BOSCH GCM 254 D Mitre Saw Instruction Manual

: August 19, 2024
: Bosch

Table of Contents

BOSCH GCM 254 D Mitre Saw
Product Information
Product Usage Instructions
Safety instructions
Product Description and Specifications
Product Features
Technical Data
Assembly
Operation
Sawing
Practical advice
Maintenance and Service
References
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BOSCH GCM 254 D Mitre Saw

Product Information

Specifications:

Brand: Bosch
Model: GCM 254 D Professional
Manufacturer: Robert Bosch Power Tools GmbH
Country of Origin: Germany
Website: www.bosch-pt.com

Product Usage Instructions

Safety Instructions

General Power Tool Safety Warnings:
WARNING: Read all safety warnings, instructions, illustrations, and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire, and/or serious injury.
Save all warnings and instructions for future reference.
The term power tool in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

Work Area Safety:

Keep work area clean and well lit. Cluttered or dark areas invite accidents.
Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Power tools create sparks which may ignite the dust or fumes.
Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

Electrical Safety:

Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce the 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.

FAQ (Frequently Asked Questions)

Q: How do I clean the GCM 254 D Professional?
A: To clean the GCM 254 D Professional, use a soft, dry cloth to wipe down the surfaces. Avoid using any harsh chemicals or abrasive materials that could damage the tool.
Q: Can I use the GCM 254 D Professional in wet conditions?
A: No, it is not recommended to use the GCM 254 D Professional in wet conditions as it can increase the risk of electric shock.Always ensure the tool is kept dry and away from water sources.

Robert Bosch Power Tools GmbH 70538 Stuttgart GERMANY
www.bosch-pt.com

Safety instructions

General Power Tool Safety Warnings
WARNING Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire and/ or serious injury.
Save all warnings and instructions for future reference.
The term “power tool” in the warnings refers to your mainsoperated (corded) power tool or battery-operated (cordless) power tool.

Work area safety

Keep work area clean and well lit. Cluttered or dark areas invite accidents.
Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

Electrical safety

Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs withearthed (grounded) power tools. Unmodified plugs andmatching 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 yourbody 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 cordaway from heat, oil, sharp edges or moving parts.
Damaged or entangled cords increase the risk of electric shock.
When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protectedsupply. Use of an RCD reduces the risk of electric shock.

Personal safety

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

Power tool use and care

Do not force the power tool. Use the correct power rtool 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

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 thepull 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 andtable 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 cut-off 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.
Do not let go of the handle once the saw head has reached the lowest position. Always guide the saw head back to the top position by hand. There is a risk of injury if the saw head moves in an uncontrolled manner.
Keep your work area clean. Material mixtures are particularly hazardous. Light metal dust may catch fire or explode.
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 saw blades made from high speed steel (HSS). Such saw blades can easily break.
Always use saw blades with correct size and shape (diamond versus round) of arbour holes. Saw blades that do not match the mounting hardware of the saw will run off-centre, causing loss of control.
Never remove cuttings, wood chips, etc. from the cutting area while the power tool is running. Always guide the tool arm back to the neutral position first and then switch the power tool off.
Do not touch the saw blade after working before it has cooled. The saw blade becomes very hot while working.
The power tool is delivered with a laser warning sign (see table: “Symbols and their meaning”).
If the text of the laser warning label is not in your national language, stick the provided warning label in your national language over it before operating for the first time.
Never make warning signs on the machine unrecognisable. Do not direct the laser beam at persons or animals and do not stare into the direct or reflected laser beam yourself. You could blind somebody, cause accidents or damage your eyes.
If laser radiation hits your eye, you must close your eyes and immediately turn your head away from the beam.
Do not make any modifications to the laser equipment. The setting options described in these operating instructions can be used safely.
Do not let children use the power tool unsupervised. They could unintentionally blind themselves or other persons

Symbols

The following symbols may be important for the operation of your power tool. Please take note of these symbols and their meaning. Correctly interpreting the symbols will help you to operate the power tool more effectively and safely

Symbols and their meaning

The left/right adjustable fence must be removed when sawing bevel angles

Product Description and Specifications

Read all the safety and general instructions.
Failure to observe the safety and general instructions may result in electric shock, fire and/or serious injury.
Please observe the illustrations at the beginning of this operating manual.

Intended Use

The power tool is intended as a stationary machine for making straight cuts in wood with and against the grain. Mitre angles of –47° to +52° as well as bevel angles of 45° (lefthand side) to 45° (right-hand side) are possible.
The power tool is designed with sufficient capacity for sawing hardwood and softwood as well as chipboard and fibreboard.
When using appropriate saw blades, sawing aluminium profiles and plastic is also possible.

Product Features

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

Locking screw for slide device
Slide device
Laser warning label
Transport handle
Handle
Lock-off function for On/Off switch
Protective guard
Retracting blade guard
Mounting holes
Insert plate
Lock button for mitre angle
Locking knob for all mitre angles
Lock button for bevel angle
Angle indicator for mitre angles
Detents for standard mitre angles
Saw table extension
Workpiece supporta)
Fixed fence
Adjustable fence
Screw clamp
Adjustment knob for 0° bevel angle
Depth stop
Depth stop adjusting screw
Hex key
Transport Safety Lock
Length stop
Recessed handles
Mounting holes for horizontal fixing
Saw table
Scale for mitre angles
Tilt protector
Guide roller
Spindle lock
Laser beam outlet aperture
On/off switch
On/Off switch for laser (cutting line indication)
Chip ejector
Wing bolt for fixing the adjustable fence
Holes for screw clamp
Stop screw for right-hand bevel angle range
Standard bevel angle stops 45°, 22.5° and 33.9°
Clamping screw for saw table extension
Securing screw for saw table extension
Opening for workpiece support (on power tool)
Opening for second workpiece support (on workpiece support)
Dust bag
Hex socket screw for mounting the saw blade
Clamping flange
Saw blade
Inner clamping flange
Wing bolt for adjusting the height of the threaded rod
Threaded rod
Wing bolt for screw clamp
Screw clamp pins
Angle indicator for bevel angles
Scale for bevel angles
Clamping screw for length stop
Guide rail for length gauge
Wing bolt for fixing the guide rail for length gauge
Screws for insert plate
Set screw for positioning the laser
Set square
Stop screw for 0° bevel angle
Hex socket screw for fence
Screw for bevel angle indicator
Screw for mitre angle indicator
Not available in all country-specific versions.

Technical Data

Permitted workpiece dimensions (maximum/minimum): (see “Permissible workpiece dimensions”,)
The specifications apply to a rated voltage [U] of 230 V. These specifications may vary at different voltages and in country-specific models.
The appliance meets IEC 61000-3-11 requirements and is subject to conditional connection. The appliance can lead to occasional voltage fluctuations under unfavorable power conditions. The impedance of this appliance is set as Zactual = 0.094 Ω. The user must make sure, that the connection point, with the impedance Zmax, on which the appliance shall be plugged in meets the impedance requirement: Zactual ≥ Zmax. If Zmax is unknown, determine Zmax in consultation with the network supplier or supply authority.
Values can vary depending on the product, scope of application and environmental conditions. To find out more, visit www.bosch-professional.com/wac

Assembly

Avoid starting the power tool unintentionally. The mains plug must not be connected to the power supply during assembly or when carrying out any kind of work on the power tool.

Items included

See the list of items included at the start of the operating manual.
Check to ensure that all the parts listed below have been supplied before using the power tool for the first time:

Sliding mitre saw with fitted saw blade
Dust bag (46)
Workpiece support (17) (2 units) (not available in all country-specific versions).
Screw clamp (20)
Hex key (24)
Set square (62)
Saw table extension (16) (2 units)

Note : Check the power tool for possible damage.
Before continuing to use the power tool, carefully check that all protective devices or slightly damaged parts are working perfectly and according to specifications. Check that the moving parts are working perfectly and without jamming; check whether any parts are damaged. All parts must be fitted correctly and all the conditions necessary to ensure smooth operation must be met.
If the protective devices or any parts become damaged, you must have them properly repaired or replaced by an authorised service centre.

Fitting individual components

Carefully remove all parts included in the delivery from their packaging.
Remove all packing material from the power tool and the accessories provided.
For ease of assembly when fitting the tool elements that are provided, be aware that the power tool is supplied in the transport position.

Fitting the saw table extensions (see figure A1)
To extend the saw table further, saw table extensions can be mounted both to the left or right of the power tool.

Unscrew the securing screws (43) from the saw table extensions with a cross-headed screwdriver.
Tilt the power tool.
Push the saw table extensions (16) on both sides of the power tool all the way into the corresponding drill holes.
For the pull-out safety device, screw the securing screws (43) back into the saw table extensions. Installing Workpiece Supports (see figure A2)
The workpiece supports (17) can be positioned left, right or in front of the power tool. The flexible connector system enables a multitude of extension or expansion variants (see figure G).
Insert the workpiece support (17) into the openings (44) on the power tool or into the openings (45) of the second workpiece support as required.
- Never carry the power tool using the workpiece supports. Only use the transport devices to transport the power tool.

Stationary or flexible mounting

To ensure safe handling, the power tool must be mounted on a flat, stable work surface (e.g. work bench) before use.

Mounting on a work surface (see figure B1−B2)

Use suitable screw fasteners to secure the power tool to the work surface. The holes (9) are used for this purpose.
Firmly clamp the base of the power tool to the work surface with commercially available screw clamps

Mounting on a Bosch saw stand

With the height-adjustable legs, Bosch GTA saw stands provide firm support for the power tool on any surface. The workpiece supports of the saw stand are used for underlying long workpieces.
Read all the warnings and instructions included with the saw stand. Failure to observe the warnings and follow instructions may result in electric shock, fire and/or serious injury.
Assemble the saw stand properly before mounting the power tool. Correct assembly is important to prevent the risk of collapsing.
- Mount the power tool on the saw stand in the transport position.
  Flexible installation (not recommended) (see figure B3) 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.
Without the tilt protector, the power tool will not be stable and can tip over especially when sawing maximum mitre and/or bevel angles.
- Rotate the tilt protector (31) inwards or outwards until the power tool is positioned straight on the work surface

Dust/Chip Extraction

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

Use a dust extraction system that is suitable for the material wherever possible.
Provide good ventilation at the workplace.
It is advisable to wear a P2 filter class breathing mask.
The regulations on the material being machined that apply in the country of use must be observed.
- Avoid dust accumulation at the workplace. Dust can easily ignite.
  The dust/chip extraction system can be blocked by dust, chips or fragments of the workpiece.
Switch the power tool off and pull the mains plug out of the socket.
Wait until the saw blade has come to a complete stop.
Determine the cause of the blockage and eliminate it. Self-generated dust extraction (see figure C)
For basic chip collection, use a dust bag (46) (accessory).
Attach the dust bag (46) to the chip ejector (37).

During sawing, the dust bag must not come into contact with moving tool components.
Always empty the dust bag in good time.

Check and clean the dust bag each time after using.
When sawing aluminium, remove the dust bag to avoid the risk of fire.

External Dust Extraction

You can also attach a dust extraction hose (35 mm diameter) to the chip ejector (37) for extraction.
The dust extractor must be suitable for the material being worked.
When extracting dry dust that is especially detrimental to health or carcinogenic, use a special dust extractor

Changing the saw blade (see figures D1−D4)

Pull the plug out of the socket before carrying out any work on the power tool.
Wear protective gloves when fitting the saw blade.

There is a risk of injury when touching the saw blade

Only use saw blades that have a maximum permitted speed higher than the no-load speed of the power tool.
Only use saw blades that match the specifications given in this operating manual and that have been tested and marked in accordance with EN 847-1.
Only use saw blades that are recommended by the power tool manufacturer and are suitable for use on the material you want to saw. This will prevent the saw teeth overheating when sawing.

Removing the Saw Blade

Bring the power tool into the work position.
Swivel the retracting blade guard (8) to the back and hold it in this position.
Turn the hex socket screw (47) with the hex key (8 mm) (24) and at the same time push the spindle lock (33) until it engages.
Keep holding the spindle lock (33) and loosen the hex socket screw (47) by turning it clockwise (left-hand thread).
Remove the clamping flange (48).
Remove the saw blade (49).
Slowly push the retracting blade guard back down.

Fitting the saw blade

When fitting the saw blade, make sure that the cutting direction of the teeth (arrow direction on the saw blade) matches the direction of the arrow on the protective guard.
If required, clean all the parts you want to fit before installing them.
- Swivel the retracting blade guard (8) to the back and hold it in this position.
- Place the new saw blade on the inner clamping flange (50).
- Fit the clamping flange (48) and the hex socket screw (47). Press the spindle lock (33) until it engages and tighten the hex socket screw by turning it anticlockwise.
- Slowly push the retracting blade guard back down.

Operation

Pull the plug out of the socket before carrying out any work on the power tool.
Products that are only sold in AUS and NZ: Use a residual current device (RCD) with a nominal residual current of 30 mA or less.

Transport Safety Lock (see figure E)
The transport safety lock (25) makes it easier to handle the power tool when transporting it to various working locations.

Unlocking the power tool (work position)

Press the tool arm down slightly by the handle (5) to release the transport safety lock (25).
Pull the transport safety lock (25) all the way out.
Slowly guide the tool arm upwards.

Locking the power tool (transport position)

Loosen the locking screw (1) if it is clamping the slide device (2) in place. Pull the tool arm fully forward and tighten the locking screw again to lock the slide device.
Screw the adjusting screw (23) all the way upwards.
To lock the saw table (29) in place, tighten the locking knob (12).
Swing the tool arm downwards by the handle (5) until you can press the transport safety lock (25) completely inwards.
The tool arm is now securely locked and ready for transportation.

Preparing for operation

To ensure precise cuts, the basic settings of the power tool must be checked and adjusted as necessary after intensiveuse.
Experience and suitable special tools are required for this. A Bosch after- sales service point will handle this work quickly and reliably.

Extending/Expanding the Saw Table (see figures F−G)
The free end of long and heavy workpieces must have something placed underneath it or be supported.
The saw table can be extended left and right using the saw table extensions (16).

Loosen the clamping screw (42).
Pull out the saw table extension (16) to the required length.
Retighten the clamping screw (42) to fix the saw table extension.

The flexible connector system of the workpiece supports (17) enables a multitude of extension or expansion variants.

Insert the workpiece support (17) into the openings (44) on the power tool or into the openings (45) of the second workpiece support as required.
- Never carry the power tool using the workpiece supports.
  Only use the transport devices to transport the power tool.
Removing the Fence (see figure H)
You have to remove the left/right adjustable fence (19) to saw bevel angles.
- Loosen the wing bolts (38).
- Remove the adjustable fence (19).
  After sawing the bevel angles, reinsert the adjustable fence (19) and tighten the wing bolts (38).

Clamping the workpiece (see figures I1–I3)

To ensure maximum safety while working, the workpiece must always be firmly clamped.
Do not saw workpieces that are too small to clamp firmly

Vertical Clamping

Press the workpiece firmly against the (18) and (19) fences.
Insert the supplied screw clamp (20) into one of the corresponding holes (39).
Loosen the wing bolt (51) and adjust the screw clamp to the workpiece. Tighten the wing bolt again.
Tighten the threaded rod (52) to fix the workpiece in place.

Horizontal clamping

Unscrew the wing bolt (53) and pull apart the screw clamp.
Insert the screw clamp (20) that has now been taken apart with the pin (54) into one of the corresponding holes (28).
Press the workpiece firmly onto the saw table (29).
Tighten the threaded rod (52) to fix the workpiece in place.

Releasing the workpiece
To loosen the screw clamp, turn the threaded rod (52) anticlockwise.

Adjusting mitre angles

Bring the power tool into the work position. Setting Standard Mitre Angles (see figure J)
For quick and precise setting of commonly used mitre angles, detents (15) are provided on the saw table:
Press the lock button (11) down and turn the saw table (29) left or right by the locking knob until the angle indicator (14) shows the standard mitre angle required.
Release the lock button (11) again. The saw table mustbe heard to click into the detent.
Retighten the locking knob (12).

Setting any Mitre Angle
The mitre angle can be set between 47° (left-hand side) and 52° (right-hand side).

Loosen the locking knob (12) if it is tightened.

Press the lock button (11) down and turn the saw table (29) left or right by the locking knob until the angle indicator (14) shows the mitre angle required.
Release the lock button (11) again.
Retighten the locking knob (12).

Adjusting bevel angles

The bevel angle can be set between 45° (left-hand side) and 45° (right-hand side).
For quick and precise setting of frequently used bevel angles, stops have been provided for the angles 0°, 22.5°, 33.9° and 45°.

Setting the Left Bevel Angle Range

Remove the left-hand adjustable fence (19)
Turn the left-hand stop (41) until the standard 45° bevel angle engages at the arrow mark.
The full swivel range to the left is now available.
Pull the lock button (13) up.
Use the handle (5) to swivel the tool arm to the left untilthe angle indicator shows the required bevel angle.
Hold the tool arm in this position and push the lock button (13) back down.

Setting the Right Bevel Angle Range

Remove the right adjustable fence (19).
Turn the right-hand stop (41) until the standard 45° bevel angle engages at the arrow mark.
The right swivel range to the right is now available.
Pull the lock button (13) up.
Turn the adjustment knob (21) slightly to the left and swivel the tool arm to the right by the handle (5) until the angle indicator shows the required bevel angle.
Hold the tool arm in this position and push the lock button (13) back down.

Setting Standard Bevel Angles (see figure K)

Remove the right/left adjustable fence (19).
Pull the lock button (13) up.
Standard mitre angle 0°:
Turn the adjustment knob (21) slightly to the left and swivel the tool arm from the right to the 0° position untilyou hear it click into place in the 0° position.
Push the lock button (13) back down. Standard mitre angles 45°, 33.9° and 22.5°:
Turn the left-hand or right-hand stop (41) until the required standard bevel angle engages at the arrow mark.
Swivel the tool arm as far as it will go to the left.
or
Turn the adjustment knob (21) slightly to the left and swivel the tool arm to the right by the handle (5) as far as it will go.
Push the lock button (13) back down

Start-up

Pay attention to the mains voltage. The voltage of the power source must match the voltage specified on the rating plate of the power tool.
Always firmly tighten the locking knob (12) and push the lock button down (13) before sawing. Otherwise the saw blade can become wedged in the workpiece.

Switching on (see figure L)

To start the power tool, first press the lock-off button (6). Then press the on/off switch (35) all the way in and keep it pressed.
Note : For safety reasons, the on/off switch (35) cannot be locked; it must remain pressed during the entire operation.

Switching off

To switch off, release the on/off switch (35).

Sawing

General sawing instructions

Always firmly tighten the locking knob (12) and push the lock button down (13) before sawing. Otherwise the saw blade can become wedged in the workpiece.
For all cuts, it must first be ensured that the saw bladeat 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.
Only saw materials which are permitted within the scope of the intended use.
Do not saw warped/bent workpieces. The workpiece must always have a straight edge to face against the fence.
The free end of long and heavy workpieces must have something placed underneath it or be supported.
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 downwards. When the tool arm is guided upwards, the retracting blade guard mustclose again over the saw blade and lock in the uppermost position of the tool arm.

Position of the operator (see figure M)

Do not stand in line with the saw blade in front of the power tool. Always stand to the side of the saw blade.
This protects your body against possible kickback.
- Keep hands, fingers and arms away from the rotating saw blade.
- Do not reach one hand across the other when in front of the tool arm

Sawing with slide movement

For cuts made using the slide device (2) (wide workpieces), loosen the locking screw (1) if it is tightened.
Set the required mitre and/or bevel angle as necessary.
Press the workpiece firmly against the fences (18) and (19).
Firmly clamp the workpiece as appropriate for its dimensions.
Pull the tool arm away from the fence (18) until the saw blade is in front of the workpiece.
Switch the power tool on.
Slowly guide the tool arm downwards using the handle (5).
Now push the tool arm towards the fences (18) and (19) and saw through the workpiece with uniform feed.
Switch off the power tool and wait until the saw blade has come to a complete stop.
Slowly guide the tool arm upwards

Sawing without slide movement (cutting off) (see figure N)

For cuts without slide movement (small workpieces), loosen the locking screw (1) if it is tightened. Push the tool arm all the way towards the fence (18) and retightenthe locking screw (1).
Set the required mitre and/or bevel angle as necessary.
Press the workpiece firmly against the fences (18) and (19).
Firmly clamp the workpiece as appropriate for its dimensions.
Switch the power tool on.
Slowly guide the tool arm downwards using the handle (5).
Saw through the workpiece applying uniform feed.
Switch off the power tool and wait until the saw blade hascome to a complete stop.
Slowly guide the tool arm upwards.

Practical advice

Marking the Cutting Line (see figure O)
A laser beam shows you 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.

To activate this, turn on the laser beam using theswitch (36).
Align your mark on the workpiece with the centre of the laser line.
Note : Before sawing, check whether the cutting line is still indicated correctly. The laser beam can be misaligned due to vibrations from intensive use, for example.

Permissible workpiece dimensions
Maximum workpiece dimensions:

Minimum workpiece dimensions (= all workpieces that can be secured left or right of the saw blade using the supplied screw clamps (20)): 130 x 50 mm (length x width)
Maximum cutting depth (0°/0°): 90 mm

Sawing workpieces of the same length (see figure P)
The length gauge (26) can be used for easily sawing workpieces of the same length.

Loosen the clamping screw (57) and move the length gauge (26) in the guide rail (58) to the required workpiece length.
Retighten the clamping screw (57).

Longer workpieces:

Loosen the wing bolt (59) and pull out the guide rail (58) as far as it will go.
Retighten the wing bolt (59).
Adjust the length gauge (26) to the required workpiece length.

Sawing without a length gauge:

Loosen the clamping screw (57) and move the length gauge (26) in the guide rail (58) all the way out.
Rotate the length gauge by 90°until it is flush with the fence (18).
Retighten the clamping screw (57).

Adjusting the depth stop (sawing the groove) (see figureQ)
The depth stop needs to be adjusted if you wish to saw a groove.

Swivel the depth stop (22) outwards.
Swivel the tool arm by the handle (5) into the required position.
Turn the adjusting screw (23) until the end of the screw touches the depth stop (22).
Slowly guide the tool arm upwards.

Special workpieces

When sawing curved or round workpieces, these must be especially secured against slipping. At the cutting line, there should be no gap between the workpiece, fence and saw table.
If necessary, you will need to manufacture special fixtures.

Replacing insert plates (see figure R)

The insert plate (10) can become worn after long use of the power tool.
Replace a defective insert plate

Bring the power tool into the work position.
Unscrew the screws (60) using a commercially available cross-headed screwdriver and remove the old insert plate (10).
Insert the new insert plate and screw the screws (60) in tight again.

Working on mouldings
Mouldings can be sawn in two different ways:

Furthermore, you can cut with or without the slide movement depending on the width of the moulding.
Always check the set mitre and/or bevel angle first by making trial cuts in scrap wood.

Adjusting the laser

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

While adjusting the laser (e.g. when moving the tool arm), never activate the on/off switch. Starting the power tool accidentally can lead to injuries.
- Bring the power tool into the work position.
- Turn the saw table (29) to the 0° detent (15). The lever must be felt to engage in the detent.

To ensure precise cuts, the laser beams must be checked and adjusted as necessary after intensive use.
Experience and suitable special tools are required for this.
A Bosch after-sales service point will handle this work quickly and reliably.

Checking (see figure S1)

Draw a straight cutting line on the workpiece.
Slowly guide the tool arm downwards using the handle (5).
Position the workpiece so that the teeth of the saw blade line up with the cutting line.
Hold the workpiece in this position and slowly guide the tool arm back up.
Clamp the workpiece.
Turn on the laser beam using the switch (36).

The laser beam must be flush with the cutting line on the workpiece along its entire length, even if the tool arm is guided downwards.

Setting (see figure S2)
Turn the set screw (61) with a suitable screwdriver until the laser beam is parallel to the entire length of the cutting line on the workpiece.

One rotation anticlockwise moves the laser beam from left to right; one rotation clockwise moves the laser beam from right to left.

Checking and Adjusting the Basic Settings

To ensure precise cuts, the basic settings of the power tool must be checked and adjusted as necessary after intensive use.
Experience and suitable special tools are required for this.
A Bosch after-sales service point will handle this work quickly and reliably

Setting the standard 0° bevel angle

Bring the power tool into the work position.
Turn the saw table (29) to the 0° detent (15). The lever must be felt to engage in the detent.
Pull the lock button (13) up.
Turn the adjustment knob (21) slightly to the left and swivel the tool arm from the right to the 0° position until you hear it click into place in the 0° position.
Push the lock button (13) back down.

Checking (see figure T1)
Position the set square (62) with the 90° angle flush with the saw blade (49) between the saw table (29) and the saw blade on the saw table (29).

The leg of the set square must be flush with the saw blade (49) along its entire length

Setting (see figure T2)

Loosen the lock nut of the stop screw (63) using a commercially available box-ended or open-ended spanner.
Turn the stop screw (63) as far in or out as needed until the leg of the set square (62) is flush with the saw blade along its entire length.
Push the lock button (13) back down.
Then re-tighten the lock nut of the stop screw (63).

If the angle indicator (55) is not aligned with the 0° mark on the scale (56) following adjustment, loosen the screw (65) using a commercially available cross-headed screwdriver and align the angle indicator along the 0° mark (see figure W).

Setting the Standard 45° Bevel Angle (right)

Bring the power tool into the work position.
Turn the saw table (29) to the 0° detent (15). The lever must be felt to engage in the detent.
Remove the right adjustable fence (19).
Turn the right stop (41) until the standard 45° bevel angle engages at the arrow mark.
Pull the lock button (13) up.
Turn the adjustment knob (21) to the left and swivel the tool arm to the right by the handle (5) as far as it will go.

Checking (see figure U1)
Position the set square (62) with the 45° angle flush with the saw blade (49) between the saw table (29) and the right-hand saw blade on the saw table.
The leg of the set square must be flush with the saw blade (49) along its entire length.

Setting (see figure U2)

Loosen the lock nut of the stop screw (40) using a commercially available box-ended or open-ended spanner.
Turn the stop screw (40) as far in or out as needed until the leg of the set square (62) is flush with the saw blade along its entire length.
Push the lock button (13) back down.
Then re-tighten the lock nut of the stop screw (40).

If the angle indicator (55) is not aligned with the 45° mark on the scale (56) following adjustment, first check the 0° setting for the bevel angle and the angle indicator once more. Then repeat the adjustment of the 45° bevel angle

Aligning the fence

Bring the power tool into the transport position.
Loosen the locking knob (12) if it is tightened.
Push the lock button (11) down and turn the saw table (29) to the 0° detent (15).
Release the lock button (11) again. The saw table must be heard to click into the detent.
Remove the adjustable fences (19).

Checking (see figure V1)
Position the set square (62) with the 90° angle flush with the saw blade (49) between the fence (18) and the saw blade on the saw table (29).
The leg of the set square must be flush with the fence along its entire length.

Setting (see figure V2)

Loosen all hex socket screws (64) with the hex key (24) provided.
Rotate the fence (18) until the set square is flush along its entire length.
Retighten the screws.
Aligning the Angle Indicator (Vertical) (see figure W)
Pull the lock button (13) up.
Turn the adjustment knob (21) slightly to the left and swivel the tool arm from the right to the 0° position until you hear it click into place in the 0° position.
Push the lock button (13) back down.

Checking
The angle indicator(55) must be in line with the 0° mark of the scale (56).

Setting

Loosen the screw (65) using a cross-headed screwdriver and align the angle indicator along the 0° mark.
Retighten the screw.

Aligning the mitre angle indicator (see figure X)

Bring the power tool into the work position
Turn the saw table (29) to the 0° detent (15). The lever must be felt to engage in the detent.

Checking
The angle indicator(14) must be in line with the 0° mark of the scale (30).

Setting

Loosen the screw (66) using a cross-headed screwdriver and align the angle indicator along the 0° mark.
Retighten the screw

Transporting the Power Tool (see figure Y)
Before transporting the power tool, the following steps must be carried out:

Loosen the locking screw (1) if it is tightened. Pull the tool arm fully forwards and retighten the locking screw.
Make sure that the depth stop (22) is pressed all the way in and that the adjusting screw (23) fits through the recess without touching the depth stop when moving the tool arm.
Bring the power tool into the transport position.
Remove all accessories that cannot be securely fitted to the power tool. If possible, transport unused saw blades in an enclosed container.
Carry the power tool by the transport handle (4) or hold it by the recessed handles (27) on the sides of the saw table.
- Only use the transport devices to transport the power tool and never the protective devices or workpiece supports.

Maintenance and Service

Maintenance and Cleaning

Pull the plug out of the socket before carrying out any work on the power tool.
To ensure safe and efficient operation, always keep the power tool and the ventilation slots clean. In order to avoid safety hazards, if the power supply cord needs to be replaced, this must be done by Bosch or by an after-sales service centre that is authorised to repair Bosch power tools.
The retracting blade guard must always be able to move freely and retract automatically. It is therefore important to keep the area around the retracting blade guard clean at all times.
Always remove dust and chips after working by blowing out with compressed air or using a brush.
Clean the guide roller (32) regularly.

Noise reduction measures
Measures implemented by the manufacturer:

Soft start
Provided with a saw blade specially developed for noise reduction
Measures implemented by the operator
Low-vibration mounting on a stable work surface
Use of saw blades with noise-reducing functions
Regular cleaning of the saw blade and power tool

After-Sales Service and Application Service

Our after-sales service responds to your questions concerning the maintenance and repair of your product as well as spare parts. You can find explosion drawings and information on spare parts at: www.bosch-pt.com
The Bosch product use advice team will be happy to help you with any questions about our products and their accessories.
In all correspondence and spare parts orders, please always include the 10‑digit article number given on the nameplate of the product.

Malaysia
Robert Bosch Sdn. Bhd.(220975-V) PT/SMY No. 8A, Jalan 13/6 46200 Petaling Jaya Selangor
Tel.: (03) 79663194
Toll- Free: 1800 880188
Fax: (03) 79583838
E-Mail : kiathoe.chong@my.bosch.com
www.bosch-pt.com.my

You can find further service addresses at:
www.bosch-pt.com/serviceaddresses

Disposal

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

Robert Bosch Power Tools GmbH
70538 Stuttgart
GERMANY
www.bosch-pt.com

References

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