BOSCH TG503 Tuck Point Grinder Guard Instruction Manual

BOSCH TG503 Tuck Point Grinder Guard

Product Specifications

• Model: TG503
• Manufacturer: Bosch
• Contact: 1-877-BOSCH99 (1-877-267-2499)
• Website: www.boschtools.com

Product Usage Instructions

Safety Symbols

The safety symbols in this manual indicate the level of severity for each signal word. It is crucial to read the manual and pay attention to these symbols.

• DANGER: Indicates a hazardous situation that will result in death or serious injury if not avoided.
• WARNING: Indicates a hazardous situation that could result in death or serious injury if not avoided.
• CAUTION: Indicates a hazardous situation that could result in minor or moderate injury if not avoided.

General Power Tool Safety Warnings

It is essential to follow these safety warnings to prevent electric shock, fire, or serious injury:

1. Work Area Safety:
   • Keep the work area clean and well-lit to avoid accidents.
   • Avoid operating power tools in explosive atmospheres.
   • Keep children and bystanders away during operations to maintain control.
2. Electrical Safety:
   • Ensure power tool plugs match the outlet and never modify them.
   • Avoid body contact with earthed surfaces to reduce the risk of electric shock.

Frequently Asked Questions (FAQ)

Q: How do I install the Tuckpointing Guard?

• A: To install the Tuckpointing Guard, follow the instructions provided in the manual on page 14. Make sure to securely attach the guard for safe operation.

Q: What is the purpose of the Adjustable Depth Stop?

• A: The Adjustable Depth Stop allows you to set the desired depth for your cutting or grinding applications, providing precision and control during use.

Q: How do I maintain the Diamond Wheels?

• A: Regularly clean the Diamond Wheels after use to remove debris and prevent build-up. Refer to the maintenance section on page 22 for detailed instructions on wheel care.

Safety Symbols

General Power Tool Safety Warnings

• 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 mains-operated (corded) power tool or battery-operated (cordless) power tool.

1. Work area safety
   • a. Keep the 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 that 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 the 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 the cord away from heat, oil, sharp edges or 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. The 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 Ground Fault Circuit Interrupter (GFCI) protected supply. The use of a GFCI 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 a dust mask, non-skid safety shoes, hard hats, 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 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.
   • 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 jewelry. Keep your hair and clothing away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts.
   • g. If devices are provided for the connec-tion of dust extraction and collection facilities, ensure these are connected and properly used. The use of dust collection can reduce dust-related hazards.
   • h. 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.
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 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 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.
   • 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 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.
   • 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, tool bits, etc. under these instruc-tions, 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.
   • h. 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.
5. Battery tool use and care (cordless only)
   • a. Recharge only with the charger specified by the manufacturer. A charger that is suitable for one type of BATTERY pack may create a risk of fire when used with another BATTERY pack.
   • b. Use power tools only with specifically designated BATTERY packs. Use of any other BATTERY packs may create a risk of injury and fire.
   • c. When the BATTERY pack is not in use, keep it away from other metal objects, like paper clips, coins, keys, nails, screws, or other small metal objects, that can make a connection from one terminal to another. Shorting the BATTERY terminals together may cause burns or a fire.
   • d. Under abusive conditions, liquid may be ejected from the BATTERY; avoid contact. If contact accidentally occurs, flush with water. If liquid contacts the eyes, additionally seek medical help. Liquid ejected from the BATTERY may cause irritation or burns.
   • e. Do not use a BATTERY pack or tool that is damaged or modified. Damaged or modified batteries may exhibit unpredictable behavior resulting in fire, EXPLOSION, or risk of injury.
   • f. Do not expose a BATTERY pack or tool to fire or excessive temperature. Exposure to fire or temperature above 265 °F / 130 °C may cause an explosion.
   • g. Follow all charging instructions and do not charge the BATTERY pack or tool outside the temperature range specified in the instructions. Charging improperly or at temperatures outside the specified range may damage the BATTERY and increase the risk of fire.
6. 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.
   • b. Never service damaged BATTERY packs. Service of BATTERY packs should only be performed by the manufacturer or authorized service providers. (cordless only)

Cut-Off Machine Safety Warnings

1. Safety warnings common for grinding or cutting-off operations

   • a. This power tool is intended to function as a cut-off tool. Read all safety warnings, in-structions, 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.
   • b. Operations such as grinding, sanding, wire brushing, polishing, or hole cutting are not to be performed with this power tool. Operations for which the power tool was not designed may create a hazard and cause personal injury.
   • c. Do not convert this power tool to operate in a way that is not specifically designed and specified by the tool manufacturer. Such a conversion may result in a loss of control and cause serious personal injury.
   • d. Do not use accessories that are not specifically designed and specified by the tool manufacturer. Just because the accessory can be attached to your power tool, it does not assure safe operation.
   • e. The rated speed of the accessory must be at least equal to the maximum speed marked on the power tool. Accessories running faster than their rated speed can break and fly apart.
   • f. The outside diameter and the thickness of your accessory must be within the capacity rating of your power tool. Incorrectly sized accessories cannot be adequately guarded or controlled.
   • g. The dimensions of the accessory mounting must fit the dimensions of the mounting hardware of the power tool. Accessories that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively, and may cause a loss of control.
   • h. Do not use a damaged accessory. Before each use inspect the accessories such as abrasive wheels for chips and cracks, a backing pad for cracks, tear, or excess wear, and a wire brush for loose or cracked wires. If a power tool or accessory is dropped, inspect for damage or install an undamaged accessory. After inspecting and installing an accessory, position yourself and bystanders away from the plane of the rotating accessory and run the power tool at maximum no-load speed for one minute. Damaged accessories will normally break apart during this test time.
   • i. Wear personal protective equipment. Depending on the application, use a face shield, safety goggles, or safety glasses. As appropriate, wear a dust mask, hearing protectors, gloves, and a workshop apron capable of stopping small abrasive or workpiece fragments. The eye protection must be capable of stopping flying debris generated by various applications. The dust mask or respirator must be capable of filtrating particles generated by the particular applica-tion. Prolonged exposure to high-intensity noise may cause hearing loss.
   • j. Keep bystanders a safe distance away from the work area. Anyone entering the work area must wear personal protective equipment. Fragments of workpieces or a broken accessory may fly away and cause injury beyond the immediate area of operation.
   • k. Hold the power tool by insulated gripping surfaces only, when performing an operation where the cutting accessory may contact hidden wiring or its 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. (corded only)
   • l. Hold the power tool by insulated gripping surfaces only, when performing an operation where the cutting accessory may contact hidden wiring.
   • Contact with a “live” wire will also make exposed metal parts of the power tool “live” and could give the operator an electric shock. (cord-less only)
   • m. Position the cord clear of the spinning accessory. If you lose control, the cord may be cut or snagged and your hand or arm may be pulled into the spinning accessory.
   • n. Never lay the power tool down until the accessory has come to a complete stop. The spinning accessory may grab the surface and pull the power tool out of your control.
   • o. Do not run the power tool while carrying it at your side. Accidental contact with the spinning accessory could snag your clothing, pulling the accessory into your body.
   • p. Regularly clean the power tool’s air vents. The motor’s fan will draw dust inside the housing and excessive accumulation of powdered metal may cause electrical hazards.
   • q. Do not operate the power tool near flammable materials. Sparks could ignite these materials.
   • r. Do not use accessories that require liquid coolants. Using water or other liquid coolants may result in electrocution or shock.

2. Kickback and related warnings

   • Kickback is a sudden reaction to a pinched or snagged rotating wheel, backing pad, brush, or any other accessory.

   • Pinching or snagging causes rapid stalling of the rotating accessory which in turn causes the uncontrolled power tool to be forced in the direction opposite of the accessory’s rotation at the point of the binding.

   • For example, if an abrasive wheel is snagged or pinched by the workpiece, the edge of the wheel that is entering into the pinch point can dig into the surface of the material causing the wheel to climb out or kick out.

   • The wheel may either jump toward or away from the operator, depending on the direction of the wheel’s movement at the point of pinching. Abrasive wheels may also break under these conditions.
     Kickback is the result of power tool misuse and/or incorrect operating procedures or con-ditions and can be avoided by taking proper precautions as given below.

   • a. Maintain a firm grip with both hands on the power tool and position your body and arms to allow you to resist kickback forces. Always use an auxiliary handle, if provided, for maximum control over kickback or torque reaction during start-up.

   • The operator can control torque reactions or kickback forces if proper precautions are taken.

   • b. Never place your hand near the rotating accessory. The accessory may kick back over your hand.

   • c. Do not position your body in the area where the power tool will move if kickback occurs. Kickback will propel the tool in a direction opposite to the wheel’s movement at the point of snagging.

   • d. Use special care when working corners, sharp edges, etc. Avoid bouncing and snagging the accessory. Corners, sharp edges, or bouncing tend to snag the rotating accessory and cause loss of control or kickback.

   • e. Do not attach a saw chain woodcarving blade, a segmented diamond wheel with

   • a peripheral gap greater than 10 mm (13/32”), or a toothed saw blade. Such blades create frequent kickbacks and loss of control.

3. Safety warnings specific for grinding and cutting-off operations

   • a. Use only wheel types that are specified for your power tool and the specific guard designed for the selected wheel. Wheels for which the power tool was not designed cannot be adequately guarded and are unsafe.
   • b. The grinding surface of center depressed wheels must be mounted below the plane of the guard lip. An improperly mounted wheel that projects through the plane of the guard lip cannot be adequately protected.
   • c. The guard must be securely attached to the power tool and positioned for maximum safety, so the least amount of wheel is exposed towards the operator. The guard helps to protect the operator from broken wheel fragments, accidental contact with the wheel and sparks that could ignite clothing.
   • d. Wheels must be used only for specified applications. For example: do not grind with the side of the cut-off wheel. Abrasive cut-off wheels are intended for peripheral grinding, side forces applied to these wheels may cause them to shatter.
   • e. Always use undamaged wheel flanges that are of the correct size and shape for your selected wheel. Proper wheel flanges support the wheel thus reducing the possibility of wheel breakage. Flanges for cut-off wheels may be different from grinding wheel flanges.
   • f. Do not use worn-down wheels from larger power tools. A wheel intended for a larger power tool is not suitable for the higher speed of a smaller tool and may burst.
   • g. When using dual-purpose wheels always use the correct guard for the application being performed. Failure to use the correct guard may not provide the desired level of guarding, which could lead to serious injury.

4. Additional safety warnings specific for cutting-off operations

   • a. Do not “jam” the cut-off wheel or apply excessive pressure. Do not attempt to make an excessive depth of cut.
   • Over-stressing the wheel increases the loading and susceptibility to twisting or binding of the wheel in the cut and the possibility of kickback or wheel breakage.
   • b. Do not position your body in line with and behind the rotating wheel. When the wheel, at the point of operation, is moving away from your body, the possible kickback may propel the spinning wheel and the power tool directly at you.
   • c. When the wheel is binding or when interrupting a cut for any reason, switch off the power tool and hold it motionless until the wheel comes to a complete stop. Never attempt to remove the cutoff wheel from the cut while the wheel is in motion otherwise kickback may occur. Investigate and take corrective action to eliminate the cause of wheel binding.
   • d. Do not restart the cutting operation in the workpiece. Let the wheel reach full speed and carefully re-enter the cut. The wheel may bind, walk up, or kick back if the power tool is restarted in the workpiece.
   • e. Support panels or any oversized workpiece to minimize the risk of wheel pinching and kickback. Large workpieces tend to sag under their weight. Supports must be placed under the workpiece near the line of cut and the edge of the workpiece on both sides of the wheel.
   • f. Use extra caution when making a “pocket cut” into existing walls or other blind areas. The protruding wheel may cut gas or water pipes, electrical wiring, or objects that can cause kickback.
   • g. Do not attempt to do curved cutting. Over-stressing the wheel increases the loading and susceptibility to twisting or binding of the wheel in the cut and the possibility of kickback or wheel breakage, which can lead to serious injury.

Additional Safety Warnings

• GFCI and personal protection devices like electrician’s rubber gloves and footwear will further enhance your safety.
• Do not use AC-only rated tools with a DC power supply. While the tool may appear to work, the electrical components of the AC-rated tool are likely to fail and create a hazard to the operator.
• Keep handles dry, clean, and free from oil and grease. Slippery hands cannot safely control the power tool.
• Develop a periodic maintenance schedule for your tool. When cleaning a tool be careful not to disassemble any portion of the tool since internal wires may be misplaced or pinched or safety guard return springs may be improperly mounted.
• Certain cleaning agents such as gasoline, carbon tetrachloride, ammonia, etc. may damage plastic parts.
• Wear hearing protection. Prolonged exposure to high-intensity noise can cause hearing loss.
• Use thick cushioned gloves and limit the exposure time by taking frequent rest periods. Vibration caused by the use of power tools may be harmful to your hands and arms.
• This tool must be used with Respiratory Protection sufficient to block clouds of dust including silica from concrete cutting. N-95-rated masks minimum or full respirator protection for the operator and others in the work area.
• Dust collection is required with a vacuum or other suitable dust collection system for concrete/masonry applications.
• Do not use a vacuum or other dust collection system when cutting metal. Sparks from metal cutting can cause a fire in the collector.
• Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to cause cancer, birth defects, or other reproductive harm.

Some examples of these chemicals are:

• Lead from lead-based paints,
• Crystalline silica from bricks and cement and other masonry products, and
• Arsenic and chromium from chemically treated lumber.
• Your risk from these exposures varies, depending on how often you do this type of work.
• To reduce your exposure to these chemicals : work in a well-ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

Intended Use

• Use this tuckpointing guard with a Bosch 4-1/2 inch, 5-inch, or 6-inch small angle grinder only as intended. Unintended use may result in personal injury and property damage.
• This tuckpointing guard and respective small angle grinder are intended for use in cutting mortar or masonry-type materials.
• The guard includes a dust port which allows it to be connected to a vacuum hose which can be connected to an appropriate dust extractor vacuum.
• (See OSHA Silica Regulation concerning vacuum, CFM, and filter requirements for tuckpointing applications/mortar removal.)
• The TG503 tuckpointing guard is designed for use with two types of Bosch small angle grinders, the type having a threaded spindle (model GWS) and the X-LOCK (model GWX).
• This guard is intended for use with Type 1A/41 diamond wheels, or specially designed sandwiched diamond wheels, available with X-LOCK or 7/8” arbor, for mounting on the two types of Bosch angle grinders.

Symbols

Important: Some of the following symbols may be used on your tool. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to operate the tool better and safely.

Important: Some of the following symbols may be used on your tool. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to operate the tool better and safely.

Functional Description

• Disconnect the plug from the power source before making any assembly, adjustments, or changing accessories.
• Such preventive safety measures reduce the risk of starting the tool accidentally.
• TG503 Tuckpointing Guard  (Compatible with GWS Spindle Grinders and GWX X-Lock Grinders)

1. Spindle Grinder
2. Slide Switch
3. Spindle Lock
4. Dust Port
5. Adjustable Depth Stop Button
6. Depth Scale
7. Depth Adjust Lock Knob
8. Guard Cover Knob
9. Stability Bracket
10. Auxiliary Handle
11. Ventilation Openings
12. X-Lock Grinder
13. TG503 Tuckpoint Guard
14. Wheel
15. Wheel’s X-Lock Mounting Hub
16. Wheel’s X-Lock Alignment Contours
17. X-Lock Accessory Mount
18. Viewing Window
19. Threaded Spindle Accessory Mount
20. Guide Plate

Specifications

NOTE: For tool specifications refer to the nameplate on your tool.

Assembly

• Disconnect the plug from the power source before making any assembly, adjustments or changing accessories. Such preventive safety measures reduce the risk of starting the tool accidentally.
• Disconnect the battery pack from the tool before making any assembly, adjustments or changing accessories. Such preventive safety measures reduce the risk of starting the tool accidentally.

Tuckpointing Guard Assembly (Fig. 2, Fig. 3, Fig. 4)

• The type 27 grinding wheel guard must be removed. Retain Type 27 guard for future use. Always reinstall the Type 27 wheel guard when converting back to grinding operations.
• The TG503 Tuckpointing Guard is for both GWS threaded spindle grinders and GWX X-Lock grinders.
• To improve the ergonomics of your grinder when cutting masonry, the gearbox must be rotated relative to the position of the switch as the tool was assembled at the factory.

Rotate gearbox:

1. Unplug the tool from the power source.
2. Completely unscrew the four screws between the Gear Housing 21 and Motor Body 22.
   • NOTE: Retain the Guard Release Lever 23 with the Spring 24 for reassembling gear housing in step 4.
3. Rotate the Gear Housing 21 to the proper orientation without removing the motor from the housing.
   • For a grinder with a Slide Switch 2, rotate the Gear Housing 21 180 degrees in the direction indicated in Fig. 3, so the Slide Switch 2 is 90 degrees from the spindle.
   • For a grinder with a Paddle Switch 27, rotate the Gear Housing 21 90 degrees in the direction indicated in Fig. 4, so the Paddle Switch 27 is facing the workpiece.
4. Screw in and tighten the three short screws you removed.
5. The screw holding the Guard Release Lever 23 is longer than the other screws. This long screw must stay with the Guard Release Lever 23 when re-attaching the Gear Housing 21 for the Guard Release Lever 23 to operate properly.
6. Attach a proper dust collection guard with a foot and wheel.

Installing Tuckpointing Guard (Fig. 5, Fig. 6)

To Attach Guard

1. Unplug the tool from the power source.
2. Position the Guard 13 on the spindle neck so that the Arrow on the Guard 25 and the Arrow on the Spindle Neck 26 align.
3. Slide the Guard 13 on the spindle neck, and rotate the Guard 13 until the Stability Bracket and the hole for the auxiliary handle are aligned.
4. Screw in the auxiliary handle to secure the Guard 13 on the tool.
5. Always position Wheel Guard 13 between the operator and the workpiece and direct sparks away from the operator.

To Remove the Wheel Guard

1. Unscrew the auxiliary handle.
2. Rotate the Guard 13 until the Arrow on the Guard 25 and the Arrow on the Spindle Neck 26 are aligned.
3. Remove the Guard 13 from the spindle neck.

Reverting to Grinding Applications (Fig. 2)

Return the Gear Housing 21 to its original position and replace the Type 27 grinding guard. See the manual for the grinder for details.

Installing and Removing Wheels on a Spindle Grinder (Fig. 7, Fig. 8, Fig. 9 )

• The backing flange and lock nut that is provided with the tuckpointing guard MUST be used together with the tuckpointing guard.
• Retain original flang-es for grinding use.

1. Loosen and remove the Guard Cover Knob 8 (Fig. 7).
2. Push the Raised Portion of the Guard Cover 28 near the Locking Clip 29 (Fig.7) in the direction of the arrow to unlock the Guard Cover 30, and swing the Guard Cover 30 out of the way (Fig. 9).
3. Place the Backing Flange 31 (provided together with the guard) on the Spindle 32 (Fig. 8). Turn the Backing Flange 31 until it is securely in place at the base of the Spindle 32.
4. Place the Wheel 14 onto the Spindle 32 and align the Arbor Hole of the Wheel 33 with the shoulder of the Lock Nut 34 (provided together with the guard).
5. Tighten the Lock Nut 34 with the supplied lock nut wrench while holding the Spindle Lock 3.
6. Return the Guard Cover 30 to its original position and push into the Locking Clip 29 to secure the Guard Cover 30 in place (Fig. 7).
7. Replace the Guard Cover Knob 8 and securely tighten the Knob 8 (Fig. 7).
8. To remove reverse procedure.

Basic X-Lock Operation (Fig. 10, Fig. 11)

• The X-Lock system is a combination of patented tool mount and Wheel 14 designs that provide the operator with fast Wheel 14 changes.
• Available on select Bosch angle grinders, X-Lock allows tool-free installation and removal of grind-er Wheels 14 (grinding, cut-off wheels, wire brushes, sanding discs, etc.).
• The X-Lock sys-tem is a replacement for the traditional method of attaching grinder Wheels 14.
• Traditional grinders have 5/8”-11 threaded spindles that require a nut and backing flange to hold the Wheel 14 in place.
• To replace a Wheel 14, a wrench is used to loosen or tighten the nut. X-Lock-equipped grinders have a tool-free interface system, eliminating the spindle, backing flange, and lock nut.
• The X-Lock interface has a tool component – X-Lock Wheel Mount 17, and a Wheel 14 component – typically a Wheel X-Lock Mounting Hub 15.
• The two components have keyed Alignment Contours 16, which help to ensure the correct as-sembly of the wheel to the tool.
• The X-Lock Wheel Mount 17 on the tool consists of a round Base 37, Clamping Height Gages 35, and a locking mechanism, which activates the Clamping Tabs 36. X-Lock-equipped grinders can only use X-Lock Wheels 14 since the specially designed X-Lock Mounting Hub on Wheels 15 matches the contours of the X-Lock Wheel Mount 17 on the tool. (See Fig. 10.) However, select X-Lock Wheel 14 is backward compatible with the traditional threaded spindle design.
• Attachment of the X-Lock Wheel 14 to the X-Lock Wheel Mount 17 on the grinder requires alignment of the Wheel’s X-Lock Mounting Hub 15 with the X-Lock Wheel Mount 17 on the tool. Once the Wheel’s X-Lock Mounting Hub 15 is aligned and pressed against the base of the X-Lock Wheel Mount 17, the locking mechanism is activated. This causes the two opposing Clamping Tabs 36 to lock Wheel 14 to the grinder. An audible ‘click’ in combination with the alignment of the flat surface of the Wheel’s X-Lock Mounting Hub 15 with the Clamping Height Gauges 35 means the Wheel 14 is firmly attached to the tool. To remove Wheel 14, the X-Lock Release Lever 38 on the grinder gearhead is actuated which will release the Clamping Tabs 36, allowing Wheel 14 to be detached from the tool (Fig. 11). To activate the X-Lock Release Lever 38, push down while simultaneously pulling up (Fig. 11).

Mounting and Removing X-Lock Wheels (Fig. 10, Fig. 12, Fig. 13, Fig. 15)

• Only use Bosch or Bosch-licensed X-LOCK accessories. Incompatible accessories may not clamp properly resulting in personal injury and/or property damage.
  Confirm proper clamping by ensuring that the top of the accessories’ X-Lock mounting hub surface is not above the top of the clamping height gauge. Accessories that are above the clamping height gauge may not be fixed properly and separate from the tool causing personal injury and/or property damage.

• Always inspect the accessory mount and accessory clamping flange before use. Do not use the tool or accessory if the accessory mount or accessory is damaged or deformed. Accessories that are not clamped properly may cause personal injury and/or property damage.

• Check for the presence or buildup of foreign material on clamping surfaces and remove it before use. Unwanted material can cause incomplete clamping and may cause personal injury and/or property damage.

• Never actuate the X-Lock Release Lever while the accessory is moving. Make sure that the accessory has come to a complete stop before removing the accessory. Releasing an accessory while still spinning could cause personal injury and/or property damage.

• Do not use a damaged accessory. Before each use inspect the accessory such as abrasive wheels for chips and cracks, a backing pad for cracks, tear, or excess wear, and a wire brush for loose or cracked wires. If a power tool or accessory is dropped, inspect for damage or install an undamaged accessory. After inspecting and installing an accessory, position yourself and bystanders away from the plane of the rotating accessory and run the power tool at maximum no-load speed for one minute. The damaged accessory will normally break apart during this test time.

• Verify that the Wheel 14 and the X-Lock Wheel Mount 17 on the tool are not deformed and are free from dirt. If necessary, clean the area around the two X-Lock Clamping Tabs 36.
  Verify that both Clamping Tabs 36 are open (Fig. 10) before fitting the X-Lock Wheel 14 (Fig. 13).

Mounting an X-Lock Wheel to the Tool (Fig. 12, Fig. 13, Fig. 14, Fig. 15, Fig. 16)

1. Loosen and remove the Guard Cover Knob 8 (Fig. 12).

2. Push the Raised Portion of the Guard Cover 28 near the Locking Clip 29 in the direction of the arrow to unlock the Guard Cover 30, and swing the Cover 30 out of the way (Fig. 12) .

3. Place the Wheel 14 on the X-Lock Wheel Mount 17. Align the Alignment Contours 16 on the Wheel’s X-Lock Mounting Hub 15 with the Contours 16 on the X-Lock Wheel Mount 17 on the grinder (Fig. 13).

4. Push the Wheel 14 into the X-Lock Wheel Mount 17. The Wheel 14 audibly clicks as the Clamping Tabs 36 lock into place (Fig. 14).

5. Check that the edge of the Wheel’s X-Lock Mounting Hub 15 is correctly engaged in the slots of the X-Lock Clamping Tabs 36 (Fig. 13, Fig. 14). If the top surface of the Wheel’s X-Lock Mounting Hub 15 is higher than the Clamping Height Gauges 35
   (located on each side of the X-Lock Wheel Mount 17), the X-Lock Wheel 14 must not be used until this condition is eliminated by cleaning the X-Lock Wheel Mount 17 or replacing the Wheel 14 (Fig. 13, Fig. 14, Fig. 15).

6. Return the Guard Cover 30 to its original position, and push it into the Locking Clip 29 to secure the Guard Cover 30 in place (Fig. 16).

7. Replace the Guard Cover Knob 8 and securely tighten the Knob 8 (Fig. 16).

Removing an X-Lock Wheel (Fig. 17, Fig. 18, Fig. 19, Fig. 20)

• Never actuate the X-Lock
• Release the Lever while the accessory is moving. Make sure that the accessory has come to a complete stop before removing the wheel.
• Releasing an accessory while still spinning could cause personal injury and/or property damage.
• Do not touch grinding and cutting discs until they have cooled down. The discs can become very hot while working.
• Do not allow accessories to fall uncontrollably after release. Falling accessories can become damaged and may cause personal injury and/or property damage.
• Before removing the accessory, make sure that the power tool has come to a complete stop and is disconnected from power.

Operating Instructions

• Hold the tool with both hands while starting the tool, since torque from the motor can cause the tool to twist.
• Start the tool before applying it to work and let the tool come to full speed before contacting the workpiece.
• Lift the tool from the work before releasing the switch. DO NOT turn the switch “ON” and “OFF” while the tool is under load; this will greatly decrease the switch life.

Adjustable Depth Stop (Fig. 1)

Your tool is equipped with an adjustable stop. Your cutting depth can be pre- set and/or repeated by using the depth stop (Fig. 1).

1.  Loosen the depth-stop lock knob.
2. Depress the adjustable depth stop button, move to the desired position on the depth bracket, and release the button to secure the stop in place.
3. Place your foot against the workpiece, and push down on the tool until it stops.
4. To secure and hold foot and guard assembly at the desired depth of cut. Move the foot to the desired depth of cut and securely tighten the depth stop lock knob.

Tuckpointing Guard (Fig. 1)

• The tuckpointing guard must be attached when using Type  41/1A Diamond wheels. Always keep a guard between you and your work while grinding.
• Position the guard such that the Dust Port 4 does not interfere with the On/Off switch.
• To adjust the guard, loosen the clamp screw and rotate the guard to the desired position, and securely tighten the screw.
• Always keep the wheel guard between you and your work when during operation.

Dust Extraction (Fig. 1)

• This tool must only be used with a dust extraction system. Always wear approved respiratory protection.
• Your tool is equipped with a Dust Port 4 for dust extraction. To use this feature, insert a vacuum hose (optional accessory) into the Dust Port 4 and connect the opposite end of the hose to a shop vacuum cleaner.
• For non-Bosch vacuum hoses, an adapter is required. Place adapter in Dust Port 4.
• Always make sure the vacuum cleaner that you use is designed for the extraction of masonry dust.

Auxiliary Handle

• The auxiliary handle, used to guide and balance the tool must be secured to the side of the tool not facing the wall.
• Always use the auxiliary handle for maximum control and ease of opera-tion.

Tuckpointing

• This tool is intended to be used as a tuckpoint-er. It is used to remove deteriorating mortar joints so that they can be replaced with new mortar.
• For best tuckpointing results use tuckpoint de-signed sandwich diamond wheels.
• Use the adjustable depth stop to obtain the desired depth of mortar removal. The tuckpointing is held with the guard window facing upward so that the user can easily see the joint during operation.
• Allow the tool to reach full speed before applying it to the workpiece surface.
• Hold the tool with both hands and apply the abrasive wheel to the mortar surface.
• If this tuck pointer is being used as a small abrasive cutoff machine, the tool is only approved for cutting or scoring masonry products like concrete, cinder blocks, bricks, and stone.

Diamond Wheels

• Do not use water when cutting with this tool. The tool is not designed for water and electric shock may occur.
• When a Tuckpointing Guard is used with a threaded spindle grinder (Bosch GWS series), use only with a Type 41/1A or sandwich design diamond wheel with a 7/8 in. arbor.
• When the TG503 Tuckpointing Guard is used on a grinder with a threaded spindle (Bosch GWS series) and with a Type 1A/41 or a sandwiched diamond wheel having a 7/8 in. arbor, then, to mount the wheel, use only the special flange and lock nut supplied with the TG503 Guard.
• When a TG503 Tuckpointing Guard is used with an X-Lock grinder (Bosch GWX series), use only with X-Lock arbor sandwich-design diamond wheels.
• Dry diamond wheels stay cooler, clog less, and last longer.

1. Before running a cut-off machine, inspect the cutting wheel for chips or cracks. Replace bad wheels immediately. New wheels should be run in at no load for at least a minute in the direction away from the presence of other people. Imperfect wheels will normally break apart during this time.
2. An abrasive cut-off machine must NEVER be operated without the attached guard securely in place. The guard should be rotated into the position where maximum protection is provided for the operator from sparks and wheel periphery.
3. Proper apparel for operating the tool includes eye protection, leather gloves, and a dust mask.
4. With the tool in the “OFF” position, become familiar with handling the tool. Control the head of the tool with the side handle. Control the cutting edge of the wheel with the switch handle. Always use both hands when operating the tool.
5. Never drop the tool. set the tool down gently, but never on the wheel.
6. CUTTING CONCRETE will throw large amounts of dust into the surrounding area. Protective dust masks are required for breathing protection for the operator and other nearby workers.
7. It is not recommended to use this tool overhead or in any position that would not allow proper control. Ladders are not considered solid support structures.
8. Avoid overloading tools. Do not allow the wheel to bind or stall. Many cuts, especially into solid concrete, require successive passes. Do not expose any more abrasive wheel than necessary to cut with a normal amount of pressure applied to the tool. Begin cutting from the edge of the material, only plunging to a depth of one diamond wheel segment. Cutting too deeply at one time does not allow dust to clear fully and erodes /thins the body of the wheel. Do not force the tool; load it normally. Depending on material hardness and density, make successively deeper passes until the cut is complete.

Maintenance

Service

• NO USER-SERVICEABLE PARTS INSIDE. Preventive maintenance performed by unauthorized personnel may result in the misplacing of internal wires and components which could cause serious hazards.
• We recommend that all tool service be performed by a Bosch Factory Service Center or Authorized Bosch Service Station.
• SERVICE MEN: Disconnect the tool and/or charger from the power source before servicing.

Tool Lubrication

• Your Bosch tool has been properly lubricated and is ready for use.

Cleaning

• To avoid accidents, always disconnect the tool and/or charger from the power supply before cleaning. The tool may be cleaned most effectively with compressed dry air. Always wear safety goggles when cleaning tools with compressed air.
• Certain cleaning agents and solvents damage plastic parts. Some of these are gasoline, carbon tetrachloride, chlorinated cleaning solvents, ammonia, and household detergents that contain ammonia.
• Ventilation openings and switch levers must be kept clean and free of foreign matter. Do not attempt to clean by inserting pointed objects through the opening.

Accessories

Do not use attachments/accessories other than those specified by Bosch. Use of attachments/accessories not specified for use with the tool described in this manual may result in damage to the tool, property damage, and or personal injury.

Tuckpoint Guard TG502/TG503 flange nuts (backing/locking, for use with threaded spindle grinders. ie. Bosch GWS… series)| Grinder (sold separately) Tuckpoint Sandwich Blade – 7/8 in. arbor Tuckpoint Sandwich Blade – X-Lock Arbor GWS (spindle) Grinder: recommended 10A or higher GWX (X-Lock) Grinder: recommended 10A or higher

LIMITED WARRANTY

• For details on the terms of the limited warranty for this product, go to https://rb-pt.io/PowerToolWarranty or call 1-877-BOSCH99.
• © Robert Bosch Tool Corporation 1800 W. Central Road
• Mt. Prospect, IL 60056-2230
• 1600A02UP3 06/2023
• 1-877-BOSCH99 (1-877-267-2499) www.boschtools.com

References

• Bosch Power Tools | Boschtools
• Product Warranty | Boschtools

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