BORMANN PRO BCS2010 Metal Saw User Manual

: June 4, 2024
: BORMANN

Table of Contents

BORMANN PRO BCS2010 Metal Saw
OVERVIEW
INSTRUCTIONS
General Safety Instructions
- Specific Safety Instructions
Description of Machine Components
- Dust extraction
Operating Instructions
Maintenance and Care
Handling and Storage
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BORMANN PRO BCS2010 Metal Saw

BORMANN-PRO-BCS2010-Metal-Saw

OVERVIEW

BORMANN-PRO-BCS2010-Metal-Saw-1

Technical Data

The manufacturer reserves the right to make minor changes to product design and technical specifications without prior notice unless these changes significantly affect the performance and safety of the products. The parts described / illustrated in the pages of the manual that you hold in your hands may also concern other models of the manufacturer’s product line with similar features and may not be included in the product you just acquired.
Please note that our equipment has not been designed for use in commercial, trade or industrial applica-tions. Our warranty will be voided if the machine is used in commercial, trade or industrial businesses or for equivalent purposes.
To ensure the safety and reliability of the product and the warranty validity, all repair, inspection, repair or replacement work, including maintenance and special adjustments, must only be carried out by technicians of the authorized service department of the manufacturer.
IMPORTANT NOTE: The following procedure applies for a D-Handle as well

INSTRUCTIONS

BORMANN-PRO-BCS2010-Metal-Saw-2 BORMANN-PRO-
BCS2010-Metal-Saw-3 BORMANN-PRO-BCS2010-Metal-
Saw-4

General Safety Instructions

WARNING ! READ THROUGH THE INSTRUCTIONS FOR USE BEFORE STARTING UP THE EQUIPMENT. Failure to follow all instructions listed below, may result in electric shock, fire and /or serious personal injury. Persons, who are not familiar with the instructions, may not operate the equipment. Keep the instructions for use in safe custody. Chil-dren and youths are not permitted to operate the equipment. BORMANN-PRO-BCS2010-Metal-
Saw-5

This machine is designed for cutting ferrous metals commensurate with the size of the machine. It is not designed for cutting other materials such as wood, stone, bricks, etc. Use only cutting discs that are suitable for use with this machine. Do not use CV, HSS or HM cutting discs or any other types of cutting discs. Everybody who operates or services this machine must be familiar with it and be informed of the possible dangers it poses. Do not make any modifications to the machine.
Even if it is used correctly for the purpose for which it is designed, the construction and type of the machine means that it will always pose a certain level of danger.

This includes the following risks:

Hearing damage if personnel fail to use approved ear protection
Danger of workpiece parts being catapulted out of the machine.
Danger of recoil by the workpiece of workpiece parts.
Harmful dust emissions from workpieces when the machine is used in enclosed areas.
Danger of accident caused by hand contact in the uncovered cutting area of the machine.
Crush injuries to fingers.
Danger of cutting disc fracture.
Danger by defective or broken cutting discs being catapulted out of the machine.

If it is not used for the purpose for which it is designed or if any modifications are made to the machine, the manufacturer cannot accept any liability. Also refer to the safety instructions, the installation and operating manual and also to the general accident prevention regulations.

Specific Safety Instructions

Important. When using electric tools, certain basic safety precautions must be taken to rule out any danger of injuries to personnel, electric shock and fire. All personnel who work on the tool must have read the safety instructions. Keep your workplace clean and well lit at all times to prevent accidents. Do not use the tool in wet or damp environments. Do not expose it to rain. Ensure that there is adequate ventilation in the place of use.

Do not use electric machines in the vicinity of inflammable liquids or gases or in wet or damp environments. If you fail to follow this instruction, there is a risk of fire or explosion. Do not leave the machine running without supervision.
Keep people away from your working area. Ensure that nobody, particularly children, do not touch either the cables or tools.
Do not use the machine if you are tired or lack concentration or your reactions are impaired due to the consumption of alcohol or medication. Inattentiveness can cause serious injuries.
Do not distract anybody working on the machine.
You may cause them to lose control of the tool. Ensure that you have a safe place to stand. Do not adopt an abnormal posture to ensure that you can keep your balance at all times.
Keep the tools clean and functional to enable you to work better and more safely with them. Refer to the instructions for servicing and for changing the tools for more details. Wear suitable work clothing.
Do not wear loose-fitting clothing or jewellery. Ensure that you have a safe place to stand and that you wear non-slip shoes. Wear a hairnet if you have long hair. Loose-fitting clothing, jewellery and long hair may become caught in moving parts. Always wear safety goggles.
Wear a breathing protection mask when working with materials that generate dust. Always wear ear protection as the levels of the produced noise are considered high. Do not use the machine if its ON/OFF switch is defective. An electric tool that cannot be switched on or off is dangerous and must be repaired. Do not touch earthed parts to protect yourself from electric shocks. Always switch on the machine before making contact with the material. Remove wrenches and setting tools before you switch on the machine.
Do not overload the machine. If the speed falls, reduce the load on the machine or switch it off. Using suitable electric tools you can work more safely and better within the specified capacity range. Secure the workpieces to prevent them turning with the machine, for example using a clamp or a vice. Do not secure the machine any workpieces that are too small to secure. If you hold the workpiece with your hand, you will not be able to operate the tool safely.
Never remove loose splinters, chips or jammed workpieces whilst the tool is operating. Keep electric tools out of the reach of children. Use only accessories that have been recommended by the manufacturer. The mains voltage must be identical with the details on the machine’s rating plate.
Never carry the machine by its cable. Only pull GB the cable out of the socket using the plug. Always protect the cable from oil, heat and sharp edges. Damaged cables can cause an electric shock. Before starting work, check the machine and the mains cable for signs of damage. Have any damage repaired only by trained personnel.
Before starting work, check that all the moving parts function correctly and are not jammed. Do not allow the tool to start accidentally. When you connect the mains plug, ensure that the main switch is not locked in its on position. Do not use tools if they have an ON/OFF switch that is not in perfect working order.
Outdoors, use only extension cables that have been specifically approved for this purpose. If you use a cable drum, extend the whole cable to prevent the cable from overheating. Replace damaged extension cables without delay.
For working outdoors the socket must be fitted with a residual current-operated circuit-breaker (RCCB). Pull the plug when the machine is not in use, you are changing the tool or are making adjustments.
Always keep your tool in a clean, dry, locked place out of the reach of children. The cable should always be guided to the rear away from the tool.
Important. Only use the metal cross-cut saw if it has been fully assembled and the guards are fitted correctly. Do not use the metal cross-cut saw if you are no familiar with how to use it. Have a qualified person show you how to handle the machine.

Always wear the following personal protection equipment when working with the metal cross-cut saw:

Safety goggles
Face protection
Ear protection
Breathing apparatus
Body aprons
Safety shoes
Long, tight-fitting sleeves Safety gloves

Use only approved, reinforced cutting discs that are suitable for speeds of over 3400 rpm and are marked as such. Before starting work, tighten all clamps and the shaft screw. Before starting work ensure that the shaft lock has been released. Never make any modifications to the safety equipment and ensure that it works correctly at all times. Never hold your hands in the vicinity of the rotating cutting disc. Never reach behind or next to the rotating cutting disc. Secure the workpieces carefully with the clamp. Ensure that the workpiece is clamped straight and securely. This will prevent the workpiece moving or becoming jammed at the end of the cutting work.
Do not machine any workpieces that are too small to secure. Wait until the cutting disc has reached a complete standstill before you attempt to remove the workpiece or secure a new workpiece. Disconnect the machine from the mains supply before starting and setting and servicing work. Before fitting a cutting disc, ensure that the disc and the flange are free of foreign bodies.
The recommended values for the thickness and the hole diameter must be observed for cutting discs that are fitted with flat flanges. When fitting a cutting disc the shaft screw must only be tightened so far that the disc is secure and cannot turn by itself. If you tighten the shaft screw to much, the cutting disc may jump off the disc flange or the disc may fracture.
After fitting a new cutting disc allow the machine to run for approximately one minute before starting any cutting work. Do not stand in the cutting direction of the machine during this process. If the disc has an invisible fracture or some other type of damage that it not obvious, it will rupture in less than one minute.
Check the cutting disc at regular intervals for signs of damage and possible cracks. Replace any such damaged or cracks cutting discs without delay. Use only cutting disc flanges that are suitable for use with this machine. Ensure that the cutting disc moves easily before you switch on the machine.
Allow the machine to accelerate to maximum speed before starting any cutting work. Always lower the cutting disc on to the workpiece slowly. Prevent the cutting disc from fluttering or jumping. This will result in poor cutting results, premature wear or even to the fracture of the cutting disc.
Keep the angle of the cutting disc to the workpiece as low as possible. Never cut without the cutting disc cover.
In the event that a mechanical part is missing from your machine, is damaged, does not function correctly or a component of the electrical system has an error or is damaged. Switch the machine off without delay, pull the plug and have the error repaired straight away.
You must comply with all the other general safety regulations and the relevant accident prevention regulations.

Description of Machine Components

D – Handle
ON/OFF switch
Carry handle
Carbon brush cover
Interlock
Cutting depth screw
Cutting depth nut
Angle guide
Vice
Base plate
Vice crank
Quick clamping lever
Cutting disc
Movable guard
Spindle lock

Before starting
Please note that the tool must be placed in a stable position on a workbench or on bolted to a solid sub-frame. Before starting the machine, check that all covers and safety equipment are correctly fitted. Ensure that the cutting disc moves easily. Before you switch on the tool, ensure that all the moving parts move easily and that the cutting disc is installed correctly. Before connecting the tool to the power supply, ensure that the data on the rating plate are identical to the mains data.
Assembly
Important. Disconnect the machine from the mains supply before starting any setting, assembly and servicing work.

Transport brace / carry-handle ( See Fig. I and Fig. II)

Push down the saw head by the handle (1) and pull out the interlock (5). (Fig.I)
Slowly raise the saw head.
Important! The resetting spring lifts the saw head automatically. Therefore, do not simply let go of the handle after cutting, but allow the saw head to rise slowly by applying slight counter-pressure.
Whenever you want to transport the machine you should use the interlock (5) to anchor the saw head again in its lower position.(Fig.II)
The saw is equipped with a carry-handle (3) to make it easier to transport.

Adjusting the stop screw (See. Fig. III)
The downward movement of the cutting disc can be adjusted with the cutting depth screw (6). This is necessary to compensate wheel wear – as the cutting disc becomes smaller in diameter it would no longer be able to cut right through the workpiece.

Release the cutting depth nut (7).
Turn the cutting depth screw (6) in or out as required.
Lower the saw head to check whether the cutting disc reaches the clamping face of the vise.
Re tighten the cutting depth nut (7).

Set the vice (See Fig. IV)
The mounting for the vice (9) can be enlarged by adjusting the angle guide (8).

Unscrew the two screws on the angle guide (8).
Adjust the angle guide (8) to the rear and secure it using the holes provided for it.
Ensure that the screw connections are tight again.

Clamp the workpiece in the vice. (See Fig. V)
Your workpiece must be secured very carefully in the vice (6) before you start the cutting process.

Move the quick clamping lever (12) to the left. This lever enables you to adjust the spindle (9) infinitely, in other words to turn it, pull it out or push it in.
Place your workpiece between the two clamping areas (8, 9).
Move the spindle right up against the workpiece.
Now move the quick clamping lever (12) to the right.
Now turn the rotate handle until the workpiece is securely fixed in the vice.

Completing mitre cuts (See Fig VII, Fig. VIII and Fig. IX)
The vice can be adjusted so that you can complete mitre cuts at angles of 45o – 0o – 45o.

Undo the two screws on the rear clamping area.
Adjust the clamping area to the angle you require.
Tighten the two screws again.

The front clamping area will automatically adjust to the angle you have set.

Change the cutting disc (See Fig. X)

Move the saw head to its highest position.
Move the front saw guard upwards. The entire cutting disc cover will open.
Move the flange cover down.
Push the shaft lock to the right.
Turn the cutting disc (13) until the shaft lock engages.
Unscrew the shaft screw by turning it anti-clock wise with a suitable socket wrench.
Remove the shaft screw, external flange and the washer.
Pull the worn cutting disc out forwards.
Before you fit the new cutting disc, carefully clean the external flange, the washer and the shaft screw.
Fit the new cutting disc. Note the direction of rotation as you do so.
Refit the washer and then the external flange.
Screw in the shaft screw again.
Important. When fitting a cutting disc the shaft screw must only be tightened so far that the disc is secure and cannot turn by itself. If you tighten the shaft screw to much, the cutting disc may jump off the disc flange or the disc may fracture.
Push the flange cover back again.
Push the front cutting disc cover downwards again.
The entire cutting disc cover will close.

Important: After fitting a new cutting disc allow the machine to run for approximately one minute before starting any cutting work. Do not stand in the cutting direction of the machine 7 during this process. If the disc has an invisible fracture or some other type of damage that it not obvious, it will rupture in less than
one minute.

Dust extraction

IMPORTANT:

Important. Not every dust extractor is suitable for metal chips since they may be very hot and in certain circumstances can cause a fire
Not every dust extractor is suitable for metal chips since they may be very hot and in certain circumstances can cause a fire.

Operating Instructions

The metal cross-cut saw can be started by pressing the ON/OFF switch.The metal cross-cut saw will be switched off again when ON/OFF switch is released.
Working with the metal cross-cut saw – First secure your workpiece in the vice.
- Switch on the machine and wait until the motor has reached its maximum speed.
- Slowly press the saw head on the handle (1). – Guide the cutting disc through the workpiece with even, firm pressure.
- Prevent the cutting disc from fluttering or jumping. This will result in poor cutting results, premature wear or even to the fracture of the cutting disc.
- Do not reduce the cutting speed even at the end of the cutting process since the workpiece may otherwise becoming unnecessarily overheated which may well result in unnecessary burr formation.
Cutting speed
Slow cuts : Less wear on the cutting disc GB (depending on the quality of the cutting disc);the workpiece may tend to form burr and become discoloured due to overheating. Fast cuts: High wear on the cutting disc (depending on the quality of the cutting disc); less burr formation and less discolouration on the workpiece since it does not become so hot.

Maintenance and Care

Pull the plug before starting any maintenance work on the machine.

Use a damp cloth and a small brush to clean the plastic parts. Do not use cleaning products, solvents or sharp objects.
Clear the ventilation openings and moving parts from deposits of dust at regular intervals using a soft brush or paintbrush.
Only use accessories and spare parts recommended by the manufacturer. If the equipment should fail some day in spite of our quality controls and your maintenance, only have it repaired by an authorised electrician.

Handling and Storage

Care must be taken when handling this product. Dropping this power tool could have an effect on its accuracy and could also result in personal injury. This product is not a toy and must be respected. Environmental conditions can have a detrimental effect on this product if neglected. Exposure to damp air can gradually corrode components. If the product is unprotected from dust and debris, components will become clogged. If not cleaned and maintained correctly or regularly the machine will not perform at its best.

Environmental Protection & Disposal
At the end of the tool’s working life or when it can no longer be repaired, ensure that it is disposed of according to national regulations. Contact your local authority for details of collection schemes in your area. In all circumstances: