BOSCH GCM-8-SJ Sliding Mitre Saw Professional Instruction Manual

GCM-8-SJ Sliding Mitre Saw Professional
Instruction Manual

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.

1. Work area safety
   a) Keep work area clean and well lit. Cluttered or dark areas invite accidents.
   b) 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.
   c) Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

2. Electrical safety
   a) 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.
   b) 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.
   c) Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
   d) 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.
   e) 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.
   f) 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.

3. Personal safety
   a) 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.
   b) Use personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries. c) 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.
   d) 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.
   e) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
   f) Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts.
   g) 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.

4. Power tool use and care a) 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.
   b) 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.
   c) 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.
   d) 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.
   e) 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.
   f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
   g) 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.

5. Service
   a) 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 Sliding Mitre Saws The power tool is provided with a warning label in English (marked with number 28 in the representation of the measuring tool on the graphics page).

Safety Warnings for Sliding Mitre Saws

• The power tool is provided with a warning label in English (marked with number 28 in the representation of the measuring tool on the graphics page).

• Never make warning signs on the machine unrecognisable.

• Never stand on the power tool. Serious injuries can occur when the power tool tips over or when inadvertently coming into contact with the saw blade.

• Make sure that the guard operates properly and that it can move freely. Never lock the guard in place when opened.

• Keep hands away from the cutting area while the machine is running. Danger of injury when coming in contact with the saw blade.

• Never remove cutting remainders, wood chips, etc. from the sawing area while the machine is running. Always guide the tool arm back to the neutral position first and then switch the machine off.

• Guide the saw blade against the workpiece only when the machine is switched on. Otherwise there is damage of kickback, when the saw blade becomes wedged in the workpiece.

• Keep handles dry, clean, and free from oil and grease. Greasy, oily handles are slippery causing loss of control.

• Operate the power tool only when the work area to the workpiece is clear of any adjusting tools, wood chips, etc. Small pieces of wood or other objects that come in contact with the rotating saw blade can strike the operator with high speed.

• Always firmly clamp the piece to be worked. Do not saw workpieces that are too small to clamp. Otherwise, the clearance of your hand to the rotating saw blade is too small.

• Use the machine only for cutting the materials listed under Intended Use. Otherwise, the machine can be subject to overload.

• If the saw blade should become jammed, switch the machine off and hold the workpiece until the saw blade comes to a complete stop. To prevent kickback, the workpiece may not be moved until after the machine has come to a complete stop. Correct the cause for the jamming of the saw blade before restarting the machine.

• Do not use dull, cracked, bent or damaged saw blades. Unsharpened or improperly set saw blades produce narrow kerf causing excessive friction, blade binding and kickback.

• Always use saw blades with correct size and shape (diamond versus round) of arbor holes. Saw blades that do not match the mounting hardware of the saw will run eccentrically, causing loss of control.

• Do not use high speed steel (HSS) saw blades. Such saw blades can easily break.

• Do not touch the saw blade after working before it has cooled. The saw blade becomes very hot while working.

• Never operate the machine without the insert plate. Replace a defective insert plate. Without flawless insert plates, injuries are possible from the saw blade.

• Check the cable regularly and have a damaged cable repaired only through an authorised customer service agent for Bosch power tools. Replace damaged extension cables. This will ensure that the safety of the power tool is maintained.

• Store the machine in a safe manner when not being used. The storage location must be dry and lockable. This prevents the machine from storage damage, and from being operated by untrained persons.

• Do not direct the laser beam at persons or animals and do not stare into the laser beam yourself, not even from a distance. This power tool produces laser class 2 laser radiation according to EN 60825-1. This can lead to persons being blinded. Do not allow children unsupervised use of the power tool with laser. They could blind other people.

• Do not replace the installed laser with another laser type. A laser that does not fit to this power tool could pose dangers for other persons. Secure the workpiece. A workpiece clamped with clamping devices or in a vice is held more secure than by hand. Keep your workplace clean. Blends of materials are particularly dangerous. Dust from light alloys can burn or explode.

• Never leave the machine before it has come to a complete stop. Cutting tools that are still running can cause injuries.

• Never use the machine with a damaged cable. Do not touch the damaged cable and pull the mains plug when the cable is damaged while working. Damaged cables increase the risk of 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.
Products sold in AUS and NZ only: Use a residual current device (RCD) with a rated residual current of 30 mA or less.

Symbols

The following symbols can be important for the operation of your power tool. Please memorise the symbols and their meanings. The correct interpretation of the symbols helps you operate the power tool better and more secure.

into the laser beam yourself, not even from a distance.
This power tool produces laser class 2 laser radiation according to EN 60825-1. This can lead to persons being blinded.
| Danger area! Keep hands, fingers or arms away from this area.
| Wear a dust respirator.
| Wear safety goggles.
| Wear ear protectors. Exposure to noise can cause hearing loss.
| Observe the dimensions of the saw blade. The hole diameter must match the tool spindle without play. Do not use  reducers or adapters.
| Only for EC countries:
Do not dispose of power tools into household waste!
According the European Guideline 2002/96/EC for Waste Electrical and Electronic Equipment and its implementation into national right, power tools that are no longer usable must be collected separately and disposed of in an environmentally correct manner.

Functional Description

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

Intended Use
The power tool is intended as a stationary machine for making straight lengthways and crossways cuts in wood as well as in particle and fibre board.
In this, mitre angles from –50° to +58° as well as bevel angles from 0° to 45° are possible.
When using appropriate saw blades, sawing aluminium profiles and plastic is also possible.

Product Features
The numbering of the components shown refers to the representation of the power tool on the graphic pages.

1. Slide device
2. Transport handle
3. Blade guard
4. On/Off switch
5. Handle
6. Retracting blade guard
7. Roller
8. Saw table
9. Scale for mitre angle (horizontal)
10. Insert plate
11. Locking knob for various mitre angles (horizontal)
12. Lever for mitre angle adjustment (horizontal)
13. Angle indicator (horizontal)
14. Detents for standard mitre angles
15. Mounting holes
16. Drill holes for material clamp
17. Extension bar*
18. Fence
19. Scale for bevel angle (vertical)
20. Angle indicator (vertical)
21. Clamping lever for various bevel angles (vertical)
22. Sawdust ejector
23. Depth stop
24. Allen screws (6 mm) of the fence
25. Locking screw for slide device
26. Allen key (size 6 mm)/Phillips screwdriver
27. Transport safety-lock
28. Laser warning label
29. Switch for marking of cutting line (“Laser”)
30. Light switch (“Light”)
31. Tilt protector
32. Tilt-protector lock nut
33. Metal bar of tilt protector
34. Dust bag
35. Locking lever
36. Phillips screw (attachment of retracting blade guard)
37. Spindle lock
38. Allen screw (size 6 mm) for mounting of saw blade
39. Clamping flange
40. Saw blade
41. Interior clamping flange
42. Material clamp
43. Wing bolt
44. Threaded rod
45. Lighting unit
46. Laser unit
47. Depth stop lever
48. Screws for insert plate
49. Rubber cap
50. Adjustment screw for laser position (parallelism)
51. Adjustment screw for laser position (flush levelling)
52. Screws for laser protection cap
53. Laser protection cap
54. Adjustment screw for laser position (lateral deviation)
55. Screw for angle indicator (horizontal)
56. Screw for angle indicator (vertical)
57. Allen screw (size 3 mm) for standard bevel angle 0° (vertical)
58. Allen screw (size 3 mm) for standard bevel angle 45° (vertical)
59. Recessed grips

*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

Article number
3 601 L16 …| | … 200| … 230| … 270| … 260
Rated power input| W| 1500| 1500| 1500| 1400
Rated voltage| V| 230/240| 230/240| 230/240| 110
Frequency| Hz| 50/60| 50/60| 50/60| 50/60
No-load speed| min’l| 5000| 5000| 5000| 5000
Reduced starting current| | •| •| •| •
Laser type| nm mW| 650
<1| 650
<1| 650
<1| 650
<1
Laser class| | 2| 2| 2| 2
Weight according to EPTA-Procedure 01/2003| kg| 15| 15| 15| 15
Protection class| | /II| /II| /II| /II

Permissible workpiece dimensions (maximal/minimal) see page 42.
The values given are valid for nominal voltages [U] of 230/240 V. For lower voltage and models for specific countries, these values can vary.
Please observe the article number on the type plate of your machine. The trade names of the individual machines may vary.

Dimension of suitable saw blades

Noise/Vibration Information

Measured sound values determined according to EN 61029.
Typically the A-weighted noise levels of the product are: Sound pressure level 98 dB(A); Sound power level 111 dB(A). Uncertainty K =3 dB.

Wear hearing protection!

Vibration total values (triax vector sum) deter­mined according to EN 61029:
Vibration emission value ah =2.5 m/s2, Uncer­tainty K =1.5 m/s2.
The vibration emission level given in this infor­mation sheet has been measured in accordance with a standardised test given in EN 61029 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 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: maintain the tool and the accessories, keep the hands warm, organisation of work patterns.

Declaration of Conformity
We declare under our sole responsibility that the product described under “Technical Data” is in conformity with the following standards or standardization documents: EN 61029,
EN 60825-1 according to the provisions of the directives 2004/108/EC, 2006/42/EC.
Technical file at:
Robert Bosch GmbH, Dept. PT/ESC,
D-70745 Leinfelden-Echterdingen

Robert Bosch GmbH, Power Tools Division
D-70745 Leinfelden-Echterdingen
Leinfelden, 16.04.2010

Assembly

Avoid unintentional starting of the machine. During assembly and for all work on the machine, the power plug must not be connected to the mains supply.
Delivery Scope
Before starting the operation of the machine for the first time, check if all parts listed below have been supplied:
– Sliding mitre saw with premounted saw blade
– Dust bag 34 – Material clamp 42
– Allen key/Phillips screwdriver 26

Note: Check the power tool for possible damage. Before further use of the machine, check that all protective devices are fully functional. Any lightly damaged parts must be carefully checked to ensure flawless operation of the tool. All parts must be properly mounted and all conditions fulfilled that ensure faultless operation. Damaged protective devices and parts must be immediately replaced by an authorised service centre.

Stationary or Flexible Mounting
To ensure safe handling, the machine must be mounted on a level and stable surface (e. g., workbench) prior to using.
Mounting to a Working Surface (see figures A1 – A2)

• Fasten the power tool with suitable screw fasteners to the working surface. The holes 15 serve for this purpose. or
• Clamp the power tool with commercially available screw clamps by the feet to the working surface.

Mounting to a Bosch Saw Stand
(GTA 2500 W, GTA 3700, GTA 3800) (see figure A3)
With the height-adjustable legs, Bosch GTA saw stands provide firm support for the power tool on any surface. The workpiece supports of the saw stand are used for underlaying long workpieces.
Read all safety warnings and instructions included with the worktable. Failure of observing safety warnings and instructions can lead to electrical shock, fire and/or cause serious injuries.
Assemble the worktable properly before mounting the power tool. Perfect assembly is important in order to prevent the risk of collapsing.

• Mount the power tool on the saw stand in the transport position.
  Flexible Mounting (not recommended!) (see figure B)
  In exceptional cases, when it is not possible to mount the machine onto a level and stable work surface, it can be set up using the tilt protector.
  Without the use of the tilt protector, the machine does not stand safely and can tip over, especially when sawing at maximum mitre/bevel angles.

• Pull the metal bar of the tilt protector 33 out forwards to the stop.

• Screw the tilt protector 31 in or out until the machine stands level on the working surface.
  Lock this position with the lock nut 32.

Dust/Chip Extraction
Dusts from materials such as lead-containing coatings, some wood types, minerals and metal can be harmful to one’s health. Touching or breathing-in the dusts can cause allergic reactions and/or lead to respiratory infections of the user  or bystanders.
Certain dusts, such as oak or beech dust, are considered as carcinogenic, especially in connection with wood-treatment additives (chro- mate, wood preservative). Materials containing asbestos may only be worked by specialists.

• Use dust extraction whenever possible.

• 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.
  The dust/chip extraction can be blocked by  dust, chips or workpiece fragments.

• Switch the machine off and pull the mains plug from the socket outlet.

• Wait until the saw blade has come to a complete stop.

• Determine the cause of the blockage and correct it.

Integrated Dust Extraction (see figure C) For basic dust collection, use the dust bag 34 provided.
Check and clean the dust bag each time after using.
When sawing aluminium, remove the dust bag to avoid the risk of fire.

• Press the clip of the dust bag 34 together and slide the dust bag over the saw dust ejector 22. The clip must engage into the groove of the saw dust ejector.

During sawing, the dust bag must never come into contact with the movable machine parts. Always empty the dust bag in good time.

External Dust Extraction
For dust extraction, a vacuum hose (size Ø 36 mm) can also be connected to the dust ejector 22.

• Connect the vacuum hose with the sawdust ejector 22.

The vacuum cleaner must be suitable for the material being worked.
When vacuuming dry dust that is especially detrimental to health or carcinogenic, use a special vacuum cleaner.

Operation

• Before any work on the machine itself, pull the mains plug.

Transport Safety (see figure E)
The transport safety-lock 27 enables easier handling of the machine when transporting to various working locations.
Releasing the Machine (Working Position)

• Push the tool arm by the handle 5 down a little in order to relieve the transport safetylock 27.

• Pull the transport safety-lock 27 completely outward.

• Guide the tool arm slowly upward.
  Securing the Machine (Transport Position) – Loosen the locking screw 25 if tightened.
  Pull the tool arm completely to the front and tighten the locking screw again.

• Screw the depth stop 23 completely to the top. (see “Adjusting the Depth Stop”, page 43)

• To lock the saw table 8, tighten the locking knob 11.

• Push the locking lever 35 and at the same time move the tool arm by the handle 5 downward.

• Guide the tool arm downward until the transport safety-lock 27 can be pushed completely inward.

Preparing for Operation
Clamping the Workpiece (see figure F)
To ensure optimum working safety, the workpiece must always be firmly clamped.
Do not saw workpieces that are too small to clamp.

• Press the workpiece firmly against the fence 18.

• Insert the material clamp 42 provided into one of the holes 16 intended for it.

• Loosen the wing bolt 43 and adapt the material clamp to the workpiece.
  Tighten the wing bolt again.

• Firmly clamp the workpiece by turning the threaded rod 44 in clockwise direction.

Adjusting the Cutting Angle
To ensure precise cuts, the basic adjustment of the machine must be checked and adjusted as necessary after intensive use (see “Checking and Adjusting the Basic Adjustment”, page 46).
Always tighten the locking knob 11 firmly before sawing. Otherwise the saw blade can become wedged in the workpiece.
Adjusting Horizontal Mitre Angles (see figure G)
The horizontal mitre angle can be set in the range from 50° (left side) to 58° (right side).

• Loosen the locking knob 11 in case it is tightened.
• Pull the lever 12 and turn the saw table 8 until the desired mitre angle is indicated on the angle indicator 13.
• Tighten the locking knob 11 again.

For quick and precise setting of often used mitre angles, detents 14 are provided on the saw table:

0°
15°; 22.5°;
30°; 45°| 15°; 22.5°;
30°; 45°

• Loosen the locking knob 11 in case it is tightened.

• Pull lever 12 and rotate the saw table 8 left or right to the requested detent.

• Release the lever again. The lever must be felt to engage in the detent.
  Adjusting Vertical Bevel Angles (see figure H)
  The vertical bevel angle can be set in the range from 0° to 45°.

• Loosen the clamping lever 21.

• Tilt the tool arm by the handle 5 until the angle indicator 20 indicates the desired bevel angle.

• Hold the tool arm in this position and retighten the clamping lever 21.

For quick and precise setting of the standard angles 0° und 45°, end stops are provided on the housing.

• For this, tilt the tool arm by the handle 5 to the stop toward the right (0°) or to the stop toward the left (45°).

Starting Operation
Switching On (see figure I)

• For starting operation, pull the On/Off switch 4 in the direction of the handle 5.
  Note: For safety reasons, the On/Off switch 4 cannot be locked; it must remain pressed during the entire operation.
  The tool arm can be guided down only after pushing the locking lever 35.

• For sawing, the locking lever 35 must be pushed in addition to pressing the On/Off switch.

Switching Off

• To switch off the machine, release the On/Off switch 4.
  Reduced starting current
  The electronic reduced starting current limits the power consumption when switching the tool on and enables operation from a 13 ampere fuse.
  Note: When the machine runs at full speed immediately after switching on, the reduced starting current has failed.
  The power tool should be sent immediately to an after-sales service (for addresses, see section “After-sales Service and Customer Assistance”, page 48).

Working Advice
General Sawing Instructions For all cuts, it must first be ensured that the saw blade at no time can come in contact with the fence, screw clamps or other machine parts. Remove possibly mounted auxiliary stops or adjust them accordingly. Protect the saw blade against impact and shock. Do not subject the saw blade to lateral pressure. Do not saw warped/bent workpieces. The workpiece must always have a straight edge to face against the fence. Long workpieces must be underlaid or supported at their free end. To additionally extend the saw table, an extension bar 17 (accessory) can be mounted both on the left and right side of the power tool.
Illuminating the Work Area (see figure J) Provide for sufficient lighting of the direct working area.

• For this, switch on the lighting unit 45 with the switch 30.

Marking the Cutting Line (see figure K)
A laser beam indicates the cutting line of the saw blade. This allows for exact positioning of the workpiece for sawing, without having to open the retracting blade guard.

• For this, switch the laser beam on with the switch 29.
• Align the cutting mark on your workpiece with reference to the right-hand edge of the laser line.
  Note: Before sawing, check if the cutting line is still indicated correctly (see “Adjusting the Laser”, page 46). The laser beam, as an example, can misadjust due to vibrations after intensive use.

Position of the Operator (see figure L)
Do not stand in a line with the saw blade in front of the machine. Always stand aside of the saw blade. This protects your body against possible kickback.

• Keep hands, fingers and arms away from the rotating saw blade.
• Do not cross your arms when operating the tool arm.
  Permissible Workpiece Dimensions
  Maximal workpiece sizes:

Mitre/Bevel Angle| Height x Width
[mm]
---|---
Horizontal| Vertical
90°| 90°| 60 x 270
45°| 90°| 60 x 190
90°| 45°| 42 x 270

Minimal workpiece sizes (= all workpieces that can be clamped left or right from the saw blade with the supplied material clamp 42): 185 x 40 mm (length x width) Cutting capacity, max. (90°/90°): 60 mm

Replacing Insert Plates (see figure M)
The red insert plates 10 can become worn after long use of the machine.
Replace defective insert plates.

• Bring the power tool into the working position.
• Unscrew the screws 48 using the provided Phillips screwdriver and remove the old insert plates.
• Insert the new right-hand insert plate.
• Screw the insert plate as far as possible to the right with the screws 48 so that the saw blade does not come into contact with the insert plate over the complete length of the possible slide motion.
• Repeat the work steps in the same manner for the left-hand insert plate.

Sawing
Sawing without Slide Movement (Cutting Off) (see figure O)

• For cuts without slide movement (small workpieces), loosen the locking screw 25 in case it is tightened. Slide the tool arm to the stop in the direction of the fence 18 and retighten the locking screw 25.
• Firmly clamp the workpiece as appropriate for its dimensions.
• Set the desired mitre angle.
• Switch on the machine.
• Push the locking lever 35 and guide the tool arm slowly downward with the tool handle 5.
• Saw through the workpiece applying uniform feed.
• Switch off the machine and wait until the saw blade has come to a complete stop.
• Guide the tool arm slowly upward.

Sawing with Slide Movement

• For cuts using the slide device 1 (wide workpieces), loosen the locking screw 25 in case it is tightened.
• Firmly clamp the workpiece as appropriate for its dimensions.
• Set the desired mitre angle.
• Pull the tool arm away from the fence 18 far enough so that the saw blade is in front of the workpiece.
• Switch on the machine.
• Push the locking lever 35 and guide the tool arm slowly downward with the tool handle 5.
• Press the tool arm in the direction of the fence 18 and saw through the workpiece ap- plying uniform feed.
• Switch off the machine and wait until the saw blade has come to a complete stop.
• Guide the tool arm slowly upward.

Adjusting the Depth Stop (Sawing Grooves) (see figure N)
The depth stop must be adjusted when a butt gap is to be sawed.

• Turn the depth stop lever 47 in anticlockwise direction to the stop (approx. 90°).
• Screw the depth stop 23 completely upward turning in anticlockwise direction.
• Lower the tool arm by the handle 5 to the desired position.
• Screw the depth stop in clockwise direction until the screw end touches the lever 47.
• Guide the tool arm slowly upward.
• To obtain the full cutting depth again, turn the depth stop lever 47 in clockwise direction back to the stop.

Special Workpieces
When sawing curved or round workpieces, these must be especially secured against slipping. At the cutting line, no gap may exist between workpiece, fence and saw table.
Provide for special fixtures, if required.

Sawing Profile Strips/Mouldings (Floor and Ceiling Strips)

Profile strips/mouldings can be sawn in two different ways:

• Placed against the fence
• Lying flat on the saw table.

In addition, the cut can be perfomed with or without slide movement depending on the width of the profile strip/moulding.
Always make trial cuts with the mitre angle setting first on scrap wood.

Floor Strips/Mouldings
The following table contains instructions for sawing floor strips/mouldings.

Ceiling Strips/Mouldings (According to US Standard)

When the ceiling strips/mouldings are to be sawn lying flat on the saw table, the standard mitre angles of 31.6° (horizontal) and 33.9° (vertical) must be set.
The following table contains instructions for sawing ceiling strips/mouldings.

Checking and Adjusting the Basic
Adjustment
Before any work on the machine itself, pull the mains plug.
To ensure precise cuts, the basic adjustment of the machine must be checked and adjusted as necessary after intensive use.
A certain level of experience and appropriate specialty tools are required for this.
A Bosch after-sales service station will handle this maintenance task quickly and reliably.
Adjusting the Laser

• Bring the power tool into the working position.

• Turn the saw table 8 to the 0° detent 14. The lever 12 must be felt to engage in the detent.
  Checking: (see figure P1)

• Draw a straight cutting line on the workpiece.

• Push the locking lever 35 and guide the tool arm slowly downward with the tool handle 5.

• Align the workpiece in such a manner that the teeth of the saw blade are in alignment with the cutting line.

• Hold the workpiece in this position and slowly guide the tool arm upward again.

• Clamp the workpiece.

• Switch the laser beam on with switch 29. The laser beam must be in alignment with the cutting line on the workpiece over the complete length, also when the tool arm is lowered.
  Adjusting the Parallelism: (see figure P2)

• Undo the rubber cap 49.

• Screw the adjustment screw 50 in or out using a suitable screwdriver until  the laser beam is parallel with the cutting line on the workpiece over the complete length.

Adjusting the Flush Leveling: (see figure P3)

• Turn the adjustment screw 51 with the Phillips screwdriver provided until the parallel laser beam is flush with the cutting line on the workpiece over the complete length.

One rotation in anticlockwise direction moves the laser beam from left to right; one rotation in clockwise direction moves the laser beam from right to left. Adjusting the Lateral Deviation while Moving the Tool Arm: (see figure P4)

• Loosen the three screws 52 of the laser protection cap 53 with the Phillips screwdriver provided.

• Move the retracting blade guard 6 completely to the rear and lift off the laser protection cap.

• Screw the adjustment screw 54 in clockwise direction with the Phillips screwdriver provided if the laser beam moves toward the left when the tool arm is lowered.
  Screw the adjustment screw 54 in anticlockwise direction if the laser beam moves toward the right.

• After adjusting, check the flushness with the cutting line again. If required, align the laser beam with the adjustment screw 51 again.

• Reattach the laser protection cap 53 again. Aligning the Angle Indicator (Horizontally) (see figure Q)

• Bring the power tool into the working position.

• Turn the saw table 8 to the 0° detent 14. The lever 12 must be felt to engage in the detent.
  Checking: The angle indicator 13 must be in alignment with the 0° mark of the scale 9.
  Adjusting:

• Loosen the screw 55 with the Phillips screwdriver provided and align the angle indicator along the 0° mark.

• Retighten the screw again.

Aligning the Angle Indicator (Vertically) (see figure R)

• Bring the power tool into the working position.

• Turn the saw table 8 to the 0° detent 14. The lever 12 must be felt to engage in the detent.
  Checking:
  The angle indicator 20 must be in alignment with the 0° mark of the scale 19.
  Adjusting:

• Loosen the screw 56 with the Phillips screwdriver provided and align the angle indicator along the 0° mark.

• Afterwards, check to ensure that the adjust- ment made is correct for the 45° mark.

• Retighten the screw again.
  Aligning the Fence

• Bring the machine into the transport position.

• Turn the saw table 8 to the 0° detent 14. The lever 12 must be felt to engage in the detent.
  Checking: (see figure S1)

• Set an angle gauge to 90° and place it on the saw table 8 between the fence 18 and the saw blade 40.
  The leg of the angle gauge must be flush with the fence over the complete length.
  Adjusting: (see figure S2)

• Loosen all Allen screws 24 with the Allen key 26 provided.

• Turn the fence 18 until the angle gauge is flush over the complete length.

• Retighten the screws again.
  Setting the Standard Bevel Angle 0° (Vertical)

• Bring the machine into the transport position.

• Turn the saw table 8 to the 0° detent 14. The lever 12 must be felt to engage in the detent.

Checking: (see figure T1)

• Set an angle gauge to 90° and place it on the saw table 8.
  The leg of the angle gauge must be flush with the saw blade 40 over the complete length.
  Adjusting: (see figure T2)

• Turn the Allen screw 57 in or out using a suitable Allen key (size 3 mm) until the leg of the angle gauge is flush with the saw blade over its complete length. In case the angle indicator 20 is not in a line with the 0° mark of the scale 19  after the adjustment, the angle indicator must be aligned accordingly (see “Aligning the Angle Indicator (Vertically)”, page 47). Setting the Standard Bevel Angle 45° (Vertical)

• Bring the power tool into the working position.

• Turn the saw table 8 to the 0° detent 14. The lever 12 must be felt to engage in the detent.

• Loosen the clamping lever 21 and tilt the tool arm leftward to the stop (45°) by the handle 5.
  Checking: (see figure U1)

• Set an angle gauge to 45° and place it on the saw table 8.
  The leg of the angle gauge must be flush with the saw blade 40 over the complete length.
  Adjusting: (see figure U2)

• Turn the Allen screw 58 in or out using a suitable Allen key (size 3 mm) until the leg of the angle gauge is flush with the saw blade over its complete length.

In case the angle indicator 20 is not in a line with the 45° mark of the scale 19, firstly check the 0° setting for the bevel angle and the angle indicator again. Then repeat the adjustment of the 45° bevel angle.

Transport (see figure V)
Before transporting the power tool, the following steps must be carried out:

• Loosen the locking screw 25 if tightened.
  Pull the tool arm completely to the front and tighten the locking screw again.

• Screw the depth stop 23 all the way up or turn the depth stop lever 47 in clockwise direction back to the stop.

• Bring the machine into the transport position.

• Remove all accessories that cannot be mounted firmly to the power tool.
  If possible, place unused saw blades in an enclosed container for transport.

• Carry the machine by the transport handle 2 or hold it by the recessed grips 59 on the sides of the saw table.
  When transporting the power tool, use only the transport devices and never use the protective devices.

Maintenance and Service

Maintenance and Cleaning
Before any work on the machine itself, pull the mains plug.
If the machine should fail despite the care taken in manufacturing and testing procedures, repair should be carried out by an after-sales service centre for Bosch power tools.
In all correspondence and spare parts order, please always include the 10-digit article number given on the type plate of the machine.
Cleaning
For safe and proper working, always keep the power tool and its 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 after each working procedure by blowing out with compressed air or with a brush.
Clean the roller 7 and the lighting and laser unit (45, 46) regularly.

Accessories

Dust bag. . . . . . . . . . . . . . . . . . . 2 605 411 222
Material clamp . . . . . . . . . . . . . . 2 608 040 205
Extension bars . . . . . . . . . . . . . . 2 607 001 978
Insert plates . . . . . . . . . . . . . . . . 2 607 001 966
Saw blades for wood and plate materials, panels and strips/mouldings Saw blade 216 x 30 mm,
48 teeth . . . . . . . . . . . . . . . . . . . 2 608 640 641
Saw blades for hardwood and composite materials Saw blade 216 x 30 mm,
60 teeth . . . . . . . . . . . . . . . . . . . 2 608 640 446
Saw blades for plastic and non-ferrous metals Saw blade 216 x 30 mm,
80 teeth . . . . . . . . . . . . . . . . . . . 2 608 640 447
After-sales Service and Customer
Assistance
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
Our customer service representatives can answer your questions concerning possible applications and adjustment of products and accessories.

Great Britain
Robert Bosch Ltd. (B.S.C.)
P.O. Box 98
Broadwater Park
North Orbital Road
Denham
Uxbridge
UB 9 5HJ
Tel. Service: +44 (0844) 736 0109
Fax: +44 (0844) 736 0146
E-Mail: boschservicecentre@bosch.com

Ireland
Origo Ltd.
Unit 23 Magna Drive
Magna Business Park
City West
Dublin 24
Tel. Service: +353 (01) 4 66 67 00
Fax: +353 (01) 4 66 68 88

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: +61 (01300) 307 044
Fax: +61 (01300) 307 045
Inside New Zealand:
Phone: +64 (0800) 543 353
Fax: +64 (0800) 428 570
Outside AU and NZ:
Phone: +61 (03) 9541 5555
www.bosch.com.au
Republic of South Africa
Customer service
Hotline: +27 (011) 6 51 96 00
Gauteng – BSC Service Centre
35 Roper Street, New Centre
Johannesburg
Tel.: +27 (011) 4 93 93 75
Fax: +27 (011) 4 93 01 26
E-Mail: bsctools@icon.co.za

KZN – BSC Service Centre
Unit E, Almar Centre
143 Crompton Street
Pinetown
Tel.: +27 (031) 7 01 21 20
Fax: +27 (031) 7 01 24 46
E-Mail: bsc.dur@za.bosch.com
Western Cape – BSC Service Centre
Democracy Way, Prosperity Park
Milnerton
Tel.: +27 (021) 5 51 25 77
Fax: +27 (021) 5 51 32 23
E-Mail: bsc@zsd.co.za
Bosch Headquarters
Midrand, Gauteng
Tel.: +27 (011) 6 51 96 00
Fax: +27 (011) 6 51 98 80
E-Mail: rbsa-hq.pts@za.bosch.com

Disposal
The machine, accessories and packaging should be sorted for environmental- friendly recycling.
The plastic components are labelled for categorized recycling. Only for EC countries:
Do not dispose of power tools into household waste!
According the European Guideline 2002/96/EC for Waste Electrical and Electronic Equipment and its implementation into national right, power tools that are no longer usable must be collected separately and disposed of in an environmentally correct manner.
Subject to change without notice.

References

• Invented for life | Bosch Global
• Location selection | Bosch Power Tools
• Home | Bosch in Australia

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