01:2014	kg	2.3	2.6
Protection class		/II	/II

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

Noise/Vibration Information

GST 90 E / GST 90 BE

Noise emission values determined according to EN 62841-2-11.

Typically, the A-weighted noise level of the power tool is:

Sound pressure leve	dB(A)	86	84
Sound power level	dB(A)	97	95
Uncertainty K	dB	5	5

Wear hearing protection
Vibration total values ah (triax vector sum) and uncertainty K determined according to EN 62841-2-11: Cutting boards with saw blade T 144 DF:

ah,B	m/s2	8.5	4.5
K	m/s2	1.5	1.5

Cutting sheet metal with saw blade T 118 A
ah,M| m/s2| 8.5| 6.5
K| m/s2| 1.5| 1.5

The vibration level and noise emission value given in these instructions have been measured in accordance with a standardised measuring procedure and may be used to compare power tools. They may also be used for a preliminary estimation of vibration and noise emissions.
The stated vibration level and noise emission value represent the main applications of the power tool. However, if the power tool is used for other applications, with different application tools or is poorly maintained, the vibration level and noise emission value may differ. This may significantly increase the vibration and noise emissions over the total working period.
To estimate vibration and noise emissions accurately, the times when the tool is switched off or when it is running but not actually being used should also be taken into account.
This may significantly reduce vibration and noise emissions over the total working period.
Implement additional safety measures to protect the operator from the effects of vibration, such as servicing the power tool and application tools, keeping their hands warm, and organising workflows correctly.

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.

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 single lug shank (T shank). The saw blade should not be longer than required for the intended cut.
Use a narrow saw blade when sawing tight curves.

Inserting the saw blade (see figure A)

Clean the shaft on the saw blade before inserting it

A dirty shaft cannot be securely fixed in place.
Press the SDS lever (8) forward to the stop and hold it down. Push the saw blade (10), with the teeth in the cutting direction, into the saw blade receptacle (13) until it clicks into place.
Make sure when inserting the saw blade that the back of the saw blade is in the groove on the guide roller (9).

Check that the saw blade is seated securely. A loose saw blade can fall out and lead to injuries.

Removing the saw blade (see figure B)

Push the SDS lever (8) all the way forwards and remove the saw blade (10).

Anti-splinter guard (see figure C)

The anti-splinter guard (14) (accessory) can prevent splintering of the surface while sawing wood. The anti-splinter guard can only be used with certain saw blade types and only at a cutting angle of 0°. When sawing with the anti-splinter guard, the base plate (5) must not be moved to the rear for sawing close to edges.
Push the anti-splinter guard (14) into the base plate (5) from below.

Dust/Chip Extraction

The dust from materials such as lead paint, some types of wood, minerals and metal can be harmful to human health.
Touching or breathing in this dust can trigger allergic reactions and/or cause respiratory illnesses in the user or in people in the near vicinity.
Certain dusts, such as oak or beech dust, are classified as carcinogenic, especially in conjunction with wood treatment additives (chromate, wood preservative). Materials containing asbestos may only be machined by specialists.

Use a dust extraction system that is suitable for the material wherever possible.
Provide good ventilation at the workplace.
It is advisable to wear a P2 filter class breathing mask.
The regulations on the material being machined that apply in the country of use must be observed.

Avoid dust accumulation at the workplace. Dust can easily ignite.

Hood (see figure D)

Fit the hood (15) before you connect the power tool to the dust extraction system.
Attach the hood (15) to the power tool so that the bracket locks into place on the shock protection guard (11).
Remove the hood (15) when working without a dust extraction system and for mitre/bevel cuts. To do this, pull the hood forwards off the shock protection guard (11).

Connecting the dust extraction (see figures E–F)

Fit the extraction outlet (16) in the recesses of the base plate (5).
Ensure that the cam on the extraction outlet slots into the corresponding recess in the power tool as shown in the figure E.
Connect a dust extraction hose (17) (accessory) to the extraction outlet (16). Connect the dust extraction hose (17) to a dust extractor (accessory).
You will find an overview of connecting to various dust extractors at the end of these operating instructions.
For optimum dust extraction, where possible use the antisplinter guard (14).
Switch off the sawdust blower device when you have connected the dust extraction system.
The dust extractor must be suitable for the material being worked.
When extracting dry dust that is especially detrimental to health or carcinogenic, use a special dust extractor.

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.

Operating modes

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

Pendulum action settings

The pendulum action can be adjusted using four different settings, allowing the cutting speed, cutting capacity and the cut itself to be optimally adapted to the material that you want to cut.

You can also adjust the pendulum action during operation using the adjusting lever (7).

Level 0 No pendulum action
Level I Low pendulum action
Level II Moderate pendulum action
Level III High pendulum action

The optimum pendulum level for each application can be determined by a practical test. Note the following recommendations:

Select a lower pendulum level or switch off the pendulum action completely if you wish to produce a finer or cleaner cutting edge.
Switch off the pendulum action when machining thin materials (e.g. sheets).
Work on hard materials (e.g. steel) with low pendulum action.
You can work on soft materials and saw wood in the direction of the grain using maximum pendulum action.

Adjusting the mitre/bevel angle (see figure G)

The base plate (5) can be swivelled to the right or left to make mitre cuts up to 45°.
The hood (15), the extraction outlet (16) and the antisplinter guard (14) cannot be used while mitre/bevel cuts are being made.

Push the extraction outlet (16) downwards slightly and pull it out of the base plate (5).
Remove the hood (15) and the anti-splinter guard (14).
Undo the screw (19) using the hex key (4) and push the base plate (5) slightly towards the mains cable.
The base plate has lock-in points at 0° and 45° on the left and right so that precise mitre/bevel angles can be set.
Swivel the base plate (5) to the required position according to the scale (18). Other mitre/bevel angles can be adjusted using a protractor.
Then push the base plate (5) towards the saw blade (10) as far as it will go.
Retighten the screw (19).

Moving the base plate (see figure G)

You can move the base plate (5) back for sawing close to edges.
Loosen the screw (19) and push the base plate (5) towards the mains cable as far as it will go.
Retighten the screw (19).
Sawing with an offset base plate (5) is only possible with a mitre/bevel angle of 0°. In addition, the parallel guide with circle cutter (22) (accessory) as well as the anti-splinter guard (14) must not be used.

Sawdust blower device

The cutting line can be kept clear of chips using the airflow from the sawdust blower device.

To switch on the sawdust blower device:
When working with high material removal in wood, plastic and other similar materials, push the switch (6) towards the extraction outlet.

To switch off the sawdust blower device:
When working in metal and with a dust extraction system connected, push the switch (6) towards the saw blade.

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 and Off (GST 90 E)

Make sure that you are able to press the On/Off switch without releasing the handle.

To switch on the power tool, slide the on/off switch (2) forwards so that “I” appears on the switch.
To switch off the power tool, slide the on/off switch (2) backwards so that “0” appears on the switch.

Switching On and Off (GST 90 BE)

Make sure that you are able to press the On/Off switch without releasing the handle.

To switch on the power tool, press the on/off switch (2).
To lock the on/off switch (2), keep it pressed down and push the locking mechanism (1) to the right or left.
To switch off the power tool, release the on/off switch (2).
If the on/off switch (2) is locked, press the switch first and then release it.

Controlling the stroke rate (GST 90 BE)

You can variably adjust the stroke rate of the power tool when it is on by pressing in the on/off switch (2) to varying extents.
Applying light pressure to the on/off switch (2) results in a low stroke rate. Applying increasing pressure to the switch increases the stroke rate.

Preselect the stroke rate

You can also preselect the stroke rate and change it during operation using the stroke rate preselection thumbwheel (3).
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.
When machining small or thin workpieces, always use a stable base or saw table (accessory).

Before sawing into wood, chipboard, building materials, etc., check for and remove any foreign objects such as nails, screws, etc.

Plunge cutting (see figure H)

Plunge cuts may only be applied to soft materials, such as wood, gypsum board, etc.

For plunge cutting, use only short saw blades. Plunge cutting is possible only with a mitre angle of 0°.
Place the power tool so that the front edge of the base plate (5) rests on the workpiece, without the saw blade (10) touching the workpiece, and switch it on. On 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 plate (5) rests fully on the workpiece, continue sawing along the required cutting line.

Parallel guide with circle cutter (accessory)

When working with the parallel guide with circle cutter (22) (accessory), the workpiece must be no more than 30 mm thick.
Parallel cuts (see figure I): Loosen the locking screw (21) and slide the scale on the parallel guide through the guide (20) in the base plate. Adjust the desired cutting width as a scale value on the inside edge of the base plate. Retighten the locking screw (21).
Circular cuts (see figure J): Drill a hole large enough to push the saw blade through on the cutting line within the circle to be cut. Machine the drill hole with a router or file so that the saw blade can lie flush with the cutting line.
Position the locking screw (21) on the other side of the parallel guide. Slide the scale on the parallel guide through the guide (20) into the base plate. Drill a hole in the workpiece in the middle of the section to be cut out. Insert the centringtip (23) through the inner opening of the parallel guide and into the drilled hole. Adjust the radius as a scale value on the inside edge of the base plate. Retighten the locking screw (21).

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.
Clean the saw blade receptacle regularly. For this, remove the saw blade from the power tool and lightly tap out the power tool on a level surface.
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.

In extreme conditions, always use a dust extractor if possible. Blow out ventilation slots frequently and install a residual current device (RCD) upstream. When machining metals, conductive dust can settle inside the power tool, which can affect its protective insulation.

If the dust outlet becomes blocked, switch off the power tool, disconnect the dust extraction system and remove the dust and chips.
Apply a drop of oil to the guide roller (9) from time to time.
Check the guide roller (9) regularly. If worn, it must be replaced through an authorised Bosch after-sales service centre.

After-Sales Service and Application Service

Our after-sales service responds to your questions concerning 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.

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: boschservicecentre@bosch.com

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-pt.com.au
www.bosch-pt.co.nz

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: bsctools@icon.co.za

KZN – BSC Service Centre
Unit E, Almar Centre
143 Crompton Street
Pinetown
Tel.: (031) 7012120
Fax: (031) 7012446
E-mail: bsc.dur@za.bosch.com

Western Cape – BSC Service Centre
Democracy Way, Prosperity Park
Milnerton
Tel.: (021) 5512577
Fax: (021) 5513223
E-mail: bsc@zsd.co.za

Bosch Headquarters
Midrand, Gauteng
Tel.: (011) 6519600
Fax: (011) 6519880
E-mail: rbsa-hq.pts@za.bosch.com

Disposal

The power tool, accessories and packaging should be recycled in an environmentally friendly manner.
Do not dispose of power tools along with household waste.

Only for EU countries:

According to the European Directive 2012/19/EU on Waste Electrical and Electronic Equipment and its implementation into national law, power tools that are no longer usable must be collected separately and disposed of in an environmentally friendly manner.

for wood

for hardwood

for metal

for plastics

for special materials

Overview

EU Declaration of Conformity

Jigsaw
GST 90 E
GST 90 BE

Article number
3 601 E8G 0..
3 601 E8F 0..

We declare under our sole responsibility that the stated products comply with all applicable provisions of the directives and regulations listed below and are in conformity with the following standards.
Technical file at: *

2006/42/EC
2014/30/EU
2011/65/EU

EN 62841-1:2015
EN 62841-2-11:2016
EN 55014-1:2006+A1:2009+A2:2011
EN 55014-2:2015
EN 61000-3-2:2014
EN 61000-3-3:2013
EN 50581:2012

* Robert Bosch Power Tools GmbH
(PT/ECS)
70538 Stuttgart
GERMANY

Henk Becker
Chairman of
Executive Management

Helmut Heinzelmann
Head of Product Certification

Robert Bosch Power Tools GmbH, 70538 Stuttgart, GERMANY Stuttgart, 18.04.2019