Bosch GSG 300 Professional Foam Rubber Cutter Instructions

BOSCH GSG 300 Professional Foam Rubber Cutter Instructions

(1) 2 607 018 013 (d<70 mm)
(2) 2 608 135 023

(1) 2 607 018 010 (d<130 mm)
(2) 2 608 135 020

(1) 2 607 018 011 (d<200 mm)
(2) 2 608 135 021

(1) 2 607 018 012 (d<300 mm)
(2) 2 608 135 022

1 609 200 265

Safety Notes

General Power Tool Safety Warnings

WARNING
Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

Save all warnings and instructions for future reference.

The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

Work area safety

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

Electrical safety

• Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.
• Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
• Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
• Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges and moving parts. Damaged or entangled cords increase the risk of electric shock.
• When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
• If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.

Personal safety

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

Power tool use and care

• Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.
• Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
• Disconnect the plug from the power source and/or the battery pack from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.
• Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.
• Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
• Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
• Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.

Service

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

Safety Warnings for Foam Rubber Cutters

Hold power tool by insulated gripping surfaces, when performing an operation where the cutting accessory may contact hidden wiring or its own cord. Cutting accessory contacting a “live” wire may make exposed metal parts of the power tool “live” and could give the operator an electric shock.

Keep hands away from the sawing range. Do not reach under the workpiece. Contact with the saw blade can lead to injuries.

Products sold in GB only: Your product is fitted with an BS 1363/A approved electric plug with internal fuse (ASTA approved to BS 1362).
If the plug is not suitable for your socket outlets, it should be cut off and an appropriate plug fitted in its place by an authorised customer service agent. The replacement plug should have the same fuse rating as the original plug. The severed plug must be disposed of to avoid a possible shock hazard and should never be inserted into a mains socket elsewhere.
Products sold in AUS and NZ only: Use a residual current device (RCD) with a rated residual current of 30 mA or less.

Functional Description

 Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

While reading the operating instructions, unfold the graphics page for the machine and leave it open.

Intended Use

The machine is intended for the cutting of flexible foamed materials made of plastic, rubber or similar materials.

Product Features

The numbering of the product features refers to the illustration of the machine on the graphics page.

1. On/Off switch
2. Saw blade guide*
3. Saw blade pair*
4. Base plate
5. Handle (insulated gripping surface)
6. Screw
7. Cover plate
8. Knurled screw
9. Tensioning screw for base plate

Accessories shown or described are not part of the standard delivery scope of the product. A complete overview of accessories can be found in our accessories program.

Technical Data

Protection class

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

Please observe the article number on the type plate of your machine. The trade names of the individual machines may vary.

Noise/Vibration Information

Measured sound values determined according to EN 60745.

Typically the A-weighted noise levels of the product are: Sound pressure level 81 dB(A); Sound power level 92 dB(A). Uncertainty K =3 dB.

Wear hearing protection!

Vibration total values (triax vector sum) determined according to EN 60745: Vibration emission value ah =2.5 m/s2, Uncertainty K =1.5 m/s2.

The vibration emission level given in this information sheet has been measured in accordance with a standardised test given in EN 60745 and may be used to compare one tool with another. It may be used for a preliminary assessment of
exposure.
The declared vibration emission level represents the main applications of the tool. However if the tool is used for different applications, with different accessories or poorly maintained, the vibration emission may differ. This may significantly increase the exposure level over the total working period.
An estimation of the level of exposure to vibration should also take into account the times when the tool is switched off or when it is running but not actually doing the job. This may significantly reduce the exposure level over the total working period.
Identify additional safety measures to protect the operator from the effects of vibration such as: maintain the tool and the accessories, keep the hands warm, organisation of work patterns.

Declaration of Conformity

We declare under our sole responsibility that the product described under “Technical Data” is in conformity with the following standards or standardization documents: EN 60745 according to the provisions of the directives 2004/108/EC, 2006/42/EC.

Technical file at:
Robert Bosch GmbH, PT/ESC, D-70745 Leinfelden-Echterdingen

Dr. Egbert Schneider
Senior Vice President Engineering

Dr. Eckerhard Strötgen
Head of Product Certification

Robert Bosch GmbH, Power Tools Division D-70745 Leinfelden-Echterdingen Leinfelden, 17.05.2010

Assembly

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

Mounting the Saw Blade Guide (see figure A)

Remove the screws 6 from the housing. Attach the saw blade guide 2 onto the housing in such a manner that the mounting pins engage into the corresponding holes and secure with the screws 6.

Inserting/Replacing Saw Blades (see figure B)

When mounting the saw blade, wear protective gloves. Danger of injury when touching the saw blade.
Loosen and remove the knurled screws 8 together with the spring washers and the cover plate 7.

1. Firstly, insert the saw blade pair 3 into the bottom of the saw blade guide 2, paying attention that the longitudinal grooves of the saw blades engage into the guide pin of the saw blade guide.
2. Secondly, locate the top of the saw blade pair 3 onto the drive tappets, ensuring that the saw blades are properly seated in the saw blade guide.

Place the cover plate 7 onto the set screws on the housing and secure them with the knurled screws 8, ensuring that the spring washers have also been mounted.

Mounting the Base Plate (see figure C)

Insert the saw blade guide 2 into the corresponding notch on the base plate 4. Tighten the tensioning screw 9.

Dust/Chip Extraction

Dusts from materials such as lead-containing coatings, some wood types, minerals and metal can be harmful to one’s health. Touching or breathing-in the dusts can cause allergic reactions and/or lead to respiratory infections of the user or bystanders. Certain dusts, such as oak or beech dust, are considered as carcinogenic, especially in connection with wood-treatment additives (chromate, wood preservative). Materials containing asbestos may only be worked by specialists.

• As far as possible, use a dust extraction system suitable for the material.
• Provide for good ventilation of the working place.
• It is recommended to wear a P2 filterclass respirator.

Observe the relevant regulations in your country for the materials to be worked.

Operation

Starting Operation

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

Switching On and Off

To start the machine, press the On/Off switch 1 and keep it pressed.

To lock the pressed On/Off switch 1, slide the On/Off switch 1 toward the rear.

To switch off the power tool, release the On/Off switch 1, or when it is locked, briefly press the On/Off switch 1 and then release it.

Working Advice

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

Saw Blades and Saw Blade Guides
Depending on the material thickness to be worked, various saw blade guides and the corresponding saw blades can be used. See the Accessories Overview for more details.

Base Plate
The foam rubber cutter can be used with or without the base plate. The base plate is equipped with rollers, and allows for easy and right-angled guidance of the cutter. For cutting random forms and for cutouts, it is recommended to work without the base plate.

Cutting Foam
For precise cuts, especially with soft foams and similar materials, work only with moderate feed. To not press the material together or squeeze it apart too excessively while working.
Dismount the base plate for smaller cutouts. Puncture the material using a knife or a pair of scissors, then insert the saw blade guide into the opening und work the cutout.
For larger cutouts, select an entry opening large enough to insert the saw blade guide with the mounted base plate. Pay attention that no obstacles are on the bottom of the material. Guide the power tool with moderate pressure alongside the cutout line.

Maintenance and Service

Maintenance and Cleaning

Before any work on the machine itself, pull the mains plug.
For safe and proper working, always keep the machine and ventilation slots clean.

The saw blade guide and the saw blades at regular intervals, approx. after 8 hours of operation. Remove the saw blades from the power tool for this and preferably clean the saw blades with petrol. If required, use a scraper to clean the saw blade guide. Apply a light coat of oil onto the saw blade guide before assembling new or resharpened saw blades.
If the machine should fail despite the care taken in manufacturing and testing procedures, repair should be carried out by an after-sales service centre for Bosch power tools.
In all correspondence and spare parts order, please always include the 10-digit article number given on the type plate of the machine.

After-sales Service and Customer Assistance

Our after-sales service responds to your questions concerning maintenance and repair of your product as well as spare parts. Exploded views and information on spare parts can also be found under:
www.bosch-pt.com
Our customer service representatives can answer your questions concerning possible applications and adjustment of products and accessories.

Great Britain
Robert Bosch Ltd. (B.S.C.)
P.O. Box 98
Broadwater Park
North Orbital Road
Denham
Uxbridge
UB 9 5HJ
Tel. Service: +44 (0844) 736 0109
Fax: +44 (0844) 736 0146
E-Mail:

Ireland
Origo Ltd.
Unit 23 Magna Drive
Magna Business Park
City West
Dublin 24
Tel. Service: +353 (01) 4 66 67 00
Fax: +353 (01) 4 66 68 88

Australia, New Zealand and Pacific Islands
Robert Bosch Australia Pty. Ltd.
Power Tools
Locked Bag 66
Clayton South VIC 3169
Customer Contact Center
Inside Australia:
Phone: +61 (01300) 307 044
Fax: +61 (01300) 307 045
Inside New Zealand:
Phone: +64 (0800) 543 353
Fax: +64 (0800) 428 570
Outside AU and NZ:
Phone: +61 (03) 9541 5555
www.bosch.com.au

Republic of South Africa

Customer service
Hotline: +27 (011) 6 51 96 00

Gauteng – BSC Service Centre
35 Roper Street, New Centre
Johannesburg
Tel.: +27 (011) 4 93 93 75
Fax: +27 (011) 4 93 01 26
E-Mail:

KZN – BSC Service Centre
Unit E, Almar Centre
143 Crompton Street
Pinetown
Tel.: +27 (031) 7 01 21 20
Fax: +27 (031) 7 01 24 46
E-Mail:

Western Cape – BSC Service Centre
Democracy Way, Prosperity Park
Milnerton
Tel.: +27 (021) 5 51 25 77
Fax: +27 (021) 5 51 32 23
E-Mail:

Bosch Headquarters
Midrand, Gauteng
Tel.: +27 (011) 6 51 96 00
Fax: +27 (011) 6 51 98 80
E-Mail:

People’s Republic of China
Website: www.bosch-pt.com.cn

China Mainland
Bosch Power Tools (China) Co., Ltd.
567, Bin Kang Road
Bin Jiang District 310052
Hangzhou, P.R.China
Service Hotline: 400 826 8484
Fax: +86 (571) 87 77 45 02
E-Mail:

HK and Macau Special Administrative Regions
Robert Bosch Hong Kong Co. Ltd.
21st Floor, 625 King’s Road
North Point, Hong Kong
Customer Service Hotline: +852 (21) 02 02 35
Fax: +852 (25) 90 97 62
E-Mail:
www.bosch-pt.com.cn

Indonesia
PT. Multi Tehaka
Kawasan Industri Pulogadung
Jalan Rawa Gelam III No. 2
Jakarta 13930
Indonesia
Tel.: +62 (21) 46 83 25 22
Fax: +62 (21) 46 82 86 45/68 23
E-Mail:
www.multitehaka.co.id

Philippines
Robert Bosch, Inc.
28th Floor Fort Legend Towers,
3rd Avenue corner 31st Street,
Fort Bonifacio Global City,
1634 Taguig City, Philippines
Tel.: +63 (2) 870 3871
Fax: +63 (2) 870 3870

www.bosch-pt.com.ph
Bosch Service Center:
9725-27 Kamagong Street
San Antonio Village
Makati City, Philippines
Tel.: +63 (2) 899 9091
Fax: +63 (2) 897 6432

Malaysia
Robert Bosch (S.E.A.) Pte. Ltd.
No. 8A, Jalan 13/6
G.P.O. Box 10818
46200 Petaling Jaya
Selangor, Malaysia
Tel.: +60 (3) 7966 3194
Fax: +60 (3) 7958 3838

Toll-Free: 1800 880 188
www.bosch-pt.com.my

Thailand
Robert Bosch Ltd.
Liberty Square Building
No. 287, 11 Floor
Silom Road, Bangrak
Bangkok 10500
Tel.: +66 (2) 6 31 18 79 – 18 88 (10 lines)
Fax: +66 (2) 2 38 47 83
Robert Bosch Ltd., P. O. Box 2054
Bangkok 10501, Thailand
Bosch Service – Training Centre
2869-2869/1 Soi Ban Kluay
Rama IV Road (near old Paknam Railway)
Prakanong District
10110 Bangkok
Thailand
Tel.: +66 (2) 6 71 78 00 – 4
Fax: +66 (2) 2 49 42 96
Fax: +66 (2) 2 49 52 99

Singapore
Robert Bosch (SEA) Pte. Ltd.
11 Bishan Street 21
Singapore 573943
Tel.: +65 6571 2772
Fax: +65 6350 5315

Toll-Free: 1800 333 8333
www.bosch-pt.com.sg

Vietnam
Robert Bosch Vietnam Co. Ltd
10/F, 194 Golden Building
473 Dien Bien Phu Street
Ward 25, Binh Thanh District
84 Ho Chi Minh City
Vietnam
Tel.: +84 (8) 6258 3690 ext. 413
Fax: +84 (8) 6258 3692

www.bosch-pt.com

Disposal

The machine, accessories and packaging should be sorted for environmental-friendly recycling.

Do not dispose of power tools into household waste!

Only for EC countries:
 According to the European Guideline 2002/96/EC for Waste Electrical and Electronic Equipment and its implementation into national right, power tools that are no longer usable must be collected separately and disposed of in an environmentally correct manner.