BOSCH 0601B19200 GCM 8 SDE Professional Sliding Mitre Saw Instruction Manual

BOSCH 0601B19200 GCM 8 SDE Professional Sliding Mitre Saw

Safety Notes

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. When using electric tools basic safety precautions should always be followed to reduce the risk of fire, electric shock and personal injury including the following.
Read all these instructions before attempting to operate this product and save these instructions.

1. Work area safety

   • Keep work area clean and well lit. Cluttered or dark areas invite accidents.
   •  Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
   •  Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control. Electrical safety
   •  Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.
   • Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
   • Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
   • Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges and moving parts. Damaged or entangled cords increase the risk of electric shock.
   • When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
   •  If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.

2. Personal safety

   • Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.
   •  Use personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.
   • Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energising power tools that have the switch on invites accidents.
   •  Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.
   •  Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
   • Dress properly. Do not wear loose clothing or jewellery. Keep your hair and clothing away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts.
   • If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards.
   • Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.

3. Power tool use and care

   • Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.

   • Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.

   • Disconnect the plug from the power source and/or remove the battery pack, if detachable, from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.

   •  Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.

   •  Maintain power tools and accessories. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly
     maintained power tools.

   •  Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.

   •  Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.

   • Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

4. Service

   • Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

Safety Warnings for Mitre Saws

•  Mitre saws are intended to cut wood or wood-like products, they cannot be used with abrasive cut-off wheels for cutting ferrous material such as bars, rods, studs, etc. Abrasive dust causes moving parts such as the lower guard to jam. Sparks from abrasive cutting will burn the lower guard, the kerf insert and other plastic parts.
• Use clamps to support the workpiece whenever possible. If supporting the workpiece by hand, you must always keep your hand at least 100 mm from either side of the saw blade. Do not use this saw to cut pieces that are too small to be securely clamped or held by hand. If your hand is placed too close to the saw blade, there is an increased risk of injury from blade contact.
•  The workpiece must be stationary and clamped or held against both the fence and the table. Do not feed the workpiece into the blade or cut “freehand” in any way. Unrestrained or moving workpieces could be thrown at high speeds, causing injury.
•  Push the saw through the workpiece. Do not pull the saw through the workpiece. To make a cut, raise the saw head and pull it out over the workpiece without cutting, start the motor, press the saw head down and push the saw through the workpiece. Cutting on the pull stroke is likely to cause the saw blade to climb on top of the workpiece and violently throw the blade assembly towards the operator.
•  Never cross your hand over the intended line of cutting either in front or behind the saw blade. Supporting the workpiece “cross handed” i.e. holding the workpiece to the right of the saw blade with your left hand or vice versa is very dangerous.
• Do not reach behind the fence with either hand closer than 100 mm from either side of the saw blade, to remove wood scraps, or for any other reason while the blade is spinning. The proximity of the spinning saw blade to your hand may not be obvious and you may be seriously injured.
•  Inspect your workpiece before cutting. If the workpiece is bowed or warped, clamp it with the outside bowed face toward the fence. Always make certain that there is no gap between the workpiece, fence and table along the line of the cut. Bent or warped workpieces can twist or shift and may cause binding on the spinning saw blade while cutting. There should be no nails or foreign objects in the workpiece.
•  Do not use the saw until the table is clear of all tools, wood scraps, etc., except for the workpiece. Small debris or loose pieces of wood or other objects that contact the revolving blade can be thrown with high speed.
•  Cut only one workpiece at a time. Stacked multiple workpieces cannot be adequately clamped or braced and may bind on the blade or shift during cutting.
• Ensure the mitre saw is mounted or placed on a level, firm work surface before use. A level and firm work surface reduces the risk of the mitre saw becoming unstable.
• Plan your work. Every time you change the bevel or mitre angle setting, make sure the adjustable fence is set correctly to support the workpiece and will not interfere with the blade or the guarding system. Without turning the tool “ON” and with no workpiece on the table, move the saw blade through a complete simulated cut to assure there will be no interference or danger of cutting the fence.
• Provide adequate support such as table extensions, saw horses, etc. for a workpiece that is wider or longer than the table top. Workpieces longer or wider than the mitre saw table can tip if not securely supported. If the cutoff piece or workpiece tips, it can lift the lower guard or be thrown by the spinning blade.
•  Do not use another person as a substitute for a table extension or as additional support. Unstable support for the workpiece can cause the blade to bind or the workpiece to shift during the cutting operation pulling you and the helper into the spinning blade.
• The cut-off piece must not be jammed or pressed by any means against the spinning saw blade. If confined, i.e. using length stops, the cut-off piece could get wedged against the blade and thrown violently.
• Always use a clamp or a fixture designed to properly support round material such as rods or tubing. Rods have a tendency to roll while being cut, causing the blade to “bite” and pull the work with your hand into the blade.
• Let the blade reach full speed before contacting the workpiece. This will reduce the risk of the workpiece being thrown.
• If the workpiece or blade becomes jammed, turn the mitre saw off. Wait for all moving parts to stop and disconnect the plug from the power source and/or remove the battery pack. Then work to free the jammed material. Continued sawing with a jammed workpiece could cause loss of control or damage to the mitre saw.
• After finishing the cut, release the switch, hold the saw head down and wait for the blade to stop before removing the cut-off piece. Reaching with your hand near the coasting blade is dangerous.
• Hold the handle firmly when making an incomplete cut or when releasing the switch before the saw head is completely in the down position. The braking action of the saw may cause the saw head to be suddenly pulled downward, causing a risk of injury.
• Keep your workplace clean. Blends of materials are particularly dangerous. Dust from light alloys can burn or explode.
• The power tool is provided with a laser warning label (marked with number 41 in the representation of the power tool on the graphics page).
• Do not direct the laser beam at persons or animals and do not stare into the direct or reflected laser beam yourself, not even from a distance. You could blind somebody, cause accidents or damage your eyes.
• If laser radiation strikes your eye, you must deliberately close your eyes and immediately turn your head away from the beam.
• Do not use any optical instruments such as binoculars to view the radiation source. Doing so can damage your eye.
•  Do not direct the laser beam at persons who are looking through binoculars or similar instruments. Doing so can damage their eye.
• Do not make any modifications to the laser equipment. The setting options described in these operating instructions can be used safely.
•  Never make warning signs on the machine unrecognizable.
•  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.
• Do not use high speed steel (HSS) saw blades. Such saw blades can easily break.
• Always use blades with correct size and shape (diamond versus round) of arbor holes. Blades that do not match the mounting hardware of the saw will run eccentrically, causing loss of control.
•  Do not replace the installed laser with another laser type. A laser that is not suitable for this power tool could pose dangers for other persons.
•  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.
•  Do not touch the saw blade after working before it has cooled. The saw blade becomes very hot while working.

Products sold in GB only: Your product is fitted with a 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 memories the symbols and their meanings. The correct interpretation of the symbols helps you operate the power tool better and more secure.

Symbols and their meaning

• Laser radiation Do not view directly with optical instruments Class 1M laser product

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

•  Wear a dust respirator.

• Wear safety goggles.

•  Wear ear protectors. Exposure to noise can cause hearing loss.

•  Danger area! Keep hands, fingers or arms away from this area.

• The table shows the recommended speed setting depending on the material to be worked: aluminium, plastic, wood.

• When sawing vertical bevel angles, the adjustable fences must be pulled outwards or removed completely.

• Observe the dimensions of the saw blade. The hole diameter must match the tool spindle without play. Do not use reducers or adapters.

• Shows the rotation direction of the SDS bolt for tightening the saw blade (counterclockwise) and for loosening the saw blade (clockwise).

• Clamping lever shut:
  The set bevel angle of the tool arm is locked.
  Clamping lever open:
  Adjusting bevel angles is possible.

Product Description and Specifications

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. In this, horizontal mitre angles from –52° to +60° as well as vertical bevel angles from 47° (leftward) to 47° (rightward) are possible. The capacity of the power tool is designed for sawing hard-wood and softwood, as well as particle and fiber board.
When using appropriate saw blades, sawing aluminum 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. Chip ejector
3. Transport handle
4. Adjusting screw of depth stop
5. Laser protection cap
6. Roller
7. On/Off switch
8. Handle
9. Locking switch for releasing the tool arm
10. Blade guard
11. Retracting blade guard
12. Saw blade
13. Saw-table extension
14. Fence
15. Adjustable fence
16. Saw table
17. Clamping lever of the saw-table extension
18. Scale for mitre angle
19. Insert plate
20. Locking bracket
21. Locking knob for various mitre angles
22. Mitre detent lever
23. Tilt protector
24. Mitre angle indicator
25. Detents for standard mitre angles
26. Mounting holes
27. Recessed handles
28. Locking screw of the adjustable fence
29. Material clamp
30. Chip deflector
31. Stop for standard 45°, 22.5° and 33.9° bevel angles 32 Scale for bevel angle
32. Right bevel angle indicator
33. Depth stop
34. Locking screw for slide device
35. Hex key (5 mm)
36. Mounting holes for material clamp
37. Material stop
38. Transport safety-lock
39. Speed regulator
40. Laser warning label
41. Laser on/off switch (for marking of cutting line)
42. Clamping lever for any bevel angle
43. Left bevel angle indicator
44. Leg extension
45. Stop for 0° standard bevel angle
46. Spindle lock
47. Hex socket screw (size 5 mm) for mounting of saw blade 49 Clamping flange
48. Interior clamping flange
49. SDS bolt
50. Threaded rod
51. Laser beam outlet
52. Screws for insert plate
53. Lock screw of the material stop*
54. Clamping screw of the material stop*
55. Adjustment screw for laser position (parallelism)
56. Stop screw for 0° bevel angle
57. Screw for bevel angle indicator
58. Stop screw for left-hand bevel angle range
59. Stop screw for right-hand bevel angle range
60. Set screws of scale 18 for mitre angles
61. Screw for mitre angle indicator
62. Velcro strap
63. Laser lens cover
    • Accessories shown or described are not part of the standard de-livery scope of the product. A complete overview of accessories can be found in our accessories program.

Technical Data

< 0.39
Laser class| | 1M
Weight according to
EPTA-Procedure 01/2003| kg| 18.9
Protection class| | /II

The values given are valid for a nominal voltage [U] of 230 V. For different voltages and models for specific countries, these values can vary.

Declaration of Conformity

We declare under our sole responsibility that the product de-scribed under “Technical Data” is in conformity with all relevant provisions of the directives 2011/65/EU, until
19 April 2016: 2004/108/EC, from 20 April 2016 on: 2014/30/EU, 2006/42/EC including their amendments and complies with the following standards:
EN 61029-1, EN 61029-2-9, EN ISO 12100, EN 60825-1.
Technical file (2006/42/EC) at: Robert Bosch GmbH, PT/ETM9, 70764 Leinfelden- Echterdingen, GERMANY

Noise/Vibration Information

• Sound emission values determined according to
• EN 61029-2-9.
• Typically the A-weighted noise levels of the product are: Sound pressure level 98 dB(A); Sound power level
• 108 dB(A). Uncertainty K =3 dB.
• Wear hearing protection!
• Vibration total values ah (triax vector sum) and uncertainty K determined according to EN 61029-2-9: ah=2.5 m/s2, K=1.5 m/s2.

The vibration emission level given in this information sheet has been measured in accordance with a standardized test given in EN 61029 and may be used to compare one tool with another. It may be used for a preliminary assessment of expo-sure.
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 in-crease 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, organization of work pat-terns.

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 mounted saw blade
• Material clamp 29
• Hex key 36
• SDS bolt51

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 mounting holes 26 serve for this pur-pose.
• Clamp the power tool with commercially available screw clamps by the feet to the working surface.

Mounting to a Bosch Saw Stand

With the height-adjustable legs, Bosch GTA saw stands pro-vide firm support for the power tool on any surface. The work-piece supports of the saw stand are used for underlaying long workpieces.

• Read all safety warnings and instructions included with the worktable. Failure to observe 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 pre-vent the risk of collapsing.
  •  Mount the power tool in transport position on the saw stand.

Flexible Mounting (not recommended!) (see figure A3)

If, in exceptional circumstances, it is not possible to mount the power tool on a flat and stable work surface, you can improvise by setting it up with the tilt protector and leg extensions.

• Without the leg extensions 45 and the tilt protector 23,  the power tool will not be stable and can tip over especially when sawing maximum mitre angles.
  • Mount the leg extensions 45 using the enclosed screws in the mounting holes 26.
  •  Screw the tilt protector 23 in or out until the machine is positioned level on the working surface.

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 (chromate, wood preservative). Materials containing asbestos may only be worked by specialists.

• Always use dust extraction.
• 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.

• Prevent dust accumulation at the workplace. Dusts can easily ignite. 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.

External Dust Extraction

For dust extraction, a vacuum hose (size Ø 35 mm) can also be connected to the chip ejector 2.

• Connect the vacuum hose with the chip ejector 2.

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.

Changing the Saw Blade

• When mounting the saw blade, wear protective gloves. Danger of injury when touching the saw blade.

Use only saw blades whose maximum permitted speed is higher than the no-load speed of the power tool.
Use only saw blades that correspond with the characteristic data given in these operation instructions and that are tested and marked in accordance with EN 847-1.
Use only saw blades recommended by the tool manufacturer and suitable for sawing the materials to be cut.

Mounting with Hex Socket Screw (see figures B1–B4)

Removing the Saw Blade:

• Bring the power tool into the working position.
• Turn the hex socket screw 48 with the hex key (5 mm) 36 and at the same time press the spindle lock 47 until it engages.
•  Hold the spindle lock 47 pressed and unscrew the hex socket screw 48 in clockwise direction (left-hand thread!).
• Remove the clamping flange 49.
• Press locking switch 9 and swing back the retracting blade guard 11 to the stop.
• Hold the retracting blade guard in this position and remove the saw blade 12.
• Slowly guide the retracting blade guard downward again.

Mounting the Saw Blade:
If required, clean all parts to be mounted prior to assembly.

• Press locking switch 9, swing back the retracting blade guard 11 to the stop and hold it in this position.
• Place the new saw blade onto the interior clamping flange 50.
• When mounting the saw blade, pay attention that the cutting direction of the teeth (arrow direction on the saw blade) corresponds with the direction of the arrow on the blade guard!
  • Slowly guide the retracting blade guard downward again.
  • Place on the clamping flange 49 and the hex socket screw 48. Press the spindle lock 47 until it engages and tighten the screw turning in anticlockwise direction.

Mounting with SDS Bolt (see figure C)

Removing the Saw Blade:

• Bring the power tool into the working position.
• Hold the spindle lock 47 pressed and unscrew the SDS bolt 51 in clockwise direction (left-hand thread!).
• Remove the clamping flange 49.
• Press locking switch 9 and swing back the retracting blade guard 11 to the stop.
• Hold the retracting blade guard in this position and remove the saw blade 12.
• Slowly guide the retracting blade guard downward again.

Mounting the Saw Blade:
If required, clean all parts to be mounted prior to assembly.

• Press locking switch 9, swing back the retracting blade guard 11 to the stop and hold it in this position.
• Place the new saw blade onto the interior clamping flange 50.
• When mounting the saw blade, pay attention that the cutting direction of the teeth (arrow direction on the saw blade) corresponds with the direction of the arrow on the blade guard!
  • Slowly guide the retracting blade guard downward again.
  • Attach the clamping flange 49 and the SDS bolt 51. Press the spindle lock 47 until it engages and tighten the SDS bolt in anticlockwise direction.

Operation

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

Transport Safety (see figure D)

The transport safety-lock 39 enables easier handling of the machine when transporting to various working locations.

Releasing the Machine (Working Position)

• Push the tool arm by the handle 8 down a little in order to relieve the transport safety-lock 39.
• Pull the transport safety-lock 39 completely outward.
•  Guide the tool arm slowly upward.

Securing the Machine (Transport Position)

• Loosen the locking screw 35 if tightened. Pull the tool arm completely to the front and tighten the locking screw again.
• Screw adjusting screw 4 completely upward.
•  To lock the saw table 16, tighten the locking knob 21.
• Press locking switch 9 and slowly guide the tool arm downward by the handle 8.
• Guide the tool arm downward until the transport safety-lock 39 can be pushed completely inward.

Preparing for Operation

Extending the Saw Table (see figure E)

Long workpieces must be underlaid or supported at their free end.
The saw table can be extended left and right with the saw-table extensions 13.

• Push clamping leve r17 upward.
• Pull out the saw-table extension 13 to the desired length.
• To lock the saw-table extension, push clamping lever 17 down again.

Moving the Fence (see figure F)

When sawing mitre/bevel angles, you have to pull the left-hand or right-hand adjustable fence 15 outward depending on the cutting direction, or remove it completely.

Adjusting Bevel Angles

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 34). The vertical bevel angle can be adjusted in a range from 47° (leftward) to 47° (rightward). For quick and precise setting of frequently used bevel angles, stops have been provided for the 0°, 45°, 22.5° and 33.9° angles.

Adjusting Any Bevel Angle (see figure J)

• Pull the stop 46 completely forward. This enables you to use the complete bevel angle range (left and right).

• Pull the right-hand adjustable fence 15 completely outward or remove it completely (see “Moving the Fence”, page 31).
  If you want to use the complete bevel angle range, you also have to pull the left-hand adjustable fence 15 completely outward or remove it completely.

• Loosen clamping lever 43.

•  Tilt the tool arm via handle 8 to the left or right until angle indicator 44 or 33 indicate the desired bevel angle.

• Tighten clamping lever 43 again.

Adjusting Standard Bevel Angles (see figure K)

Standard 0° Bevel Angle :

• Swing the tool arm by the handle 8 slightly to the left and push the stop 46 completely backward. Standard bevel angles 45°, 33.9° and 22.5°:
• Turn the left-hand or right-hand stop 31 until the required standard bevel angle engages at the arrow mark.

Starting Operation

• Observe correct mains voltage! The voltage of the power source must agree with the voltage specified on the nameplate of the machine. Power tools marked with 230 V can also be operated with 220 V.

Switching On (see figure L)

To save energy, only switch the power tool on when using it.

• To start the machine, press the On/Off switch 7 and keep it pressed.

Note: For safety reasons, the On/Off switch 7 cannot be locked; it must remain pressed during the entire operation. The tool arm can only be guided downward by pressing locking switch 9.

• For sawing, the locking switch 9 must be therefore pushed in addition to pressing the On/Off switch 7.

Switching Off

• To switch off the machine, release the On/Off switch 7.

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 Application Service”, page 35).

Working Advice

General Sawing Instructions

• Always tighten the locking knob 21 and the clamping lever 43 firmly before sawing. Otherwise the saw blade can become wedged in the workpiece.
•  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 any 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.

Make sure that the retracting blade guard operates properly and that it can move freely. The retracting blade guard must open when the tool arm is guided downward. When the tool arm is guided upward, the retracting blade guard must close again over the saw blade and lock in the uppermost position of the tool arm.

Marking the Cutting Line (see figure M)

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 42.
• 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 34). The laser beam, as an example, can misadjust due to vibrations after intensive use.

Position of the Operator (see figure N)

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
Maximum workpiece sizes:

45 °
(rightward/leftward)| 0°| 70 x 225
0°| 45° (leftward)| 45 x 312
0°| 45° (rightward)| 20 x 312
45 °| 45° (leftward)| 45 x 225
45 °| 45° (rightward)| 20 x 225
45 °                       45° (leftward (rightward/leftward) with SDS bolt)| 30 x 225

Minimum workpiece sizes (= all workpieces that can be  clamped left or right from the saw blade with the supplied material clamp 29): 100 x 40 mm (length x width) Cutting depth, max. (0°/0°): 70 mm

Replacing Insert Plates (see figure O)

The red insert plates 19 can become worn after prolonged use of the machine. Replace defective insert plates.

• Bring the power tool into the working position.
• Unscrew the screws 54 with a hex key (4 mm) 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 54 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

• Always tighten the locking knob 21 and the clamping lever 43 firmly before sawing. Otherwise the saw blade can become wedged in the workpiece.

Adjusting the Speed

The speed regulator 40 enables continuously variable adjustment of the speed of the power tool even during operation.

Note: Always set the suitable speed for the workpiece material (see table below). This prevents overheating of the saw teeth during sawing.

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

• For cuts without slide movement (small workpieces), loosen the locking screw 35 in case it is tightened. Slide the tool arm to the stop in the direction of the fence 14 and retighten the locking screw 35.
• Set the desired mitre angle.
• Firmly clamp the workpiece as appropriate for its dimensions.
• Switch on the machine.
• Press locking switch 9 and slowly guide the tool arm downward by the handle 8.
• 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 35 in case it is tightened.
• Set the desired mitre angle.
• Firmly clamp the workpiece as appropriate for its dimensions.
• Pull the tool arm away from the fence 14 far enough so that the saw blade is in front of the workpiece.
• Switch on the machine.
•  Press locking switch 9 and slowly guide the tool arm downward by the handle 8.
• Press the tool arm in the direction of the fence 14 and 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 Workpieces of the Same Length (see figure Q)

The material stop 38 (accessory) can be used for easily sawing workpieces to the same length.
The material stop can be mounted on either side of the saw table extension 13.

• Loosen lock screw 55 and swing the material stop 38 over clamping screw 56.
• Retighten lock screw 55.
• Adjust the saw table extension 13 to the desired length
  (see “Extending the Saw Table”, page 31).

Adjusting the Depth Stop (Sawing Grooves) (see figure R)

The depth stop must be adjusted when a trench gap is to be sawed.

• Swivel the depth stop 34 outward.
• Press locking lever 9 and tilt the tool arm to the desired position.
• Turn adjusting screw 4, until the screw end touches depth stop 34.
• Guide the tool arm slowly upward.

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.

Checking and Adjusting the Basic Adjustment

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

Note: To test the laser function, the machine must be connected to power.

• While adjusting the laser (e. g. when moving the tool arm), never actuate the On/Off switch. Accidental starting of the power tool can lead to injuries.
  • Bring the power tool into the working position.
  • Turn the saw table 16 to the 0° detent 25. The lever 22 must be felt to engage in the detent.

Checking: (see figure S1)

• Draw a straight cutting line on the workpiece.
• Press locking switch 9 and slowly guide the tool arm downward by the handle 8.
• 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 42.
  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: (see figure S2)

• Turn the adjustment screw 57 with a suitable screwdriver until the laser beam is parallel to the complete length of the cutting line on the workpiece.

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.

Setting the Standard Bevel Angle 0° (Vertical)

• Bring the power tool into the working position.
• Turn the saw table 16 to the 0° detent 25. The lever 22 must be felt to engage in the detent.

Checking: (see figure T1)

• Adjust an angle gauge to 90° and position it on the saw table 16.
  The leg of the angle gauge must be flush with the saw blade 12 over the complete length.

Adjusting: (see figure T2)

• Loosen clamping lever 43.
• Push the stop 46 completely to the rear.
• Loosen the lock nut of the stop screw 58 using a commercial box-end or open-end spanner (size 10 mm).
• Screw the stop screw in or out until the leg of the angle gauge is flush with the saw blade over the complete length.
• Tighten clamping lever 43 again.
• Afterwards, retighten the lock nut of the stop screw 58 again.

In case the angle indicator 38 is not in a line with the 0° mark of the scale 32 after the adjustment, loosen the screw 59 using a commercial cross-head screwdriver and align the angle indicator along the 0° mark.

Setting the Standard 45° Bevel Angle (Leftward)

• Bring the power tool into the working position.
• Turn the saw table 16 to the 0° detent 25. The lever 22 must be felt to engage in the detent.
• Remove the left-hand adjustable fence 15 (see “Moving the Fence”, page 31).
•  Turn the left-hand stop 31 until the standard 45° bevel angle engages at the arrow mark.
• Loosen clamping lever 43.
• Swing the tool arm to the left by the handle 8 until the stop screw 60 rests on the stop 31.

Checking: (see figure U1)

• Set an angle gauge to 45° and place it on the saw table 16. The leg of the angle gauge must be flush with the saw blade 12 over the complete length.

Adjusting: (see figure U2)

• Loosen the lock nut of the stop screw 60 using a conventional ring spanner or open-end spanner (10 mm).
• Tighten clamping lever 43 again.
• Screw the stop screw in or out until the leg of the angle gauge is flush with the saw blade over the complete length.
• Then retighten the lock nut of the stop screw 60.

When the angle indicators 44 and 33 are not in line with the 45° marks of scale 32 after adjusting, firstly once more check the 0° setting for the bevel angle and the angle indicators. Then repeat the adjustment of the 45° bevel angle.

Setting the Standard 45° Bevel Angle (Rightward)

• Bring the power tool into the working position.
• Turn the saw table 16 to the 0° detent 25. The lever 22 must be felt to engage in the detent.
• Remove the right-hand adjustable fence 15 (see “Moving the Fence”, page 31).
• Pull the stop 46 completely forward.
•  Turn the right-hand stop 31 until the standard 45° bevel angle engages at the arrow mark.
• Loosen clamping lever 43.
• Swing the tool arm to the right by the handle 8 until the stop screw 61 rests on the stop 31.

Checking: (see figure V1)

• Set an angle gauge to 135° and place it on the saw table 16.
  The leg of the angle gauge must be flush with the saw blade 12 over the complete length.

Adjusting: (see figure V2)

• Loosen the lock nut of the stop screw 60 using a conventional ring spanner or open-end spanner (10 mm).
• Screw the stop screw in or out until the leg of the angle gauge is flush with the saw blade over the complete length.
• Tighten clamping lever 43 again.
• Then retighten the lock nut of the stop screw 60.

When the angle indicators 44 and 33 are not in line with the 45° marks of scale 32 after adjusting, firstly once more check the 0° setting for the bevel angle and the angle indicators. Then repeat the adjustment of the 45° bevel angle. Aligning the Scale for Mitre Angles

• Bring the power tool into the working position.
• Turn the saw table 16 to the 0° detent 25. The lever 22 must be felt to engage in the detent.

Checking: (see figure W1)

• Adjust an angle gauge to 90° and position it between the fence 14 and the saw blade 12 on the saw table 16. The leg of the angle gauge must be flush with the saw blade 12 over the complete length.

Adjusting: (see figure W2)

• Loosen all four set screws 62 with a cross-head screwdriver and turn the saw table 16 together with the scale 18 until the leg of the angle gauge is flush with the saw blade over the complete length.
• Retighten the screws again. When the angle indicator 24 is not in line with the 0° mark of scale 18 after adjusting, loosen screw 63 with a cross-head screwdriver and align the angle indicator alongside the 0°mark.

Transport (see figure X)

Before transporting the power tool, the following steps must be carried out:

• Loosen the locking screw 35 if tightened. Pull the tool arm completely to the front and tighten the locking screw again.
• Make sure that the depth stop 34 is pushed completely inward and that adjusting screw 4 fits through the recess without touching the depth stop when moving the tool arm.
• 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.

• Wind up the mains cable and tie it together with Velcro strap 64.
• Carry the machine by the transport handle 3 or hold it by the recessed handles 27 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 replacement of the supply cord is necessary, this has to be done by Bosch or an authorized Bosch service agent in order to avoid a safety hazard.

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 6 regularly. To clean the laser unit, turn the laser lens cover 65 outward and remove any dust using the brush.

Accessories

• Material clamp 1 609 B04 224
• Insert plates 1 609 B03 717
• Dust bag 1 609 B05 010
• Material stop 1 609 B02 365
• Lock screw of the material stop 1 609 B00 263
• Saw blades for wood and plate materials, panels and strips/moldings
• Saw blade 216 x 30 mm, 48 teeth 2 608 640 641
• Saw blades for plastic and non-ferrous metals
• Saw blade 216 x 30 mm, 80 teeth 2 608 640 447
• Saw blades for all types of laminate flooring
• Saw blade 216 x 30 mm, 60 teeth 2 608 642 133

After-sales Service and Application Service

Our after-sales service responds to your questions concerning maintenance and repair of your product as well as spare parts. Exploded views and information on spare parts can also be found under: www.bosch-pt.com Bosch’s application service team will gladly answer questions concerning our products and their accessories.
In all correspondence and spare parts order, please always include the 10-digit article number given on the type plate of the machine.

Great Britain
Robert Bosch Ltd. (B.S.C.)
P.O. Box 98
Broadwater Park
North Orbital Road
Denham
Uxbridge
UB 9 5HJ
At www.bosch-pt.co.uk you can order spare parts or arrange the collection of a product in need of servicing or repair.
Tel. Service: (0344) 7360109
E-Mail: boschservicecentre@bosch.com

Ireland
Origo Ltd.
Unit 23 Magna Drive
Magna Business Park
City West
Dublin 24
Tel. Service: (01) 4666700
Fax: (01) 4666888
Australia, New Zealand and Pacific Islands
Robert Bosch Australia Pty. Ltd.
Power Tools
Locked Bag 66
Clayton South VIC 3169
Customer Contact Center

Inside Australia:
Phone: (01300) 307044
Fax: (01300) 307045

Inside New Zealand:
Phone: (0800) 543353
Fax: (0800) 428570

Outside AU and NZ:
Phone: +61 3 95415555
www.bosch.com.au
Republic of South Africa

Customer service
Hotline: (011) 6519600
Gauteng – BSC Service Centre
35 Roper Street, New Centre

Johannesburg
Tel.: (011) 4939375
Fax: (011) 4930126
E-Mail: bsctools@icon.co.za
KZN – BSC Service Centre
Unit E, Almar Centre
143 Crompton Street

Pinetown
Tel.: (031) 7012120
Fax: (031) 7012446
E-Mail: bsc.dur@za.bosch.com
Western Cape – BSC Service Centre
Democracy Way, Prosperity Park

Milnerton
Tel.: (021) 5512577
Fax: (021) 5513223
E-Mail: bsc@zsd.co.za

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

Disposal
The machine, accessories and packaging should be sorted for environmental- friendly recycling.
Do not dispose of power tools into household waste!

Only for EC countries:
According to the European Directive 2012/19/EU 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
• The domain name bosch.mk is for sale
• bosch-powertools.com.ua
• Bosch Elektrowerkzeuge | Bosch Elektrowerkzeuge
• Bosch Услуги | Электроинструменты Bosch
• Bosch Power Tools | Bosch Power Tools
• Location selection | Bosch Power Tools
• Bosch Elektrowerkzeuge | Bosch Elektrowerkzeuge
• Outillage électroportatif Bosch | Outillage électroportatif Bosch
• Elettroutensili Bosch | Elettroutensili Bosch
• Home | Bosch Power Tools
• Bosch Elektrowerkzeuge und Zubehör | Bosch Elektrowerkzeuge
• Bosch el-værktøj | Bosch el-værktøj
• Bosch-sähkötyökalut | Bosch-sähkötyökalut
• Outillage électroportatif Bosch | Outillage électroportatif Bosch
• Home | Bosch Power Tools
• Bosch elektromos kéziszerszámok | Bosch elektromos kéziszerszámok
• Elektronarzędzia Bosch | Elektronarzędzia Bosch
• Bosch Услуги | Электроинструменты Bosch
• Elektrické náradie Bosch | Elektrické náradie Bosch
• Bosch România | Bosch în România
• Начало | Бош в България
• Invented for life | Bosch Global
• Home | Bosch in Australia
• Domovská stránka | Bosch Česká republika
• Innostavia tuotteita ja palveluita | Bosch Suomessa
• Дом | Қазақстандағы Bosch
• Strona główna | Bosch w Polsce
• Domov | Bosch Slovensko
• herramientasbosch.net

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