BORMANN BBP3830 Power Tool Instruction Manual

BORMANN BBP3830 Power Tool

Safety instructions

WARNING! READ AND UNDERSTAND ALL INSTRUCTIONS.
Failure to follow all instructions listed below, may result in electric shock, fire and/or serious personal injury.

Work area

1. Keep work area clean and well lit. Cluttered and dark areas invite accidents.
2. 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.
3. Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

Electrical Safety

1. Do not abuse the cord. Never use the cord to carry the tool. Keep cord away from heat, oil, sharp edges, or moving parts.
   Replace damaged cords immediately. Damaged cords may create a fire.
   (The following applies only to tools with a separate battery pack)
2. A battery operated tool with integral batteries or a separate battery pack must be recharged only with the specified charger for the battery. A charger that may be suitable for one type of battery may create a risk of fire when used with another battery.

Personal Safety

1. 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.
2. Dress properly. Do not wear loose clothing or jewellery. Contain long hair. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jew-ellery, or long hair can be caught in moving parts.
3. Avoid accidental starting. Be sure switch is in the locked or off position before inserting batter pack. Carrying tools with your finger on the switch invites accidents.
4. Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enable better control of the tool in unexpected situations
5. Use safety equipment. Always wear eye protection, Dust mask, non-skid safety shoes, hard hat, or hearing protection must be used for appropriate condi-tions.

Power tool use and care

1. Use clamps or other practical ways to secure and support the work piece to a stable platform. Holding the work piece by hand or against your body is unstable and may lead to loss of control.
2. Do not force tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed.
3. Do not use tool if switch does not turn it on of off. A tool that cannot be controlled with the switch is dangerous and must be repaired.
4. Store idle tools out of reach of children and other untrained persons. Tools are dangerous in the hands of untrained users
5. Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools with sharp cutting edge are less likely to bind and are easier to control.
6. Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tool’s operation. If damaged, have the tool serviced before using .Many accidents are caused by poorly maintained tools.
7. Use only accessories that are supplied with your model. Other accessories that may not be suitable for this tool and may create a risk of injury when used.

Specific Safety Rules Cutting procedures

1. DANGER: Keep hands away from cutting area and the blade. Keep your second hand on auxiliary handle, or motor housing. If both hands are holding the saw, they cannot be cut by the blade.
2. Do not reach underneath the workpiece. The guard cannot protect you from the blade below the workpiece.
3. Adjust the cutting depth to the thickness of the workpiece. Less than a full tooth of the blade teeth should be visible below the workpiece.
4. Never hold the workpiece in your hands or across your leg while cutting. Secure the workpiece to a stable platform. It is important to support the work properly to minimise body exposure, blade binding, or loss of control.
5. Hold the power tool by insulated gripping surfaces, when performing an operation where the cutting tool may contact hidden wiring. Contact with a “live” wire will also make exposed metal parts of the power tool “live” and could give the operator an electric shock.
6. When ripping, always use a rip fence or straight edge guide. This improves the accuracy of cut and reduces the chance of blade binding.
7. Always use blades with correct size and shape (diamond versus round) of arbour holes. Blades that do not match the mounting hardware of the saw will run off-centre, causing loss of control.
8. Never use damaged or incorrect blade washers or bolt. The blade washers and bolt were specially designed for your saw, for optimum performance and safety of operation.

Kickback causes and related warnings

—Kickback is a sudden reaction to a pinched, jammed or misaligned saw blade, causing an uncontrolled saw to lift up and out of the workpiece toward the operator;
—When the blade is pinched or jammed tightly by the kerf closing down, the blade stalls and the motor reaction drives the unit rapidly back toward the operator;
—If the blade becomes twisted or misaligned in the cut, the teeth at the back edge of the blade can dig into the top surface of the wood causing the blade to climb out of the kerf and jump back toward the operator.
Kickback is the result of saw misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below.

1. Maintain a firm grip with both hands on the saw and position your arms to resist kickback forces. Position your body to either side of the blade, but not in line with the blade. Kickback could cause the saw to jump backwards, but kickback forces can be controlled by the operator, if proper precautions are taken.
2. When blade is binding, or when interrupting a cut for any reason, release the trigger and hold the saw motionless in the material until the blade comes to a complete stop. Never attempt to remove the saw from the work or pull the saw backward while the blade is in motion or kickback may occur. Investigate and take corrective actions to eliminate the cause of blade binding.
3. When restarting a saw in the workpiece, centre the saw blade in the kerf so that the saw teeth are not engaged into the material. If a saw blade binds, it may walk up or kickback from the work- piece as the saw is restarted.
4. Support large panels to minimise the risk of blade pinching and kickback. Large panels tend to sag under their own weight. Supports must be placed under the panel on both sides, near the line of cut and near the edge of the panel.
5. Do not use dull or damaged blades. Unsharpened or improperly set blades produce narrow kerf causing excessive friction, blade binding and kickback.
6. Blade depth and bevel adjusting locking levers must be tight and secure before making the cut. If blade adjustment shifts while cutting, it may cause binding and kickback.
7. Use extra caution when sawing into existing walls or other blind areas. The protruding blade may cut objects that can cause kickback.
8. ALWAYS hold the tool firmly with both hands. NEVER place your hand, leg or any part of your body under the tool base or behind the saw, especially when making cross-cuts. If kickback occurs, the saw could easily jump backwards over your hand, leading to serious personal injury.
9. Never force the saw. Push the saw forward at a speed so that the blade cuts without slowing. Forcing the saw can cause uneven cuts, loss of accuracy, and possible kickback.

Lower guard function

1. Check the lower guard for proper closing before each use. Do not operate the saw if the lower guard does not move freely and close instantly. Never clamp or tie the lower guard into the open position. If the saw is accidentally dropped, the lower guard may be bent. Raise the lower guard with the retracting handle and make sure it moves freely and does not touch the blade or any other part, in all angles and depths of cut.
2. Check the operation of the lower guard spring. If the guard and the spring are not operating properly, they must be serviced before use. Lower guard may operate sluggishly due to damaged parts, gummy deposits, or a build-up of debris.
3. The lower guard may be retracted manually only for special cuts such as “plunge cuts” and “compound cuts”. Raise the lower guard by the retracting handle and as soon as the blade enters the material, the lower guard must be released. For all other sawing, the lower guard should operate automatically.
4. Always observe that the lower guard is covering the blade before placing the saw down on bench or floor. An unprotected, coasting blade will cause the saw to walk backwards, cutting whatever is in its path. Be aware of the time it takes for the blade to stop after switch is released.
5. To check lower guard, open lower guard by hand, then release and watch guard closure. Also check to see that retracting handle does not touch tool housing. Leaving blade exposed is VERY DANGEROUS and can lead to serious personal injury.

Additional safety warnings

1. Use extra caution when cutting damp wood, pressure treated lumber, or wood containing knots. Maintain smooth advancement of tool with- out decrease in blade speed to avoid overheating the blade tips.
2. Do not attempt to remove cut material when blade is moving. Wait until blade stops before grasping cut material. Blades coast after turn off.
3. Avoid cutting nails. Inspect for and remove all nails from lumber before cutting.
4. Place the wider portion of the saw base on that part of the workpiece which is solidly supported, not on the section that will fall off when the cut is made. If the workpiece is short or small, clamp it down. DO NOT TRY TO HOLD SHORT PIECES BY HAND!
5. Before setting the tool down after completing a cut, be sure that the guard has closed and the blade has come to a complete stop.
6. Never attempt to saw with the circular saw held upside down in a vise. This is extremely dangerous and can lead to serious accidents.
7. Some material contains chemicals which may be toxic. Take caution to prevent dust inhalation and skin contact. Follow material supplier safety data.
8. Do not stop the blades by lateral pressure on the saw blade.
9. Do not use any abrasive wheels.
10. Only use the saw blade with the diameter that is marked on the tool or specified in the manual. Use of an incorrectly sized blade may affect the proper guarding of the blade or guard operation which could result in serious personal injury.
11. Keep blade sharp and clean. Gum and wood pitch hardened on blades slows saw and increases potential for kickback. Keep blade clean by first removing it from tool, then cleaning it with gum and pitch remover, hot water or kerosene. Never use gasoline.
12. Wear a dust mask and hearing protection when use the tool.
13. Always use the saw blade intended for cutting the material that you are going to cut.
14. Only use the saw blades that are marked with a speed equal or higher than the speed marked on the tool.
15. (For European countries only) Always use the blade which conforms to EN847-1.

WARNING : KEEP THESE INSTRUCTIONS IN A SAFE PLACE FOR FUTURE REFERENCE.

Important safety instructions for battery cartridge

WARNING : DO NOT let comfort or familiarity with product (gained from repeated use) replace strict adherence to safety rules for the subject product. MISUSE or failure to follow the safety rules stated in this instruction manual may cause serious personal injury.

1. Before using battery cartridge, read all instructions and cautionary markings on (1) battery charger, (2) battery, and (3) product using battery.
2. Do not disassemble battery cartridge.
3. If operating time has become excessively shorter, stop operating immediately. It may result in a risk of overheating, possible burns and even an explosion.
4. If electrolyte gets into your eyes, rinse them out with clear water and seek medical attention right away. It may result in loss of your eyesight.
5. Do not short the battery cartridge:
(1) Do not touch the terminals with any conductive material.
(2) Avoid storing battery cartridge in a container with other metal objects such as nails, coins, etc.
(3) Do not expose battery cartridge to water or rain
A battery short can cause a large current flow, overheating, possible burns and even a breakdown.
6. Do not store the tool and battery cartridge in locations where the temperature may reach or exceed 50 °C (122 °F).
7. Do not incinerate the battery cartridge even if it is severely damaged or is completely worn out. The battery cartridge can explode in a fire.
8. Be careful not to drop or strike battery.
9. Do not use a damaged battery.
10. Lithium-ion batteries are subject to the Dangerous Goods Legislation requirements.
For commercial transports e.g. by third parties, forwarding agents, special requirement on pack- aging and labelling must be observed. For preparation of the item being shipped, consulting an expert for hazardous material is required. Please also observe possibly more detailed national regulations. Tape or mask off open contacts and pack up the battery in such a manner that it cannot move around in the packaging.
11. Follow your local regulations relating to disposal of battery.

Symbols

The following show the symbols used for the equipment. Be sure that you understand their meaning before use.

WARNING : Always wear protective goggles to protect your eyes from injury when using power tools. The goggles must comply with EN 166 in Europe, it is legally required to wear a face shield to protect your face, too.

Recommended and Proper Use
The tool is intended for performing lengthways and crossways straight cuts and miter cuts with angles in wood while in firm contact with the workpiece. With appropriate Bormann genuine saw blades, other materials can also be sawed.

Description of main parts (picture A)

1. Circular Saw Blade
2. Lower guard
3. Lock-off Button
4. Switch trigger
5. Soft Handle
6. Laser
7. Base
8. Rip fence (Guide rule)*
9. Upper guard
10. Dust outlet
11. Cutting angle adjust clamping screw
12. Clamping screw
13. Cutting depth adjust clamping screw
14. Hex wrench
15. Front Grip
16. Shaft lock
17. Battery Cartridge (sold separately)
18. Button of Battery Cartridge
19. on/off switch of laser
    (): not available on all models.

Technical data

35mm at 45°

• The manufacturer reserves the right to make minor changes to product design and technical specifications without prior notice unless these changes significantly affect the performance and safety of the products. The parts described / illustrated in the pages of the manual that you hold in your hands may also concern other models of the manufacturer’s product line with similar features and may not be included in the product you just acquired.

• To ensure the safety and reliability of the product and the warranty validity, all repair, inspection or replacement work, including maintenance and special adjustments, must only be carried out by technicians of the authorized service department of the manufacturer.

• Always use the product with the supplied equipment. Operation of the product with non-provided equipment may cause malfunctions or even serious injury or death. The manufacturer and the importer shall not be liable for injuries and damages resulting from the use of non-conforming equipment.

• This tool is delivered without battery and charger.
  To purchase a compatible battery and charger for the tool, please contact one of our partner retail stores.

Operating instructions

CAUTION : Always be sure that the tool is switched off and the battery cartridge is removed before adjusting or checking function on the tool.

Installing or removing battery cartridge
CAUTION: Always switch off the tool before installing or removing of the battery cartridge.
CAUTION: Hold the tool and the battery cartridge firmly when installing or removing battery cartridge. Failure to hold the tool and the battery cartridge firmly may cause them to slip off your hands and result in damage to the tool and battery cartridge and a personal injury.

1. Button
2. Battery cartridge

To remove the battery cartridge, slide it from the tool while sliding the button on the front of the cartridge. To install the battery cartridge, align the tongue on the battery cartridge with the groove in the housing and slip it into place. Insert it all the way until it locks in place with a little click.

CAUTION

• Always install the battery cartridge fully. If not, it may accidentally fall out of the tool, causing injury to you or someone around you.
• Do not install the battery cartridge forcibly. If the cartridge does not slide in easily, it is not being inserted correctly.
• Always bring down the base when installing/removing the batteries. Be careful not to pinch your fingers.
• Do not use the battery adapter with the circular saw. The cable of the battery adapter may hinder the operation and result in personal injury.

Battery protection system
The tool is equipped with a battery protection system. This system automatically cuts off power to the motor to extend battery life. The tool will automatically stop during operation if the tool and/or battery are placed under one of the following conditions:
Overload protection: The tool is operated in a manner that causes it to draw an abnormally high current. In this situation, turn the tool off and stop the application that caused the tool to become overloaded. Then turn the tool on to restart. If the tool does not start, the battery is overheated. In this situation, let the battery cool before turning the tool on again.

Overheat protection When the tool/battery is overheated, the tool stops automatically. In this situation, let the tool/battery cool before turning the tool on again.
Overdischarge protection: The remaining battery capacity is too low and the tool will not operate. In this situation, remove and recharge the battery.

Indicating the remaining battery capacity
Press the check button on the battery cartridge to indicate the remaining battery capacity. The indicator lamps light off immediately when release the check button. Below for detail remaining capacity information.

Switch action
WARNING:

• Before installing the battery cartridge into the tool, always check to see that the switch trigger actuates properly and returns to the “OFF” position when released.
• NEVER defeat the lock-off button by taping down or some other means. A switch with a negated lock-off button may result in unintentional opera-tion and serious personal injury.
• NEVER use the tool if it runs when you simply pull the switch trigger without pressing the lock-off button. A switch in need of repair may result in unintentional operation and serious personal injury. Return tool to a Bormann service center for proper repairs BEFORE further usage.

To prevent the switch trigger from being accidentally pulled, a lock-off button is provided. To start the tool, depress the lock-off button and pull the switch trigger. The tool will start-ing running in maximal speed immediately. Release the switch trigger to stop.
NOTICE : Do not pull the switch trigger hard without pressing in the lock-off button. This can cause switch breakage.
CAUTION : The tool starts to brake the circular saw blade rotation immediately after you release the switch trigger. Hold the tool firmly to respond the reaction of the brake when releasing the switch trigger. Sudden reaction can drop the tool off your hand and can cause a personal injury.

Adjusting depth of cut
CAUTION : After adjusting the depth of cut, always tighten the clamping screw securely.

Turn anticlockwise to loosen the cutting depth adjust clamping screw and move the base up or down. At the desired depth of cut, secure the base by tightening the clamping screw through turning it clockwise.
For cleaner, safer cuts, set cut depth so that no more than one blade tooth projects below workpiece.
Using proper cut depth helps to reduce potential for dangerous KICKBACKS which can cause personal injury.

Bevel cutting
CAUTION: After adjusting the bevel angle, always tighten the clamping screws securely.

Loosen the cutting angle adjust clamping screw and move the base up or down.
At the desired angle of cut, secure the base by tightening the clamping screw through turning it clockwise.
Tighten the clamping screw when you do precise 45° angle cutting.
Fully turn the stopper as illustrated depending on 0° – 45° bevel cut.

Sighting
For straight cuts, align the 0° position on the front of the base with your cutting line.
For 45° bevel cuts, align the 45° position with it.

Laser for straight cutting
CAUTION : Do not look in the laser or see the source of laser directly. Do not Laser on any other people or animal.

For better and easy straight cuts, a laser is provided.
To light on the laser, depress the on/off switch directly.
To light off the laser, depress the on/off switch again. The laser goes out immediately after depress the button again.
NOTE: Use a dry cloth to wipe the dirt off the lens of the laser. Be careful not to scratch the lens of laser, or it may lower the illumination.

Electric brake
This tool is equipped with an electric blade brake. If the tool consistently fails to quickly stop the circular saw blade after switch lever release, have tool serviced at a Bormann service center.

CAUTION : The blade brake system is not a substitute for blade guard.
NEVER USE TOOL WITHOUT A FUNCTIONING BLADE GUARD. SERIOUS PERSONAL INJURY CAN RESULT.

Electronic function
The tools equipped with electronic function are easy to operate because of the following feature(s). Soft start feature Soft start because of suppressed starting shock.

Assembly Instructions

CAUTION : Always be sure that the tool is switched off and the battery cartridge is removed before carrying out any work on the tool.

Hex wrench storage
When not in use, store the hex wrench as shown in the figure to keep it from being lost.

Removing or installing circular saw blade
CAUTION : Be sure the circular saw blade is installed with teeth pointing up at the front of the tool. CAUTION: Use only the Bormann wrench to install or remove the circular saw blade.
To remove the circular saw blade, press the shaft lock fully so that the circular saw blade cannot revolve and use the hex wrench to loosen the hex bolt. Then remove the hex bolt, outer flange, circular saw blade and Inner flange.

To install the circular saw blade, follow the removal procedure in reverse.

The inner flange has a certain diameter protrusion on one side of it and a different diameter protrusion on the other side.
Choose a correct side on which protrusion fits into the saw blade hole perfectly.
Mount the inner flange onto the mounting shaft so that the correct side of protrusion on the inner flange faces outward and then place saw blade and outer flange.

WARNING : BE SURE TO TIGHTEN THE HEX BOLT CLOCKWISE SECURELY.
Also be careful not to tighten the bolt forcibly. Slipping your hand from the hex wrench can cause a personal injury.
WARNING : Make sure that the protrusion “a” on the inner flange that is positioned outside fits into the saw blade hole “a” perfectly. Mounting the blade on the wrong side can result in the dangerous vibration.

Blade guard cleaning
When changing the circular saw blade, make sure to also clean the upper and lower blade guards of accumulated sawdust as discussed in the Maintenance section. Such efforts do not replace the need to check lower guard operation before each use.
WARNING : This tool is intended to cut wood products. With appropriate Bormann genuine circular saw blades, following materials can also be sawed:

Checking blade guard function
Set the bevel angle to 0°, and then retract the lower guard manually to the end and release it. The lower guard is properly functioning, if:

• it is retracted above the base without any hindrance and;
• it automatically returns and contacts with the stopper.

If the lower guard is not functioning properly, check if saw dust is accumulated inside of the upper and lower guards.
If the lower guard is not functioning properly even after removing dust, have your tool serviced at a Bormann service center.

Cutting operation

CAUTION : Wear dust mask when performing cutting operation.
CAUTION : Be sure to move the tool forward in a straight line gently. Forcing or twisting the tool will result in overheating the motor and dangerous kickback, possibly causing severe injury.
NOTE : When the battery cartridge temperature is low, the tool may not work to its full capacity. At this time, for example, use the tool for a light-duty cut for a while until the battery cartridge warms up as high as room temperature. Then, the tool can work to its full capacity.

• Hold the tool firmly. The tool is provided with both a front grip and rear handle.
• Use both to best grasp the tool. If both hands are holding saw, they cannot be cut by the circular saw blade.
• Set the base on the workpiece to be cut without the circular saw blade making any contact.
• Then turn the tool on and wait until the circular saw blade attains full speed.
• Now simply move the tool forward over the workpiece surface, keeping it flat and advancing smoothly until the sawing is completed.
• To get clean cuts, keep your sawing line straight and your speed of advance uniform.
• If the cut fails to properly follow your intended cut line, do not attempt to turn or force the tool back to the cut line.
• Doing so may bind the circular saw blade and lead to dangerous kickback and possible serious injury.
• Release switch, wait for circular saw blade to stop and then withdraw tool.
• Realign tool on new cut line, and start cut again.
• Attempt to avoid positioning which exposes operator to chips and wood dust being ejected from saw. Use eye protection to help avoid injury.
• NOTICE : Do not cover vents when working, or it may cause over-heating and damage to the tool.
• NOTE : If the tool is operated continuously until the battery cartridge has discharged, allow the tool to rest for 15 minutes before proceeding with a fresh battery.

Rip fence (Guide rule)
CAUTION : Make sure that the rip fence is securely installed in the correct position before use. Improper attachment may cause dangerous kickback.
The handy rip fence allows you to do extra-accurate straight cuts. Simply slide the rip fence up snugly against the side of the workpiece and secure it in position with the clamping screw on the front of the base. It also makes repeated cuts of uniform width possible.

Maintenance

• CAUTION : Always be sure that the tool is switched off and the battery cartridge is removed before attempting to perform inspection or maintenance.
• NOTICE : Never use gasoline, benzine, thinner, alcohol or the like. Discolouration, deformation or cracks may result.
• CAUTION : Clean out the upper and lower guards to ensure there is no accumulated sawdust which may impede the operation of the lower guarding system. A dirty guarding system may limit the proper operation which could result in serious personal injury.
• The most effective way to accomplish this cleaning is with compressed air. If the dust is being blown out of the guards, be sure the proper eye and breathing protection is used.
• CAUTION : After each use, wipe off the saw dust on the tool. Fine saw dust may come inside the tool and cause malfunction or a fire.
• To maintain product safety and reliability, repairs, any other maintenance or adjustment should be performed by Bormann authorized or factory service centers, always using Bormann replacement parts.

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