Bosch GTS1041A Operating/safety Instructions Manual

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Operating/Safety Instructions Consignes de sécurité/d’utilisation Instrucciones de funcionamiento y seguridad

GTS1041A

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General Safety Rules

READ ALL INSTRUCTIONS. Failure to follow the safety rules listed below and

other basic safety precautions may result in serious personal injury.

Work Area

KEEP CHILDREN AWAY. Do not let visitors con-

tact tool or extension cord. All visitors should be kept away from work area. KEEP WORK AREAS CLEAN. Cluttered areas and benches invite accidents. MAKE WORKSHOP CHILD-PROOF with padlocks and master switches. AVOID DANGEROUS ENVIRONMENTS. Don’t use power tools in damp or wet locations. Keep work area well lit. Do not expose power tools to rain. Do not use tool in presence of flammable liquids or gases.

Personal Safety

KNOW YOUR POWER TOOL. Read the owner’s

manual and labels affixed to the tool. Learn its application and limitations as well as the specific potential hazards particular to this tool. DON’T OVERREACH. Keep proper footing and balance at all times. STAY ALERT. Watch what you are doing. Use common sense. Do not operate tool when you are tired. Do not operate while under medication or while using alcohol or other drug. DRESS PROPERLY. Do not wear loose clothing or jewelry. They can be caught in moving parts. Rubber gloves and non-skid footwear are recommended when working outdoors. Wear protective hair covering to contain long hair. USE SAFETY GOGGLES. Also face or dust mask if cutting operation is dusty, and ear plugs during extended periods of operation. GUARD AGAINST ELECTRIC SHOCK. Prevent body contact with grounded surfaces. For example: pipes, radiators, ranges, refrigerator enclosures.

DISCONNECT TOOL FROM POWER SOURCE.

When not in use, before servicing, when changing blades, bits, cutters, etc. KEEP GUARDS IN PLACE. In working order, and in proper adjustment and alignment.

REMOVE ADJUSTING KEYS AND WRENCHES. When not in use, before servicing, when

changing blades, bits, cutters, etc. AVOID ACCIDENTAL STARTING. Make sure the switch is in the “OFF” position before plugging in tool. NEVER STAND ON TOOL OR ITS STAND. Seri-

ous injury could occur if the tool is tipped or if the cutting tool is accidentally contacted. Do not store materials on or near the tool such that it is necessary to stand on the tool or its stand to reach them. CHECK FOR DAMAGED PARTS. Before further use of the tool, a guard or other part that is damaged should be carefully checked to ensure that it will operate properly and perform its intended function. Check for alignment of moving parts, mounting and any other conditions that may affect its operation. A guard or other part that is damaged should be properly replaced.

All repairs, electrical or mechanical, should be attempted only by trained repairmen. Con-

tact the nearest Bosch Factory Service Center, Authorized Service Station or other competent repair service.

Use only Bosch replacement parts. Others may create a hazard.

Use only accessories that are recommended by the manufacturer for your model. Accesso-

ries that may be suitable for one tool, may become hazardous when used on another tool.

Tool Use

DON’T FORCE TOOL. It will do the job better and

safer at the rate for which it was designed. USE THE RIGHT TOOL. Don’t force small tool or attachment to do the job of a heavy-duty tool. Don’t use tool for purpose not intended — for example; don’t use circular saw for cutting tree limbs or logs. SECURE WORK. Use clamps or a vise to hold work. It’s safer than using your hand and it frees both hands to operate the tool. USE PROPER DIRECTION OF FEED. Feed work into a blade or cutter against the direction of rotation of the blade or cutter only.

NEVER LEAVE TOOL RUNNING UNATTENDED. Turn the power off. Don’t leave tool until it

comes to a complete stop.

Tool Care

DO NOT ALTER OR MISUSE TOOL. These tools

are precision built. Any alteration or modification not specified is misuse and may result in dangerous conditions.

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General Safety Rules

READ ALL INSTRUCTIONS. Failure to follow the safety rules listed below and

other basic safety precautions may result in serious personal injury.

AVOID GASEOUS AREAS. Do not operate electric tools in gaseous or explosive atmospheres. Motors in these tools normally spark, and may result in a dangerous condition. MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for better and safer performance. Follow instructions for lubricating and changing accessories. Inspect tool cords periodically and if damaged, have repaired by authorized service facility. Inspect extension cords periodically and replace if damaged. Keep handles dry, clean and free from oil and grease. Keep saw dust from building up to the horizontal cast stop wall in the under table blade cover. See Maintenance section for more information.

Before connecting the tool to a power source (receptacle, outlet, etc.), be sure voltage supplied is the same as that specified on the nameplate of the tool. A power source with volt-

age greater than that specified for the tool can result in serious injury to the user — as well as damage to the tool. If in doubt, DO NOT PLUG IN THE TOOL. Using a power source with voltage less than the nameplate rating is harmful to the motor.

For your own safety, do not operate your table saw until it is completely assembled and installed according to the instructions.

ENSURE STABILITY OF SAW. Your table saw

MUST BE BOLTED securely to a stand or workbench. In addition, if there is any tendency for the table saw to tip over or move during certain operations such as cutting long, heavy boards, use an auxiliary support.

SELECT A PROPER WORKING LOCATION.

Use the table saw in a well lit area and on a level surface, clean and smooth enough to reduce the risk of trips and falls. Use it where neither the operator nor the casual observer is forced to stand inline with the blade.

Kickback and related warnings

Kickbacks can cause serious injury: A “KICKBACK” occurs when a part of the work piece binds between the saw blade and the rip fence or other fixed object. A work piece binding in the

blade due to misalignment, can also cause kickback. During kickback, the work piece can rise from table and be thrown toward the operator. Keep your face and body to one side of the saw blade, and out of line with the saw blade.

KICKBACKS AND POSSIBLE INJURY CAN USUALLY BE AVOIDED BY: a. Maintaining the rip fence parallel to the saw

blade.

b. Keeping the saw blade sharp and ensuring

there are no broken teeth. Replacing or sharpening anti-kickback pawls when points become dull.

c. Keeping saw blade guard, riving knife and anti-

kickback pawls in place and operating properly. The riving knife must be in alignment with the saw blade and the pawls must stop a kickback once it has started. Check their action before ripping.

d. NOT ripping a work piece that is twisted or

warped or does not have a straight edge to guide along the rip fence.

e. NOT releasing work until you have pushed it all

the way past the saw blade.

f. Using a Push Stick for ripping widths of 2” to 6”

and an auxiliary fence and Push Block for ripping widths narrower than 2” (See “Basic Saw Operation, Using The Rip Fence” section, page

34).

g. NOT confining the cut-off piece when ripping or

cross cutting.

h. When ripping, apply the feed force to the sec-

tion of the work piece between the saw blade and the rip fence. Use Push Stick or Push Block when appropriate (See item f. above).

i. Feeding material at a rate that does not tax the

saw motor.

j. Using featherboards whenever possible. k. Immediately stopping the cutting process when

resistance beyond that of normal cutting is encountered.

l. Never cutting without the use of the rip fence or

miter gauge.

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Additional Safety Warnings

READ ALL INSTRUCTIONS. Failure to follow the safety rules listed below and

other basic safety precautions may result in serious personal injury.

PROTECTION:

Eyes, hands, face, ears and body.

TO AVOID BEING PULLED INTO THE SPINNING TOOL, DO NOT WEAR:

• LOOSEFITTINGGLOVES

• LOOSECLOTHING

• NECKTIE,JEWELRY

DO:

• TIEBACKLONGHAIR

• ROLLLONGSLEEVESABOVEELBOWS

a. If any part of your saw is missing, malfunction-

ing, has been damaged or broken, such as the motor switch, or other operating control, a safety device or the power cord cease operating immediately until the particular part is properly repaired or replaced.

b. The injury mitigation system requires contact

with the operator’s body in order to react. This will cause some injury to be sustained if the contact occurs. The best defense against injury remains the knowledge of how to safely operate the saw contained within this manual and the operator’s attention to the cutting operation underway.

c. Be aware of the status indicator lights. Do not

use the tool unless you understand it is safe to use.

d. Wear safety goggles and a face shield if op-

eration is dusty. Wear ear plugs or muffs during extended periods of operation. Small loose pieces of wood or other objects that contact the rear of the rotating blade can be thrown back at the operator at excessive speed. This can usually be avoided by keeping the guard and riving knife in place for all “THROUGHCUTTING” operations (cutting entirely through the work) AND by removing all loose pieces from the table with a long stick of wood IMMEDIATELY after they are cutoff.

e. Use extra caution when the guard assembly is

removed for cutting, dadoing or rabbeting — replace the guard as soon as that operation is completed.

f. NEVER turn the saw “ON” before clearing the

table of all tools, wood scraps, etc., except the

SAVE THESE INSTRUCTIONS

work piece and related feed or support devices for the operation planned.

g. NEVER place your face or body in line with the

cutting tool.

• NEVER place your fingers andhands inthe

path of the saw blade or other cutting tool. Keep your fingers and hands at least 4 inches away from the blade or other cutting tool.

• NEVER reachin back of the cutting tool with

either hand to hold down or support the work piece, remove wood scraps, or for any other reason. Avoid awkward operations and hand positions where sudden slip could cause fingers or hand to move into a saw blade or other cutting tool. Even with the injury mitigation system engaged, these actions can lead to your hand or arms being forced into the blade at high speeds. A significant injury is likely under these conditions.

• DONOTperformanyoperation“FREEHAND”

— always use either the rip fence or the miter gauge to position and guide the work.

• NEVERusetheripfencewhencrosscuttingor

the miter gauge when ripping. DO NOT use the rip fence as a length stop.

• NEVERholdontoortouchthe“freeend”ofthe

work piece or a “free piece” that is cut off, while power is “ON” and/or the saw blade is rotating.

• Shut“OFF”thesawanddisconnectthepower

cord when removing the table insert, changing the cutting tool, removing or replacing the blade guard, resetting the safety system or making adjustments.

• Provideadequatesupporttotherearandsides

of the saw table for wider or long work pieces.

• Plasticandcomposition(likehardboard)materials may be cut on your saw. However, since these are usually quite hard and slippery, the anti-kickback pawls may not stop a kick back. Therefore, be especially attentive to following proper set-up and cutting procedures for ripping. Do not stand, or permit anyone else to stand, in line with a potential kickback.

h. If you stall or jam the saw blade in the work

piece, turn saw “OFF”, remove the work piece from the saw blade, and check to see if the saw

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blade is parallel to the table slots or grooves and if the riving knife is in proper alignment with the saw blade. If ripping at the time, check to see if rip fence is parallel with the saw blade. Readjust as indicated.

i. NEVER gang crosscut — lining up more than

one work piece in front of the blade (stacked vertically, or horizontally outward on the table) and then pushing through saw blade. The blade could pick up one or more pieces and cause a binding or loss of control and possible injury.

j. DO NOT remove small pieces of cut-off mate-

rial that may become trapped inside the blade guard while the saw is running. This could endanger your hands or cause a kick back. Turn saw “OFF” and wait until blade stops.

KNOW YOUR CUTTING TOOLS

Dull, gummy or improperly sharpened or set cutting tools can cause material to stick, jam, stall the saw, or kickback at the operator. Minimize potential injury by proper cutting tool and machine maintenance. NEVER ATTEMPT TO FREE A STALLED SAW BLADE WITHOUT FIRST TURNING THE SAW OFF.

a. NEVER use grinding wheels, abrasive cut-off

wheels, friction wheels (metal slitting blades) wire wheels or buffing and sanding wheels, molding cutter, wobble or adjustable dado.

b. USE ONLY RECOMMENDED ACCESSO-

RIES.

c. Crosscutting operations are more conveniently

worked and with greater safety if an auxiliary wood facing is attached to the miter gauge. (See Page 32).

d. Make sure the top of the cutting tool rotates to-

ward you when standing in normal operating position. Also make sure the cutting tool, arbor collars and arbor nut are installed properly. Keep the cutting tool as low as possible for the operation being performed. Keep all guards in place whenever possible.

• Do not use any blade or other cutting tool

marked for an operating speed less than 4800/ min (RPM). Never use a cutting tool larger in diameter than the diameter for which the saw was designed. For greatest safety and efficiency when ripping, use the maximum diameter blade for which the saw is designed, since under these conditions the riving knife is nearest the blade.

e. Make sure the table insert is flush or slightly

below the table surface on all sides except for rear side. NEVER operate the saw unless the proper insert is installed.

THINK SAFETY

SAFETY IS A COMBINATION OF OPERATOR COMMON SENSE AND ALERTNESS AT ALL TIMES WHEN THE TABLE SAW IS BEING USED.

Do not allow familiarity

(gained from frequent use of your table saw) to become common place. Always remember that a careless fraction of a second is sufficient to inflict severe injury.

The operation of any power tool can result in foreign objects being thrown into the eyes, which can result in severe eye damage. Always wear safety goggles

that comply with ANSI Z87.1 (shown on package) before commencing power tool operation.

Do not use a cellular phone when operating the table saw.

Some dust created by pow-

er sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

• Leadfromlead-basedpaints,

• Crystalline silica from bricks and cement and

other masonry products, and

• Arsenicandchromiumfromchemicallytreated

lumber.

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

Before each use, review all warnings located

on the table saw.

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Motor Specifications

In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This tool is equipped with an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances. This saw is wired for operation on 110-120 volts, 60 Hz. alternating current. Before connecting the motor cord to power source, make certain the switch is in the “OFF” position and be sure the electric current is of the same characteristics as stamped on the table saw nameplate.

Connection To A Power Source

This machine must be grounded while in use to protect the operator from electric shock.

Plug power cord into a 110-120V properly grounded type outlet protected by a 15-amp dual element time delay fuse or circuit breaker.

Not all outlets are properly grounded. If you are not sure that your outlet, as pictured on this page, is properly grounded; have it checked by a qualified electrician.

To avoid electric shock, do not

touch the metal prongs on the plug when installing or removing the plug to or from the outlet.

Failure to properly ground this

power tool can cause electrocution or serious shock, particularly when used near metal plumbing or other metal objects. If shocked, your reaction could cause your hands to hit the tool.

If power cord is worn, cut or

damaged in any way, have it replaced immediately to avoid shock or fire hazard.

Your unit is for use on 120

volts and is equipped with a 3-conductor cord and grounding type plug, approved by Underwriters Laboratories and the Canadian Standards Association.

The ground conductor has a green jacket and is attached to the tool housing at one end and to the ground prong in the attachment plug at the other end.

If the outlet you are planning to use for this power tool is of the two-prong type, DO NOT REMOVE OR ALTER THE GROUNDING PRONG IN ANY MANNER. Have a qualified electrician replace the TWO-prong outlet with a properly grounded THREE-prong outlet. Do not use any adapter plugs.

Improper connection of the equipment-grounding conductor can result in a risk of electric shock. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipment grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment grounding conductor to a live terminal.

Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the tool is properly grounded.

Extension Cords

Replace damaged cords im-

cords can shock, burn or electrocute.

extension cords which have 3-prong grounding type plugs and 3-pole receptacles which accept the tool’s plug. If an extension cord is

necessary, a cord with adequate size conductors should be used to prevent excessive voltage drop, loss of power or overheating. The table shows the correct size to use, depending on cord length and nameplate amperage rating of tool. If in doubt, use the next heavier gauge. Always use U.L. and CSA listed extension cords.

RECOMMENDED SIZES OF EXTENSION CORDS 120 VOLT ALTERNATING CURRENT TOOLS

Tool’s

Ampere

Rating

3-6 18 16 16 14 0.75 0.75 1.5 2.5 6-8 18 16 14 12 0.75 1.0 2.5 4.0

8-10 18 16 14 12 0.75 1.0 2.5 4.0 10-12 16 16 14 12 1.0 2.5 4.0 — 12-16 14 12 — — — — — —

NOTE: The smaller the gauge number, the heavier the cord.

mediately. Use of damaged

Always use proper extension cord. Use only 3-wire

Cord Size in A.W.G. Wire Sizes in mm

Cord length in feet Cord length in Meters

25 50 100 150 15 30 60 120

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Table of Contents

General Safety Rules....................................2

Additional Safety Warnings ........................... 4

Glossary of Terms ......................................... 7

Tools Needed for Assembly .......................... 8

Getting to Know Your Table Saw ................... 9

Unpacking And Checking Contents .............. 12

Assembly ...................................................... 13

Glossary of Terms

ANTI-KICKBACK PAWLS

Spring-loaded “fingers” that engage the work piece as it is being fed through the saw. They restrict movement of the work piece back in the direction of the operator.

ARBOR

The shaft on which a cutting tool is mounted.

ACTIVE RESPONSE TECHNOLOGY™ INJURY MITIGATION SYSTEM

The system capable of detecting contact between a human and the saw’s blade, which then pushes the blade under the table preventing a more severe injury.

BARRIER GUARD

An assembly that consists of the mounting fork and two side barriers. This assembly is intended to provide a physical barrier between the operator and the spinning saw blade.

BEVEL

Blade angle relative to the table surface.

BOSCH TOOLBOX APP

Smart phone application used in conjunction with NFC to interact with the Active Response Technology™ System

BYPASS SWITCH

The control that allows the saw user to disable the Active Response Technology™ injury mitigation system for a single cycle of the power switch.

CROSSCUT

A cutting or shaping operation made across the width of the work piece cutting the work piece to length.

DADO

A non-through cut which produces a square sided notch or trough in the work piece.

Setting / Resetting the Active Response

Technology™ system .................................... 13

Adjustments .................................................. 19

Basic Table Saw Operation ........................... 25

Maintaining your Table Saw .......................... 41

Accessories .................................................. 43

Troubleshooting ............................................ 44

ELECTRICALLY CONDUCTIVE MATERIALS

Materials that permit the flow of electrical current. Metals such as steel, aluminum, and copper are examples of electrically conductive materials.

FEATHERBOARD

A device which can help guide work pieces during rip type operation by keeping work piece in contact with the rip fence. It also helps prevent kickback.

FREEHAND

Performing a cut without a fence, miter gauge, fixture, hold down or other proper device to keep the work piece from twisting during the cut and can be a safety hazard.

GUM

A sticky, sap-based residue from wood products. After it has hardened, it is referred to as “RESIN”.

HEEL

Misalignment of the blade which causes the trailing or out feed side of the blade to contact the cut surface of the work piece. Heel can cause kickback, binding, excessive force, burning of the work piece or splintering. In general, heel creates a poor quality cut and can be a safety hazard.

KERF

The space in the work piece where the material was removed by the blade.

KICKBACK

An uncontrolled grabbing and throwing of the work piece back toward the front of the saw during a rip type operation.

LEADING END

The end of the work piece which, during a rip type operation, is pushed into the cutting tool first.

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MOLDING

A non-through cut which produces a special shape in the work piece used for joining or decoration.

NEAR FIELD COMMUNICATIONS (NFC)

A wireless technology for communicating between enabled devices such as smart phone. This tool is NFC enabled.

NON THROUGH-CUTTING

Any cutting operation where the blade does not extend through the work piece (e.g. Dado, Rabbet).

PUSH BLOCK

A device used for ripping-type operations too narrow to allow use of a Push Stick. Use a Push Block for rip widths less than 2 inches.

PUSH STICK

A device used to feed the work piece through the saw during narrow ripping-type operation and helps keep the operator’s hands well away from the blade. Use the Push Stick for rip widths less than 6 inches and more than 2 inches.

RABBET

A notch in the edge of a work piece. Also called an edge dado.

REVOLUTIONS PER MINUTE (R.P.M.)

The number of turns completed by a spinning object in one minute.

RIPPING

A cutting operation along the length of the work piece cutting the work piece to width.

RIVING KNIFE OR SPREADER

A device that keeps the kerf of the work piece open as the material is cut. This minimizes the potential of the work piece binding against the saw blade.

SMART GUARD

A system made up of 3 components: Riving Knife or Spreader, Anti-Kickback Pawls, and Main Barrier Guard.

THROUGH-CUTTING

Any cutting operation where the blade extends through the workpiece.

WORK PIECE

The item on which the cutting operation is being performed. The surfaces of a work piece are commonly referred to as faces, ends and edges.

Tools Needed for Assembly

Disconnect plug from power source before performing any assembly, adjustment or repair to avoid possible injury.

COMBINATION SQUARE MUST BE TRUE

FLAT SCREWDRIVER

COMBINATION SQUARE

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PHILLIPS SCREWDRIVER

10 MM WRENCH

OR ADJUSTABLE WRENCH

DRAW LIGHT LINE ON

BOARD ALONG THIS EDGE.

SHOULD BE NO GAP OR OVERLAP

HERE WHEN SQUARE IS FLIPPED

OVER IN DOTTED POSITION.

STRAIGHT EDGE OF BOARD

3/4” THICK. THIS EDGE

MUST BE PERFECTLY

STRAIGHT.

Getting To Know your Table Saw

1. POWER SWITCH

Switch for turning motor on and off. Switch incorporates a hole for use with padlock to prevent accidental starting.

2. TABLE

Provides large working surface to support work piece.

3. BASE / SUB-BASE

Supports table saw. Sub-base provides additional stability and ability for easy sliding onto surfaces. Holes are provided in base to bolt the saw to a workbench or stand.

4. BLADE BEVEL LOCK HANDLE

Locks the blade to desired bevel angle.

5. TABLE EXTENSION

Provides a larger work surface for wider work pieces.

6. TABLE EXTENSION LOCK HANDLE

Allows you to lock the table extension at desired distances.

7. ELEVATION WHEEL

Elevates or lowers the blade. Also used to tilt the blade 0 to 45 degrees.

8. BLADE BEVEL SCALE

Shows the degree the blade is tilted.

9. RIP FENCE SCALE

Shows the distance from the blade to rip fence through a convenient viewing and magnifying window. Lower portion of scale can be used up to

12.75 inches. Upper portion of scale is used for cuts beyond 12.75 inches.

10. MITER GAUGE

Head can be locked in desired position for crosscutting or mitering by tightening the lock knob. ALWAYS SECURELY LOCK IT WHEN IN USE.

11. RIP FENCE STORAGE

Conveniently stores rip fence on bottom of table when not in use.

12. PRE-CUT (KERF) INDICATOR

Allows you to mark and locate exactly where the blade will enter the work piece.

13. MITER GAUGE STORAGE

Conveniently stores miter gauge when not in use.

14. BLADE STORAGE & WRENCH

Allows you to store 10” blades, blade wrench and activation cartridge installation tool. Blade wrench also has a 10mm hex hole allowing assembly of the Gravity-Rise stand and for use with dado clamp bolt.

15. HEX WRENCH / PHILLIPS SCREWDRIVER

Hex wrench for adjusting various hex head bolts on saw. Phillips screwdriver is for assembling the saw to a Gravity-Rise stand.

16. CORD WRAP

Allows you to easily secure the cord so it’s out of the way when transporting or storing.

17. VACUUM HOOK-UP

Your table saw is equipped for vacuum hook-up. This feature will allow you to attach any 2-1/4” vacuum hose into the dust port provided for convenient saw-dust removal. An adaptor is available for use with alternate hose sizes.

Fig. 1

10 21 35

26 27 25

19 12

4 8

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18. RIP FENCE

Exclusive Self-Aligning, Squarelock rip fence can be easily moved or locked in place by simply raising or lowering lock handle.

19. SMART GUARD SYSTEM

Consists of three key elements: Adjustable (3 position) Riving Knife, Anti-Kickback Pawls, and Barrier Guard Device. All of these are part of a modular system that requires no tools to assemble or disassemble. This Guard System must always be in place and working properly for all through-cutting cuts.

20. SMART GUARD SYSTEM STORAGE

When not in use or for transportation, the Main Barrier Guard and Anti-Kickback Pawls can be stored under the right side table extension.

21. TABLE INSERT

Removable for removing or installing blade or other cutting tools, to adjust or store the riving knife, and to reset the Active Response Technol-

22. TABLE INSERT LOCK

Rotates to retain or eject the table insert in the table.

23. PUSH STICK

Allows you to rip smaller pieces of stock with a greater level of safety.

24. PUSH STICK STORAGE

On tool storage location for the push stick.

25. INFORMATION PANEL

The system of indicator LEDs and the NFC feature that inform the operator about the tool’s current status

26. BYPASS SWITCH

The control that allows the saw user to disable the Active Response Technology™ injury mitigation system for a single cycle of the power switch. A hole is provided to padlock this switch so that only authorized users can disable the Active Response Technology™ system.

ogy™ injury mitigation system.

Fig. 2a Fig. 2b

14 15

Fig. 2c

3420

17 1616

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27. NEAR FIELD COMMUNICATION INTERFACE

Target to place a smart phone with the Bosch power tools app next to this surface to get a status report about the saw

28. DROP ARM

Moves the blade down and away from the operator after contact between the user and the blade is detected.

29. ACTIVATION CARTRIDGE

Contains two single shot cylinders each of which can independently force drop arm to drop below table surface away from the user. Only one of the two single shot cylinders is active during operation.

30. LATCH

Ensures the drop arm is held in the proper position for operation. The latch also prevents the arm returning to the closed position until a new Activation Cartridge is properly installed

31. DROP ARM LOCK

Ensures the drop arm stays underneath the table after activation. Release for reset to operating position.

Fig. 2d

32. DETECTION PLATE

Allows the Active Response Technology™ to measure the blade for signs of user contact with the saw blade.

33. ACTIVATION CARTRIDGE RETAINER

Holds the Activation Cartridge in place during operation and activation. It must be installed properly to latch the drop arm in the operating position.

34. SIDE STORAGE COMPARTMENT

Holds spare activation cartridges, quick reset instructions, and the manual.

35. RIVING KNIFE OR SPREADER

A device that keeps the kerf of the work piece open as the material is cut. This minimizes the potential of the work piece binding against the saw blade. It is stored under table when not in use.

36. CARTRIDGE PLUG

Electrical connection that links the saw electronics to the activation cartridge.

37. RIVING KNIFE RELEASE LEVER

Lever that allows for adjustments

2237

29 28 313336

1600A009XC 09-15.indb 11 9/14/15 1:51 PM

Unpacking And Checking Contents

To avoid injury from unexpected starting or electrical

shock during unpacking and setting up, do not plug the power cord into a source of power.

This cord must remain unplugged whenever you are working on the table saw.

Model GTS1041A Table Saw is shipped complete in one carton.

Separate all parts from packing materials and check each one with the illustration and the list of loose parts to make certain all items are accounted for before discarding any packing material (Fig. 3a).

If any parts are missing, do

not attempt to assemble the table saw, plug in the power cord or turn the switch on until the missing parts are obtained and are installed correctly.

TABLE OF LOOSE PARTS (Fig. 3a)

ITEM DESCRIPTION QTY.

1 Table Saw 1 2 Rip Fence 1 3 Table Insert 1 4 Barrier Guard Assembly 1 5 Anti-Kickback Pawls 1 6 Miter Gauge 1 7 Push Stick 1 8 Activation Cartridge 1

9 Blade, 10”, 40 Tooth 1 10 Blade Wrench 1 11 Activation Cartridge Installation Tool 1 12 Hex Wrench / Philips Screwdriver 1 13 Manual 1

• Remove Styrofoam block A (for shipping pur- pose only) located between the table and motor (Fig. 3b). Styrofoam block B (not shown) is located between the drop arm and throat plate. It needs to be removed to enable the tool for it’s first use. You may cause damage to the table saw’s mechanical systems if the Styrofoam is not removed.

• Cut thecable tie thatholds the drop arm during transportation using scissors or wire cutters as shown (Fig. 3c). Then pull the cable tie out and discard.

Fig. 3a

Fig. 3b

Fig. 3c

1600A009XC 09-15.indb 12 9/14/15 1:51 PM

Assembly

SETTING / RESETTING THE ACTIVE

RESPONSE TECHNOLOGY™ INJURY

MITIGATION SYSTEM

To prevent personal injury,

always disconnect the plug from the power source before making any adjustments.

The Active Response Technology™ system prevents the motor from restarting if the switch is on when the plug is connected to a power source. Automatic restart protection helps prevent accidental startups after power has been interrupted, e.g. the tool was unplugged with the power switch locked in the ON position. To resume operation, turn power switch to the OFF position, then restart the tool.

DISASSEMBLE

1. Turn elevation wheel clockwise until the blade

is up as high as it will go, remove any parts of the Smart Guard system that were in use, then remove table insert 21 by rotating the table insert lock 22, and use the front edge (Fig. 4) to lift clear off the table.

2. Ensure the riving knife 35 is set below the top

position. Lower the riving knife by loosening the riving knife release lever 37 (Fig. 5). For more information see “POSITIONING THE RIVING KNIFE” section on page 15.

Fig. 4

Fig. 5

21A

REPLACE CARTRIDGE

3. Using the activation cartridge installation tool

loosen the activation cartridge retainer 33 counterclockwise then continue to unscrew the activation cartridge retainer by hand until it is free on the wire. Slide along the wire to the rear of the saw near the riving knife (Fig. 6).

Fig. 6

1600A009XC 09-15.indb 13 9/14/15 1:51 PM

4. If an Activation Cartridge 28 is present, discon-

nect the cartridge plug 36 from the cartridge by squeezing the latches between the thumb and forefinger, then sliding the plug back (Fig. 7).

Extreme force on this wire may damage it. The Active

Response Technology™ system will disable the saw if the wire is damaged.

5. Grasp the left cylinder of Activation Cartridge

(if present) and slide it up out of the saw. If the system has just fired the active cylinder, then the right side piston 28b will extend over an inch out of the cartridge (Fig. 7). When both pistons are extended, discard the cartridge.

6. Slide a functioning Activation Cartridge 28a into

the right position.

7. Reattach the cartridge plug 36 to the cartridge’s

right side cylinder.

8. Push down on the left cylinder Activation Car-

tridge 28 with one hand. Tighten the Activation Cartridge Retainer 33 clockwise with the other hand into the saw until it is finger tight. Then using the activation cartridge installation tool rotate tighten the retainer into place 1/8th turn further (Fig. 8).

Always tighten the activa-

tion cartridge retainer as instructed. Failure to tighten the activation car-

tridge retainer as instructed can reduce effectiveness of the Active Response Technology™ system and result in tool damage and personal injury.

Ensure the riving knife is

positioned away from the path of the hand as it moves upward. Injury to

the hand or fingers is possible if they collide. (See step 2 above)

9. Pull and hold the drop arm lock 31 toward the

front of the saw. Take the blade wrench 14 and slide it over the arbor nut. Grasp the handle tightly. Quickly pull the wrench up. The drop arm 27 should connect solidly to the latch (Fig.

9). If the drop arm 27 fails to latch, make sure the Activation Cartridge 28 is properly in place and the Activation Cartridge Retainer 33 is screwed down as instructed in step 8 above.

Fig. 7

28a 28b

Fig. 8

Fig. 9

ACTIVATION CARTRIDGE

DISPOSAL INSTRUCTIONS

Fully used activation cartridges can be recycled or discarded through standard recycling methods.

For disposal of unused activation cartridges contact your city, county, state or federal government and request information regarding the proper disposal of hazardous materials such as pyrotechnic

articles and fireworks.

1/8

REASSEMBLE

10. Raise the riving knife by loosening the riving

knife release lever 37 (Fig. 5). Position table insert 21 in pocket of table so tabs 21a on table

1600A009XC 09-15.indb 14 9/14/15 1:51 PM

insert 21 are in slots in pocket of table and push down and secure in place using table insert lock

22 (Fig.4). Re-attach the smart guard system.

ATTACHING THE

SMART GUARD SYSTEM

To prevent personal injury,

always disconnect plug from power source before attaching or removing the Smart Guard System.

POSITIONING THE RIVING KNIFE

1. Remove table insert using table insert lock.

2. Raise the blade as high as it will go and set it

perpendicular to table (0° on bevel scale) (Fig.

10).

3. Rotate the riving knife release lever 1 clock-

wise, so that it points upward (Fig. 10).

4. Pull riving knife 2 towards release lever to dis-

engage it from the pins 3 (Fig. 11).

5. Slide the riving knife 2 up to its highest posi-

tion, so that it is directly over the center of the blade (Fig. 11).

6. Align holes in riving knife with pins 3 and lock

the release lever 1 by rotating it counter-clockwise. Push/pull riving knife to verify that it is locked in place (Fig. 11).

7. Replace table insert and lock.

ATTACHING THE

GUARD ASSEMBLY

8. With one hand, hold the front of the barrier

guard assembly 4 by the metal “fork”. With the other hand, hold the guard release lever 5 up (Fig. 12).

9. Lower the rear of guard assembly and slip the

cross bar 6 into the rear notch 7 on top of the riving knife 2 (Fig. 12).

Fig. 10

Fig. 11

Fig. 12

1600A009XC 09-15.indb 15 9/14/15 1:51 PM

10. Lower the front of the guard as-

sembly 4 until the metal “fork” is parallel with the table (Fig. 13).

11. Press down on the guard re-

lease lever 5 until you feel and hear it snap into the locking position. Check that the guard assembly is properly and securely connected (Fig. 13).

ATTACHING THE

ANTI-KICKBACK PAWLS

12. Attach the Anti-Kickback Pawls

7 into the flat recessed area 8 of the riving knife 2 (Fig. 14).

13. Squeeze the compression pads

9 while nesting the device into the flat area (Fig. 14).

14. Release the compression pads

such that the Anti-Kickback Pawls lock onto the riving knife immediately behind the guard assembly. Check that the attachment pin is securely connected into locking hole. Carefully raise and lower the pawls 10 – when letting go, the spring-loaded pawls must come down and contact the table insert (Fig. 14).

Hint: Position the Anti-Kickback Pawls behind the flat recessed area and slide it towards the front until it drops into the recessed area – then release the compression pins.

Note: The two attachments are independent of each other, so the Anti-Kickback Pawls can be attached before the Guard Assembly.

Fig. 13

Fig. 14

SELECTING AND

CHANGING THE BLADE

Fig. 15

.090” RIVING KNIFE

To prevent personal injury,

always disconnect plug from power source before changing blades.

USING THE CORRECT BLADE

IMPORTANT: The saw blade provided on this

MUST BE .094” OR MORE

KERF WIDTH

BLADE TEETH

tool has a carbide-tipped kerf width of .128” and a plate (body) thickness that is .086” thick. When looking for a replacement blade, select one with

BLADE BODY PLATEMUST BE LESS THAN .090”

dimensions close to the original blade. This information may not be printed on the blades pack-

1600A009XC 09-15.indb 16 9/14/15 1:51 PM

aging. If not, check the manufacturers catalog or website. Bosch offers an extensive line of Premium-Quality Professional Saw Blades that match the requirements for this tool. You must select a blade with a kerf width of .094” or more and a plate (body) thickness .090” or less (Fig. 15).

The Active Response Technology™ injury mitigation system will function with a large variety of 10” blades and body coatings. Coatings on the body of the blade do not impact the system’s ability to detect human/blade contact.

Make several cuts using

safe crosscutting techniques to wear off any varnish from the blade teeth before beginning production work at each blade change. Blades that have varnish

coating on the teeth reduce the ability of the Active Response Technology™ injury mitigation system to detect contact between the operator and the blade.

To reduce the risk of injury,

do not use extra thin kerf saw blades. The kerf of the blade must be .094”

or more. Extra thin kerf saw blades (less than .094”) may cause the work piece to bind against the riving knife during cutting. It is recommended that the kerf of the replacement blade used on this saw be .094” or more.

To reduce the risk of injury,

do not use saw blades made with a thick body plate. If the replace-

ment saw blade’s plate thickness is greater than .088”, the riving knife would not properly serve as an aid to reduce kickback. The replacement blade’s plate thickness must be equal to or less than .088”.

To reduce the risk of injury,

do not use blade “dampeners,” “stabilizers,” or “stiffening collars” on a replacement blade. Use of these devices on

both sides will prevent the blade from being properly aligned with the riving knife, which may bind the work piece during cutting and prevent the Active Response Technology™ system from working.

Cutting tool should not be

allowed to touch or wear against the detection plate when the motor is running. Contact between the detection plate

and the cutting tool will cause the system to activate. Damage to the detection plate may cause delay or negate the ability of the Active Response Technology™ System to detect the operator’s contact with the blade. Always check to ensure

the blade spins freely before re-applying power to the saw.

CHANGING THE BLADE

1. Turn elevation wheel clockwise until the blade is up as high as it will go, remove table insert 21 by rotating the table insert lock 22, and use the front edge to lift clear off the table (Fig. 4, page 13).

Fig. 16

2. Slide and hold the arbor lock lever 2 towards the back of the saw and slowly rotate blade by hand until lock fully engages with the saw arbor and stops rotation (Fig. 16). Loosen arbor nut 3 counter clockwise with the blade wrench 4 provided (Fig. 17). Set wrench aside and continue to loosen arbor nut 3 by hand and remove arbor nut 3 and outer washer 5. Blade may now

Fig. 17

1600A009XC 09-15.indb 17 9/14/15 1:51 PM

Fig. 18

Fig. 19

be removed or installed by sliding on or off arbor shaft 6 (Fig. 18).

3. Assemble inner washer 7 and new blade as shown in figure 18, making certain the TEETH OF THE BLADE ARE POINTING DOWN AT THE FRONT OF THE TABLE. NOTE: The printing on different saw blades is not always on the same side.

4. Assemble outer washer 5 and arbor nut 3 as shown in figure 17. While holding arbor lock lever 2 securely, tighten arbor nut 3 clockwise with the wrench 4. (Fig. 16).

5. Position table insert 21 in pocket of table so tabs 21a on table insert 21 are in slots in pocket of table and push down and secure in place using table insert lock 22 (Fig.4, page 13).

ATTACHING RIP FENCE

1. Raise rip fence handle 1, so holding clamp 2 is out far enough to fit on the table 3 and into “V” groove located on the back of rear rail (Fig. 19).

2. Position the rip fence 4 over table 3 holding up the front end, first engage holding clamp 2 with rear rail.

3. Lower front end onto front rail 5.

MOUNTING THE TABLE SAW

If table saw is to be used in a permanent location, it should be fastened securely to a firm supporting surface such as a stand or workbench, using the four mounting holes 6 (Fig. 19).

1. If mounting to a workbench, the base should be bolted securely using 5/16” hex bolts (not included) through mounting holes 6.

Hint: If workbench is 3/4” thick, bolts will have to be at least 3-1/2” long - if workbench is 1-1/2” thick, bolts should be at least 4-1/2” long.

2. Locate and mark where the saw is to be mounted, relative to holes in the base of the tool.

3. Drill four (4) 3/8” diameter holes through workbench.

4. Place table saw on workbench aligning holes in base with holes drilled in workbench.

5. Insert four (4) 5/16” dia. bolts through holes in base and supporting surface; then secure with (4) 5/16” flat washers and (4) 5/16” hex nuts.

Fig. 20

5/16” HEX BOLT,

WASHER &

HEX NUT (X4)

1600A009XC 09-15.indb 18 9/14/15 1:51 PM

Adjustments

ADJUSTING 0 AND 45 DEGREE POSI-

TIVE STOPS

Your saw is equipped with positive stops for fast and accurate positioning of the saw blade at 0 and 45 degrees to the table.

The blade was adjusted at the factory. In order to insure accurate cuts, this adjustment should be rechecked. If adjustment is necessary, follow the steps below.

To prevent personal injury,

always disconnect plug from the power source when making adjustments.

1. Turn elevation wheel 2 clockwise and raise

blade to maximum height (Fig. 21).

ADJUSTING 0 DEGREE POSITIVE

STOP:

2. Loosen the blade bevel lock handle 1 and push

the elevation wheel 2 to the left as far as possible and tighten the blade bevel lock handle 1 (Fig. 21).

3. Place a combination square on the table with

one end of the square against the blade as shown (Fig. 22), and check to see if the blade is 90 degrees to the table. If the blade is not 90 degrees to the table, loosen the blade bevel lock handle 1, loosen 0 degree adjustment screw 4, loosen 0 degree bevel stop cam 5 and push the elevation wheel until the blade is 90 degrees to the table.

4. Tighten blade bevel lock handle 1, rotate the

bevel stop cam 5 until it touches the bevel stop housing 7, then tighten 0 degree adjustment screw 4.

5. Loosen adjustment screw 6 and adjust pointer

3 to indicate 0 degrees on the bevel scale.

ADJUSTING 45 DEGREE POSITIVE

STOP:

6. Loosen the blade bevel lock handle 1 and push

the elevation wheel 2 to the right as far as possible and tighten the blade bevel lock handle 1.

7. Place a combination square on the table with

one end of square against the blade as shown (Fig. 23), and check to see if the blade is 45 degrees to the table. If the blade is not 45 degrees to the table, loosen the blade bevel lock handle 1, loosen 45 degree adjustment screw 8, loosen 45 degree bevel stop cam 9 and push the

Fig. 21

8. Tighten blade bevel lock handle 1, rotate the

Fig. 22

Fig. 23

elevation wheel until the blade is 45 degrees to the table.

45 degree bevel stop cam 9 until it touches the bevel stop housing 7, then tighten 45 degree

adjustment screw 8.

1600A009XC 09-15.indb 19 9/14/15 1:51 PM

ADJUSTING BLADE PARALLEL TO

THE MITER GAUGE SLOTS

The blade was adjusted parallel to the miter gauge slots at the factory. In order to insure accurate cuts and help prevent kickback, this adjustment should be rechecked. If adjustment is necessary, follow the steps below.

To prevent personal injury,

always disconnect the plug from the power source before making any adjustments.

1. Turn elevation wheel and raise blade as high

as it will go.

2. Select a point on the body of the saw blade that

is set to the left when viewing blade from the front of saw, and mark 1 with a pencil (Fig. 24).

3. Place the base of a combination square against

the edge of the miter gauge slot, and extend the sliding rule of square so it just touches the marked point 1 on the body of the saw blade at the rear of the table.

4. Rotate blade and check the same marked point

1 of the saw blade at the front of the table (Fig.

24).

5. If the front and back measurements, shown

in Figure 24, are not identical, loosen the four alignment bolts 2, located on the top of the table one half turn at the front and rear of the saw with hex wrench supplied with your saw (Fig. 25). Carefully move the saw blade until the blade is parallel to the miter gauge slot using the combination square, and securely tighten all four bolts.

MITER GAUGE ADJUSTMENT

To check your miter gauge accuracy, move the miter gauge in line with blade and use a combination square to make sure the miter gauge body is 90 degrees to the blade (Fig. 26). To adjust the miter gauge for 90 degrees:

1. Loosen lock nut 3, adjustment screw 4, and

lock knob 5.

2. Flip stop plate 6 down.

3. Rotate miter gauge body until it is 90 degrees

to the blade.

4. Tighten lock knob 5.

5. Engage stop plate 6 and tighten adjustment

screw 4 until it contacts stop plate 6.

6. Tighten lock nut 3.

7. If pointer 7 is not pointing to 90 degrees, loosen

set screw 8 on side of miter gauge bar and ro-

Fig. 24

Fig. 25

Fig. 26

tate pointer 7 to 90 degrees mark. Tighten set screw 8.

8. To adjust the miter gauge for 45 degrees left and right, repeat steps 1-6, but use 45 degree

stops.

1600A009XC 09-15.indb 20 9/14/15 1:51 PM

ALIGNING RIP FENCE

To prevent personal injury, always disconnect plug

from power source before making any adjustments. The rip fence must be parallel with the

Saw blade in order to prevent KICKBACK when ripping.

Your table saw is equipped with a Self-Aligning, Quick-Set rip fence. Once the adjustments below have been made, the rip fence will self align when the fence is locked into position.

NOTE: The blade must be parallel with the miter gauge slots (see page 20) and be perpendicular to table before proceeding with rip fence alignment.

To prevent personal injury, always make sure the rip

fence is locked before making rip cuts.

1. Lift both guard barriers 2 to their up locked position.

2. Raise lock handle 1 and slide fence 3 until it is alongside the saw blade, by lifting right side pawl 4 above fence (Fig. 27). The fence should touch the blade teeth at the front and rear of the blade when locked. If fence does not touch the teeth at front and rear of blade continue with the following the steps:

3. Loosen the two screws 5 on the top front section of the rip fence using the included 5mm hex wrench.

4. Move fence 3 until it touches the teeth and is parallel to the blade.

5. Hold fence in place and lower lock handle, check to make sure the fence stayed parallel to the blade then tighten screws (Fig. 27).

6. Clamp rip fence to check if it holds securely at front and rear. If rear is not clamped securely, unclamp fence and turn rear clamp adjustment screw 6 clockwise for increased clamping. Try clamping the fence to verify if it self-aligns and clamps tightly at the front and rear. Overtightening of the rear clamp adjustment screw 6 will cause the rip fence to be non-self aligning (Fig.

27). Overtightening may cause friction or “chatter” when fence is moved side to side.

RIP FENCE POINTER ADJUSTMENT

The distance of the rip fence body from the blade when ripping on the right side of the blade is determined by lining the pointer 7 with the desired dimension on the scale 8 (Fig. 28).

TO SET THE RIP FENCE POINTER:

1. Lift both guard barriers 2 to their up locked position (Fig. 27).

2. Raise lock handle 1 and slide fence 3 until it is alongside the saw blade, by lifting right side pawl 4 above fence (Fig. 27).

3. Loosen pointer adjustment screw 9, adjust pointer 7 to “0” mark on lower scale 8, then re-

tighten screw 9 (Fig. 28).

Fig. 27

Fig. 28

10 11 12 13

Changing to Table Pointer

7 98

1600A009XC 09-15.indb 21 9/14/15 1:51 PM

TABLE POINTER ADJUSTMENT

If an adjustment to the table pointer is necessary, loosen pointer adjustment screw 1, adjust pointer 2 and tighten screw 1 (Fig. 29). The table pointer should always be adjusted relative to fence pointer.

1. Adjust fence pointer to (zero) – see “Rip Fence Pointer Adjustment”.

2. Slide fence to the right until it hits the stop plate on front rail and lock fence in place.

3. Look at fence pointer and note measurement on lower scale (at or near 12.75”).

4. Adjust the table pointer 2 to the same reading on upper scale as that shown on the fence pointer. Both pointers must agree when fence is at this position.

Example: If fence pointer is at 13-9/16”, then table pointer should also be set at 13-9/16”.

ADJUSTING THE TABLE INSERT

The table insert includes five (5) adjustment screws 3 to set the height (Fig. 30). Place the insert into the table. Place a straight edge (such as the metal ruler from a combination square) across the table top and insert top – the surfaces should be at the same level. Alternately, the front edge may be below the table top by the thickness of dollar bill folded twice. Place the bill between the insert and straight edge to check. The rear edge may be proud of the table by the same amount. Place the bill between the table and straight edge to check. If adjustment is necessary, use flat head screwdriver to adjust all support screws. First adjust corner adjustment screws 3 to get the alignment described above. Then adjust the center adjustment screw 3A such that it does not change the table insert alignment.

RIVING KNIFE ALIGNMENT

IMPORTANT: The Riving Knife 1 must always be

in line with the Saw Blade 2. The Riving Knife 1 is thinner than the width of the Kerf 4 by approximately three thicknesses of paper 5 on each side (Fig. 31). Note: The Kerf is the width of the cut made by the teeth on the saw blade.

To prevent personal injury,

always disconnect plug from power source before making any adjustments and when attaching or removing the Smart guard System.

Fig. 29

Fig. 30

Fig. 31

LOOKING DOWN ON

SAW

WORK

1600A009XC 09-15.indb 22 9/14/15 1:51 PM

CHECKING RIVING KNIFE

ALIGNMENT

Check riving knife align-

ment to blade periodically and make adjustments as necessary. Improp-

erly aligned riving knife may result in work piece instability, loss of control, and KICKBACK. If the riving knife is misaligned and cannot be adjusted, do not attempt to operate the saw. Have a qualified service technician perform riving knife alignment.

1. Check that the blade is properly aligned paral-

lel with the miter gauge groove per instructions listed under “Adjusting Blade Parallel to Miter Gauge slots” (page 20) and adjust the blade if necessary. Check that the rip fence is aligned with the blade (see instructions listed under “Aligning Rip Fence”, page 21) and adjust the rip fence if necessary.

2. Raise the blade to the full height (up) position.

Raise the riving knife to its full up position (see instructions listed under “Positioning The Riving Knife”, page 15). Remove the Anti-Kickback Pawls and Guard Assembly from the riving knife. Remove the insert plate.

3. Place the rip fence 3 on the left side of the table.

Carefully move the rip fence against the blade so that the rip fence is parallel to the blade and

just touches the tips of the saw teeth. Lock the rip fence and make sure the blade at the front and back is still touching the rip fence (Fig 32).

4. Using the rip fence as a guide, check the riving knife alignment with the plane of the saw blade. Since the riving knife is thinner, by approximately three thicknesses of paper on each side, than the width of the blade’s KERF (Fig

31) you must make a temporary paper “spacing gauge“. Make two folds in a small piece (6” X 6”) of ordinary newspaper making three thicknesses. Place the paper spacing gauge 5 between the riving knife 1 and the rip fence 3 (Fig 33).

5. Repeat step 4 with the rip fence 3 on the right of the blade and check with paper spacing gauge 5 (Fig. 35).

6. If the paper spacing gauge does not fit between the rip fence and the riving knife per steps 4 and 5 above, the riving knife is not correctly aligned with the blade and must be adjusted. If the riving knife needs adjustment proceed to section Adjusting Riving Knife. If the riving knife is correctly aligned with the blade then no adjustment is necessary.

NOTE: The Riving Knife has been properly aligned at the factory - Check the alignment before making any adjustments.

Fig. 32

Fig. 33

1600A009XC 09-15.indb 23 9/14/15 1:51 PM

ADJUSTING RIVING KNIFE

1. Check that the blade is properly aligned parallel with the miter guage groove per instructions listed under “Adjusting Blade Parallel to the Miter Gauge Slots (page 20) and adjust the blade if necessary. Check that the rip fence is aligned with the blade (see instructions listed under “Aligning Rip Fence” on page 21) and adjust the rip fence if necessary.

2. Raise the blade to the full height (up) position. Raise the riving knife to its full up position (see instructions listed under “Positioning The Riving Knife”, page 15). Remove the Anti-Kickback Pawls and Guard Assembly from the riving knife. Remove the insert plate.

3. Place the rip fence 3 on the left side of the table. Carefully move the rip fence against the blade so that the rip fence is parallel to the blade and just touches the tips of the saw teeth. Lock the rip fence and make sure the blade at the front and back is still touching the rip fence (Fig. 32).

4. Loosen Hex Nut 6 with 10mm open end wrench (Fig. 34). Slightly loosen Clamping Screws 8 (1/4-1/2 turns) using a 5mm hex wrench provided with table saw (stored in left side of base). Loosen Set Screw 7 using a flat screwdriver (Fig. 34).

5. Make two folds in a small piece (6“ X 6“) of ordinary newspaper making three thicknesses. Paper 5 is used as a “Spacing Gauge”.

NOTE: The spacing instructions above are based on using a standard kerf blade (.128” kerf on the Bosch blade included). If a smaller kerf blade is used, adjust the paper spacer. For instance, if the kerf of the replacement blade is near .100”, use 1 thickness of paper as a spacer; if the kerf is near .110”, use 2 thicknesses.

6. Place the paper spacing gauge 5 between the riving knife 1 and the rip fence 3 (Fig 35).Hold or clamp Riving Knife and paper firmly against Fence (Fig. 35).

a. Lightly tighten the clamp screws 8. b. Remove the paper - Slide fence away from

blade.

c. Slowly turn the Set Screw 7 while watching

the Riving Knife tilt until it is in line with the blade.

d. Recheck squareness of riving knife to table

by sliding fence against blade. Readjust if necessary.

7. After completing adjustments: a. Lightly tighten hex nut 6 (hold set screw posi-

tion with screwdriver while tightening nut).

b. Fully tighten Clamp Screws 8 with hex

wrench. Then fully tighten the hex nut.

IMPORTANT: The riving knife must always be INLINE with the saw blade body when blade is at any bevel angle. Replace the Table Insert Plate, Barrier Guard Assembly and Anti-Kickback Pawls before making cuts.

Fig. 34

Fig. 35

7 6

1600A009XC 09-15.indb 24 9/14/15 1:51 PM

Basic Table Saw Operation

USING THE ACTIVE RESPONSE

TECHNOLOGY™ INJURY MITIGATION

SYSTEM.

The Active Response Technology™ that is integral to the table saw is intended to be used together with the Smart Guard system to provide the operator the greatest level of protection. These two elements must be used together for all cuts except those that require elements of the Smart Guard to be removed (i.e. non-through cuts). Any Smart Guard components that need to be removed to complete a cut should be immediately reinstalled when finished. Always remember that the best accident prevention is the operator’s use of common sense and alertness at all times when using the table saw.

The Active Response Technology™ injury mitigation system is designed to function without limiting the performance or versatility of the table saw. This system continually monitors the saw blade for contact with the operator. If a contact is made with the operator the blade will retract under the table to reduce injury severity to the operator.

The information panel includes a lighted display that indicates saw status. Under normal conditions the system turns on a green light above the power switch. The saw can be used normally once the green light is illuminated. If the green light is not on or a blue or red light is on, then refer to the troubleshooting section on page 45. When cutting electrically conductive materials the tool can be placed in bypass mode indicated by the yellow light.

This system is designed to accommodate 25 system actuations before needing inspection by a factory authorized service center. After 25 system activations the tool will become inoperable until service is performed by a factory authorized service center. It is recommended to perform service before 25 system activations are reached. When there is one remaining activation in the system the blue service light will begin to flash when the saw is plugged in. Additionally by using the NFC function in the Bosch Toolbox App the system will provide information regarding system activations.

Always use the Smart Guard system to minimize

chances of contact between your body and spinning blade. The Active Response Technol-

ogy™ injury mitigation system activates after physical contact between the operator and the blade is made. In case the Smart Guard system is

not in use the Active Response Technology™ system will mitigate the severity of injury due to contact between operator and spinning blade. The degree of injury mitigation will depend on factors such as the direction and speed of the operator’s body movement at the time it contacts the spinning blade.

Do not touch the blade until

stop. The Active Response Technology™ injury

mitigation system is armed and will activate anytime the blade is spinning, except at 240 revolutions per minute (RPM) or less, or when in bypass mode. The detection system is active at all times the saw is connected to power and properly initiated.

it comes to a complete

THE INFORMATION PANEL

In keeping with the straightforward function of the system, the Information Panel has four lights to explain the saws current status (Fig. 36).

Green (3) – The saw is ready to use and the Active Response Technology™ injury mitigation system will activate if the user contacts the blade.

Yellow (4) – This indicator lights when the user disarms the system when using the bypass switch 1.

Red (5) – An error is present that the user can correct. For example, if the activation cartridge is installed incorrectly.

Blue (6) – An error is present that can only be corrected at a service center. For example, if the

Fig. 36

OFF

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tool has activated 25 times. Also, this light will flash when service is recommended.

For additional information and Troubleshooting see page 45.

CUTTING ELECTRICALLY

CONDUCTIVE MATERIALS

The Active Response Technology™ injury mitigation system monitors for change in the detection plate signal caused by operator contacting the blade. Some materials such as aluminum veneered plywood may mimic this effect.

Any metal, metal foil composite, or wet lumber will cause the system to react if cut.

Allow the pressure treated materials to air dry before

cutting in normal mode. Pressure treated lum-

ber is treated with chemicals that are electrically conductive when wet.

POWER SWITCH

NOTE: This table saw has two safety features that helps prevent accidental starting. The switch can be locked in the off position, see “To prevent unauthorized use” below. Also, the Active Response Technology™ system prevents the motor from restarting if the switch is on when the plug is connected to a power source.

To turn saw on: lift switch lever by pinching side walls and lifting, or reach under the switch and pull up. This action starts the saw (Fig. 37)

To turn off power: push switch lever down to its original position (Fig. 36).

To prevent unauthorized use, the switch can accommodate a padlock with a 3/16” or 1/4” diameter shackle (not provided with table saw), (Fig. 36).

BYPASS SWITCH

Use bypass mode only when cutting electrically

conductive materials. Using bypass mode

when not needed eliminates protection provided by Active Response Technology™.

If a conductive material needs to be cut, the tool has a bypass switch which disarms the Active Response Technology™ injury mitigation system. Press and hold the bypass switch A with one hand, then turn on the power switch B with the other. The saw blade will start to spin. The information panel will change from Green to Yellow (Fig. 37).

Fig. 37

When the power switch is turned off, the bypass mode will be deactivated. Then the indicator will change from Yellow to Green. The Active Response Technology™ will be active for the next cut unless the bypass switch is pressed again.

To prevent unauthorized system bypass, the switch can accommodate a padlock with a 3/16” or 1/4” diameter padlock (not provided with table saw), (Fig. 36).

NEAR FIELD COMMUNICATION (NFC)

INTERFACE

The Active Response Technology™ injury mitigation system can interface with smart phones that have NFC functionality and the Bosch Power Tools app installed.

Do not use the NFC function while the saw blade is

spinning. Distraction while cutting may result in

tool damage and serious personal injury. To connect to the NFC, launch the Bosch Toolbox

App and click the “Connect to tool” button. Place the smart phone against the Near Field Communication interface. The system will send all the current data to phone.

The operator can use this to get maintenance recommendations, reset procedures or troubleshooting procedures. You can also use this system to register the tool with Bosch. In case the tool is stolen, this registration cannot be obscured by defacing the nameplate.

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ELECTRONICALLY LOCKING THE

SAW

Using the NFC and a smart phone, the operator can lock or unlock the saw’s motor. The system ships unlocked. The user can program a fourdigit PIN, then set the lock mode.

Lock Modes: Unlocked – Any user can use the tool. Green

light indicated. Locked – The saw cannot be used until unlocked.

Red light indicated. Timer – Set a duration for the working time in

the day. When time elapses, the system enters Locked mode.

Single Use – Allow a single cut to be made.

SMART GUARD SYSTEM

The Bosch Smart Guard system is the primary safety system of this table saw. The Smart Guard system is supplemented by the Active Response Technology™. The Active Response Technology™ provides injury mitigation protection when the table saw is connected to power and smart guard system is not in use when making special cuts. Any Smart Guard components that need to be removed to complete a cut should be immediately reinstalled when finished. Always remember that the best accident prevention is the operator’s use of common sense and alertness at all times when using the table saw.

The Bosch Smart Guard System has been designed for modularity, enabling the use of multiple combinations of the three main components – Main barrier guards, Anti-Kickback Pawls, and riving knife. Additionally, the riving knife can be quickly adjusted to three positions (high, middle, and stored), depending on the application requirement.

Component parts (Fig. 38):

Fig. 38

➊ Riving Knife

The Riving Knife is the central element of the Bosch Smart Guard blade guarding system, serving as the attachment point for both the Main Barrier Guard and the Anti-Kickback Pawls. In the event that the Main Barrier Guard and Anti-Kickback Pawls are removed, the Riving Knife maintains its functionality as material splitter, and is adjustable to three positions. Because of this adjustability, the Riving Knife can be appropriately positioned for all cutting applications.

➋ Main barrier guard

The main guard is comprised of a pair of plastic barriers attached to the metal upper barrier guard. The side barriers (one to the left and one to the right of the blade) operate independently of one another, maintaining maximum blade coverage during cutting operations. The main guard incorporates a quick-connect attachment point and can be attached or removed from the blade guarding system independent of the Anti-Kickback Pawls and Riving Knife.

Note: To best secure the main guard for transport, adjust the blade to its lowest position. This keeps the guard tight to the table surface and prevents damage related to the guard swinging during transport.

➌ Anti-Kickback Pawls

In the event of kickback, the Anti-Kickback Pawls, (also known as dogs, or pawls) are intended to help prevent the board from being thrown in the direction of the user. The sharp teeth of the pawls are intended to “catch” the material in the event of kickback.

ATTACHMENT/REMOVAL

(see pages 15 and 16 for detailed instructions) The three primary components of the Smart

Guard blade guarding system are designed for rapid attachment, adjustment, and/or removal without the need for additional tools.

The Main Barrier Guard component can be quickly attached and detached through the use of a quick release lever. The guard is attached by seating the crossbar into the top of the Riving Knife and engaging the locking lever. Following this process in reverse, the guard can be easily removed for special operations such as dados or rabbets.

The Anti-Kickback Pawls can be easily attached by aligning the attachment pin with the hole in the rear of the riving knife. It can be easily removed by depressing the compression pads on either

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side of the Anti-Kickback Pawls and lifting it away. The Riving Knife can be easily adjusted to one of

three heights by removing the table insert, raising the blade to its full height and releasing the riving knife release lever at the base of the Riving Knife.

The Riving Knife should be locked in its highest position for use with the Main Barrier Guard and Anti-Kickback Pawls. It can be adjusted to its middle position for non-through cuts and for use as a material splitter without the Main Barrier Guard and Anti-Kickback Pawls. In the event that the Riving Knife cannot be used for a specific cut, it can be adjusted to its lowest position, thus placing it 1” above the surface of the table (while the blade is at its full height).

SYSTEM STORAGE

When not in use, the Main Barrier Guard and Anti-Kickback Pawls can be stored under the right side table extension.

Use of all the components

of the Smart Guard System, including Main Barrier Guard, Anti-Kickback Pawls, and Riving Knife is highly recommended to provide protection against accidents and injury.

1. Slide the Main Barrier Guard assembly (upside

down) up and back into the U-bracket at the rear right side of the saw (Fig. 39).

2. Pivot the rear of the guard up and into the front

mounting bracket.

3. Lock the Main Barrier Guard assembly into

place in the same manner as you would attach it to the Riving Knife (Fig. 40).

4. Attach the Anti-Kickback Pawls to the hanging

bracket in the same manner that it attaches to the Riving Knife.

BLADE BEVEL CONTROL

Loosen blade bevel lock handle 1 counterclockwise (Fig. 41), slide the elevation wheel 2 until pointer 3 is at desired angle and tighten blade bevel lock handle 1 clockwise.

EXTENDING TABLE EXTENSION

To extend the table, raise the table extension lock handle 4 (Fig. 41) and slide table extension 5 to desired width (Fig 42). To secure table setting, lower the lock handle 4.

Fig. 39

Fig. 40

Fig. 41

Fig. 42

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Changing to

Table Pointer

8910 11 12 13

15 14 13

PRE-CUT LOCATOR

Allows you to mark and locate exactly where the blade will enter the work piece.

Always make sure table saw is turned off and unplugged.

Set blade 1 at 90 degrees square to table. Using a straight edge and a soft pencil, place straight edge 2 against both sides of blade and mark lines on locator 3 (Fig. 43). These lines indicate the “path” of the cut (kerf) made by the blade. When cutting the work piece, line up mark on work piece with the line on the disc (Fig. 44).

USING THE RIP FENCE POINTER WHEN TABLE IS NOT EXTENDED

The rip fence pointer shows the distance from the blade to rip fence through a convenient viewing and magnifying window. Align rip fence pointer 4 with lower portion of scale 5. The lower scale can be used for widths up to 12.75 inches (Fig. 45).

USING THE TABLE POINTER WHEN

TABLE IS EXTENDED

The upper portion of scale 6 is used for rip cut

12.75 to 25 inches. Align table pointer 7 with upper portion of scale 6 (Fig. 45).

MAKING RIP CUTS BEYOND 25 INCH-

ES WITHOUT THE USE OF SCALE

When positioning fence for maximum rip without the use of scale, loosen screw 8 and lower plate 9 below the head 10 of the rip fence 11 (Fig. 45). DO NOT rip or cut dados with the fence beyond this position because it cannot be locked.

Fig. 43

Fig. 44



Fig. 45

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WORK HELPERS

Before cutting any wood on your saw, study all of the “Basic Saw Operations”.

Notice that in order to make some of the cuts, it is necessary to use certain devices, “Work Helpers”, like the Push Stick, the Push Block and the Auxiliary Fence, which you can make yourself.

After you have made a few practice cuts, make these “helpers” before starting any projects. Make the “Push Stick” first.

PUSH STICK AND PUSH BLOCK

Make the Push Stick 1 using a piece of 1 x 2 as shown (Fig. 46).

Make the Push Block 2 using pieces of 3/8” plywood 3 and 3/4” hardwood 4 (Fig. 47). For proper use of push block (see page 36).

The small piece of wood, 3/8” x 3/8” x 2-1/2”, should be GLUED to the plywood. DO NOT USE NAILS. This is to prevent dulling the saw blade in the event you mistakenly cut into the Push Block.

Position the handle in the center of the plywood and fasten together with glue and wood screws.

Use a push stick whenever the fence is 2 inches or more from the blade. Use a push block when the operation is too narrow to allow the use of a push stick. For proper use, see page 36.

Both a push stick or block should be used in the place of the user’s hand to guide the material only between the fence and blade.

When using a push stick or push block, the trailing end of the board must be square. A push stick or block against an uneven end could slip off or push the work away from the fence.

AUXILIARY FENCE

Make one using pieces of 3/8” plywood 3 and 3/4” hardwood 4. Fasten together with glue and woodscrews (Fig. 48).

NOTE: Since the Push Block 2 is used with the Auxiliary Fence 5, the 4-3/4” dimensions must be held identical on both the pieces.

MAKING A FEATHERBOARD

Fig. 49 illustrates dimensions for making a typical feather board. It should be made from a straight piece of wood that is free of knots or cracks. Kerf 5 should be about 1/4” apart (fig. 49).

Fig. 46

1-1/2

Fig. 47

2-1/2

THESE EDGES MUST BE PARALLEL

Fig. 48

THIS FACE AND THIS EDGE MUST BE PARALLEL

Fig. 49

3/4

WORK PIECE

END

1/4

4-3/4

3/8

5-1/8

21-1/2

4-1/2

2-1/2

3/8

3/4

4-3/4

45°

NOTCH

3/8

2-1/4

5-1/2

NOTE: ALL DIMENSIONS IN INCHES

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+ 114 hidden pages