Bosch GTS 635-216 Professional Table Saw Instruction Manual

BOSCH GTS 635-216 Professional Table Saw

General Power Tool Safety Warnings

Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

Work Area Safety

Keep work area clean and well lit. Cluttered or dark areas invite accidents.
Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.
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 or moving parts. Damaged or entangled cords increase the risk of electric shock.
When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) 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 a dust mask, non-skid safety shoes, hard hat or hearing protection used for appropriate conditions will reduce personal injuries.
Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energizing 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 jewelry. Keep your hair and clothing away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards.
Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.

Power Tool Use and Care

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

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 Instructions for Table Saws

Guarding Related Warnings

Keep guards in place. Guards must be in working order and be properly mounted. A guard that is loose, damaged, or is not functioning correctly must be repaired or replaced.
Always use saw blade guard and riving knife for every through-cutting operation. For through-cutting operations where the saw blade cuts completely through the thickness of the workpiece, the guard and other safety devices help reduce the risk of injury.
Immediately reattach the guarding system after completing an operation (such as rabbeting) which requires removal of the guard and/or riving knife. The guard and riving knife help to reduce the risk of injury.
Make sure the saw blade is not contacting the guard, riving knife or the workpiece before the switch is turned on. Inadvertent contact of these items with the saw blade could cause a hazardous condition.
Adjust the riving knife as described in this instruction manual. Incorrect spacing, positioning and alignment can make the riving knife ineffective in reducing the likelihood of kickback.
For the riving knife to work, it must be engaged in the workpiece. The riving knife is ineffective when cutting workpieces that are too short to be engaged with the riving knife. Under these conditions a kickback cannot be prevented by the riving knife.
Use the appropriate saw blade for the riving knife. For the riving knife to function properly, the saw blade diameter must match the appropriate riving knife and the body of the saw blade must be thinner than the thickness of the riving knife and the cutting width of the saw blade must be wider than the thickness of the riving knife.

Cutting Procedures Warnings

DANGER: Never place your fingers or hands in the vicinity or in line with the saw blade. A moment of inattention or a slip could direct your hand towards the saw blade and result in serious personal injury.
Feed the workpiece into the saw blade only against the direction of rotation. Feeding the workpiece in the same direction that the saw blade is rotating above the table may result in the workpiece, and your hand, being pulled into the saw blade.
Never use the mitre gauge to feed the workpiece when ripping and do not use the rip fence as a length stop when cross cutting with the mitre gauge. Guiding the workpiece with the rip fence and the mitre gauge at the same time increases the likelihood of saw blade binding and kickback.
When ripping, always apply the workpiece feeding force between the fence and the saw blade. Use a push stick when the distance between the fence and the saw blade is less than 150mm, and use a push block when this distance is less than 50 mm. “Work helping” devices will keep your hand at a safe distance from the saw blade.
Use only the push stick provided by the manufacturer or constructed in accordance with the instructions. This push stick provides sufficient distance of the hand from the saw blade.
Never use a damaged or cut push stick. A damaged push stick may break causing your hand to slip into the saw blade.
Do not perform any operation “freehand”. Always use either the rip fence or the mitre gauge to position and guide the workpiece. “Freehand” means using your hands to support or guide the workpiece, in lieu of a rip fence or mitre gauge. Freehand sawing leads to misalignment, binding and kickback.
Never reach around or over a rotating saw blade. Reaching for a workpiece may lead to accidental contact with the moving saw blade.
Provide auxiliary workpiece support to the rear and/or sides of the saw table for long and/or wide work-pieces to keep them level. A long and/or wide workpiece has a tendency to pivot on the table’s edge, causing loss of control, saw blade binding and kickback.
Feed workpiece at an even pace. Do not bend or twist the workpiece. If jamming occurs, turn the tool off immediately, unplug the tool then clear the jam. Jamming the saw blade by the workpiece can cause kickback or stall the motor.
Do not remove pieces of cutoff material while the saw is running. The material may become trapped between the fence or inside the saw blade guard and the saw blade pulling your fingers into the saw blade. Turn the saw off and wait until the saw blade stops before removing material.
Use an auxiliary fence in contact with the table top when ripping workpieces less than 2 mm thick. A thin workpiece may wedge under the rip fence and create a kickback.

Kickback Causes and Related Warnings

Kickback is a sudden reaction of the workpiece due to a pinched, jammed saw blade or misaligned line of cut in the workpiece with respect to the saw blade or when a part of the workpiece binds between the saw blade and the rip fence or other fixed object.
Most frequently during kickback, the workpiece is lifted from the table by the rear portion of the saw blade and is propelled towards the operator.
Kickback is the result of saw misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below.

Never stand directly in line with the saw blade. Always position your body on the same side of the saw blade as the fence. Kickback may propel the workpiece at high velocity towards anyone standing in front and in line with the saw blade.
Never reach over or in back of the saw blade to pull or to support the workpiece. Accidental contact with the saw blade may occur or kickback may drag your fingers into the saw blade.
Never hold and press the workpiece that is being cut off against the rotating saw blade. Pressing the workpiece being cut off against the saw blade will create a binding condition and kickback.
Align the fence to be parallel with the saw blade. A misaligned fence will pinch the workpiece against the saw blade and create kickback.
Use a feather board to guide the workpiece against the table and fence when making non-through cuts such as rabbeting. A feather board helps to control the workpiece in the event of a kickback.
Support large panels to minimize the risk of saw blade pinching and kickback. Large panels tend to sag under their own weight. Support(s) must be placed under all portions of the panel overhanging the table top.
Use extra caution when cutting a workpiece that is twisted, knotted, warped or does not have a straight edge to guide it with a mitre gauge or along the fence. A warped, knotted, or twisted workpiece is unstable and causes misalignment of the kerf with the saw blade, binding and kickback.
Never cut more than one workpiece, stacked vertically or horizontally. The saw blade could pick up one or more pieces and cause kickback.
When restarting the saw with the saw blade in the workpiece, center the saw blade in the kerf so that the saw teeth are not engaged in the material. If the saw blade binds, it may lift up the workpiece and cause kickback when the saw is restarted.
Keep saw blades clean, sharp, and with sufficient set. Never use warped saw blades or saw blades with cracked or broken teeth. Sharp and properly set saw blades minimize binding, stalling and kickback.

Table Saw Operating Procedure Warnings

Turn off the table saw and disconnect the power cord when removing the table insert, changing the saw blade or making adjustments to the riving knife or saw blade guard, and when the machine is left unattended. Precautionary measures will avoid accidents.
Never leave the table saw running unattended. Turn it off and don’t leave the tool until it comes to a complete stop. An unattended running saw is an uncontrolled hazard.
Locate the table saw in a well-lit and level area where you can maintain good footing and balance. It should be installed in an area that provides enough room to easily handle the size of your workpiece. Cramped, dark areas, and uneven slippery floors invite accidents.
Frequently clean and remove sawdust from under the saw table and/or the dust collection device. Accumulated sawdust is combustible and may selfignite.
The table saw must be secured. A table saw that is not properly secured may move or tip over.
Remove tools, wood scraps, etc. from the table before the table saw is turned on. Distraction or a potential jam can be dangerous.
Always use saw blades with correct size and shape
(diamond versus round) of arbor holes. Saw blades that do not match the mounting hardware of the saw will run off-centre, causing loss of control.
Never use damaged or incorrect saw blade mounting means such as flanges, saw blade washers, bolts or nuts. These mounting means were specially designed for your saw, for safe operation and optimum performance.
Never stand on the table saw, do not use it as a stepping stool. Serious injury could occur if the tool is tipped or if the cutting tool is accidentally contacted.
Make sure that the saw blade is installed to rotate in the proper direction. Do not use grinding wheels, wire brushes, or abrasive wheels on a table saw. Improper saw blade installation or use of accessories not recommended may cause serious injury.

Additional Safety Warnings

When mounting the saw blade, wear protective gloves. This poses a risk of injury.
Do not use HSS saw blades. Such saw blades can easily break.
Only use saw blades that match the specifications given in this operating manual and that are tested and marked in accordance with EN 847-1
Never use the tool without the table insert. Replace table insert if defective. Without flawless table inserts, injuries are possible from the saw blade.
Keep your work area clean. Material mixtures are particularly hazardous. Light metal dust may catch fire or explode.
Choose the saw blade suited to the material you want to work on.
Only use saw blades that are recommended by the power tool manufacturer and are suitable for using on the material you want to saw.
Only advance the workpiece towards the saw blade when it is running. Otherwise there is a risk of kickback occurring if the saw blade catches in the workpiece.

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 authorized 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.

Product Description and Specifications

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

Intended Use

The power tool is a stationary machine for cutting in a straight line with and against the grain in hardwood, softwood, chipboard and fiberboard. Mitre angles of –30° to+30° as well as bevel angles of 0° to 45° are possible.
It is also possible to saw aluminum profiles and plastic using the appropriate saw blades.

Product Features

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

Scale for spacing between saw blade and parallel guide.
Angle guide
Protective cover
Riving knife
Parallel guide
Saw table expansion
Angle guide storage compartment
Assembly holes
Ring spanner (24 mm; 23 mm)
Hex key (5 mm)
Bracket for storing the protective cover
Push stick
Clamping handle for saw table expansion
Hand wheel
Crank for raising and lowering the saw blade
Safety flap for the on/off switch
Stop for 45° bevel angle
Locking lever for setting the bevel angle
Scale for bevel angles
Stop for 0° bevel angle
Saw table
Adjusting screw for adjusting the clamping force of the parallel guide
Table insert
Saw blade
Guide groove for parallel guide
Cable holder
Carrying handle
Guide groove for angle guide
Dust extraction adapter
V guide groove on the saw table for the parallel guide
(31) Base plate
(32) Locking screw for base grid
(33) Clamping lever/clamp markings
(34) Clamping lever for riving knife
Positioning pins for riving knife
Table insert locking screw
Clamping lever for protective cover
Guide pin for protective cover
Clamping handle for parallel guide
V guide for parallel guide
Additional parallel guide
“Additional parallel guide” fastening set
Guide rail for angle guide
Lower saw blade cover
Tab for lower saw blade cover
Gripping hole for lifting the table insert
Clamping nut
Spindle locking lever
Clamping flange
Mounting flange
Tool spindle
Angle indicator (vertical)
Locking knob for all mitre angles
Angle indicator on the angle guide
Magnifying glass
Saw table spacing indicator
On button
Viewing window
Cross-head screw for setting the 0° stop
Screw for bevel angle indicator
Cross-head screw for setting the 45° stop
Hex socket screws (5 mm) on the front for adjusting the parallelism of the saw blade
Hex socket screws (5 mm) on the rear for adjusting the parallelism of the saw blade
Screw for saw table spacing indicator
Hex socket screws (5 mm) for adjusting the parallelism of the parallel guide
Screw for parallel guide spacing indicator
Adjusting screws for table insert
Push stick storage compartment
Hex key storage compartment
Ring spanner storage compartment

Noise Information

Noise emission values determined according to
EN 62841-3-1.
Typically, the A-weighted noise level of the power tool is: Sound pressure level 94 dB(A); sound power level
103 dB(A). Uncertainty K = 3 dB.
Wear hearing protection!
The noise emission value given in these instructions has been measured in accordance with a standardized measuring procedure and may be used to compare power tools. It may also be used for a preliminary estimation of noise emissions.
The noise emission value given represents the main applications of the power tool. However, if the power tool is used for other applications, with different application tools or is poorly maintained, the noise emission value may differ. This may significantly increase noise emissions over the total working period.
To estimate noise emissions accurately, the times when the tool is switched off, or when it is running but not actually being used, should also be taken into account. This may significantly reduce noise emissions over the total working period.

Assembly

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

Items Included

Check to ensure that all the parts listed below have been supplied before using the power tool for the first time:

Table saw with fitted saw blade (24) and riving knife (4)
Angle guide (2)
Parallel guide (5)
Additional parallel guide (41)
“Additional parallel guide” fastening set (42) (2 fastening screws, 2 washers, 2 wing nuts)
Protective cover (3)
Hex key (10)
Ring spanner (9) with slotted screwdriver tip
Push stick (12)
Table insert (23)

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

Fitting Individual Components

Carefully remove all parts included in the delivery from their packaging.
Remove all packing material from the power tool and the accessories provided.
Turn the locking screws (32) as far as possible in the “Unlock” direction using the tip of the ring spanner (9) and open the base grid (31).
Remove the packing material under the motor block.

The following tool elements are attached directly to the tool housing: Push stick (12), ring spanner (9), hex key (10), parallel guide (5), angle guide (2), extraction adapter (29), additional parallel guide (41) with fastening set (42), protective cover (3).

If you require one of these parts, remove it carefully from its storage location.

Positioning the Riving Knife
Note: If necessary, clean all parts to be fitted before you position them.

Turn the crank (15) clockwise as far as possible so that the saw blade (24) is in the highest possible position above the saw table.
Release the clamping lever (34) clockwise until it points upwards.
Slide the riving knife (4) towards the clamping lever (34) until it can be pulled upwards.
Pull the riving knife all the way up until it is positioned exactly over the center of the saw blade.
Allow both pins (35) to engage in the lower bore holes in the riving knife and then retighten the clamping lever (34).
The markings (33) on the clamp and clamping lever (34) must be aligned as shown.

Fitting the Table Insert

Place the table insert (23) over the riving knife (4) and into the tool chamber.
Turn the locking screw (36) as far as it will go in the “Lock” direction using the tip of the ring spanner (9).

The front side of the table insert (23) must lie flush with or a little below the saw table; the rear must lie flush with or a little above the saw table.

Fitting the Protective Cover
Note: Only fit the protective cover when the riving knife is in the top position directly over the center of the saw blade (see figure b2). Do not fit the protective cover when the riving knife is in the bottom position (position when delivered/position for sawing grooves).

Loosen the clamping lever (37) and remove the protective cover (3) from the bracket (11).
Hold the saw blade guard (upper metal rail) of the protective cover (3) with one hand, while using the other hand to move the clamping lever (37) up.
Push the guide pin (38) backwards into the groove on the riving knife (4).
Move the protective cover (3) down until the saw blade guard (upper metal rail) is parallel with the surface of the saw table (21).
Push the clamping lever (37) down. The clamping lever must be felt and heard to engage; the protective cover (3) must be securely and safely fitted.
Always check that the blade guard can move properly before use. Do not use the power tool if the blade guard cannot move freely and does not close immediately.

Fitting the Parallel Guide
The parallel guide (5) can be positioned on either the left or the right of the saw blade.

Loosen the clamping handle (39) of the parallel guide (5). This lightens the load on the V guide (40).
First insert the parallel guide with the V guide into the guide groove (30) of the saw table. Then position the parallel guide in the front guide groove (25) of the saw table. The parallel guide can now be moved freely.
To secure the parallel guide, push the clamping handle (39) down.

Fitting the Additional Parallel Guide
To saw narrow workpieces and bevel angles, you must fit the additional parallel guide (41) on the parallel guide (5). The additional parallel guide can be fitted on the left or right of the parallel guide (5) as required.
Use the “additional parallel guide” fastening set (42) (two fastening screws, two washers, two wing nuts) for fitting the guide.

Slide the fastening screws through the lateral holes on the parallel guide (5).
The heads of the screws are used to guide the additional parallel guide.
Slide the additional parallel guide (41) over the heads of the fastening screws.
Place the washers on the fastening screws and tighten the screws using the wing nuts.

Fitting the Angle Guide

Push the rail (43) of the angle guide (2) into one of the guide grooves (28) provided in the saw table.

Stationary or Flexible Mounting

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

Mounting on a Work Surface

Use suitable screw fasteners to secure the power tool to the work surface. The holes (8) are used for this purpose.

Mounting on a Bosch Saw Stand
Thanks to their height-adjustable legs, Bosch saw stands (e.g. GTA 560) provide firm support for the power tool on any surface.

Read all the warnings and instructions included with the saw stand. Failure to observe the warnings and follow instructions may result in electric shock, fire and/or serious injury.
Assemble the saw stand properly before mounting the power tool. Correct assembly is important to prevent the risk of collapsing.
- Mount the power tool on the saw stand in the transport position.

Dust/Chip Extraction

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

Use a dust extraction system that is suitable for the material wherever possible.
Provide good ventilation at the workplace.
It is advisable to wear a P2 filter class breathing mask. The regulations on the material being machined that apply in the country of use must be observed.
The dust/chip extraction system can be blocked by dust, chips or fragments of the workpiece.
Switch the power tool off and pull the mains plug out of the socket.
Wait until the saw blade has come to a complete stop.
Determine the cause of the blockage and eliminate it.
Avoid dust accumulation at the workplace. Dust can easily ignite.
To prevent the risk of fire when sawing aluminum, empty the lower saw blade cover and do not use chip extraction.

Cleaning the Lower Saw Blade Cover
You can open the lower saw blade cover (44) to remove workpiece fragments and large chips.

Switch the power tool off and pull the mains plug out of the socket.
Wait until the saw blade has come to a complete stop.
Turn the power tool on its side.
Open the base grid (31) (see figure a).
Gently pull apart the tabs (45) of the lower saw blade cover and open the lower saw blade cover (44).
Remove workpiece fragments and chippings.
Close the lower saw blade cover (44) again, making sure that the tabs click into place (45).
Close the base grid (31).
Bring the power tool into the work position.

External Dust Extraction

Firmly insert a suitable dust extraction hose into the dust extraction adapter (29).

The dust extractor must be suitable for the material being worked.
When extracting dry dust that is especially detrimental to health or carcinogenic, use a special dust extractor.

Changing the Saw Blade

Pull the plug out of the socket before carrying out any work on the power tool.
When mounting the saw blade, wear protective gloves. This poses a risk of injury.
Only use saw blades the maximum permitted speed of which is higher than the no-load speed of the power tool.
Only use saw blades that match the specifications given in this operating manual and that are tested and marked in accordance with EN 847-1
Only use saw blades that are recommended by the power tool manufacturer and are suitable for use on the material you want to saw. This prevents the saw tooth tips from overheating and the plastic you want to saw from melting.
Do not use HSS saw blades. Such saw blades can easily break.

Removing the Saw Blade

Open the clamping lever (37) and pull the protective cover (3) out of the groove on the riving knife (4).
Turn the locking screw (36) as far as possible in the “Unlock” direction using the tip of the ring spanner (9) and lift the table insert (23) out of the tool chamber. A gripping hole (46) is integrated into the tool for ease of lifting.
Turn the crank (15) clockwise as far as possible so that the saw blade (24) is in the highest possible position above the saw table.
Turn the clamping nut (47) using the ring spanner (9) while pulling the spindle locking lever (48) until it engages.
Keep pulling the spindle locking lever and unscrew the clamping nut anticlockwise.
Remove the clamping flange (49).
Remove the saw blade (24).

Fitting the Saw Blade

If necessary, clean all the parts you want to fit before installing them.
Place the new saw blade on the mounting flange (50) of the tool spindle (51).

Note: Use sufficiently large saw blades. The radial clearance between the saw blade and the riving knife must not exceed 3-8 mm (max.).

When fitting the saw blade, make sure that the cutting direction of the teeth (direction of the arrow on the saw blade) matches the direction of the arrow on the riving knife.
Fit the clamping flange (49) and the clamping nut (47).
Turn the clamping nut (47) using the ring spanner (9) while pulling the spindle locking lever (48) until it engages.
Tighten the clamping nut by turning it clockwise.
Place the table insert (23) over the riving knife (4) and into the tool chamber. Turn the locking screw (36) as far as it will go in the “Lock” direction using the tip of the ring spanner (9).
Refit the protective cover (3).

Operation

Pull the plug out of the socket before carrying out any work on the power tool.

Transport position and work position of the saw blade

Transport Position

Remove the protective cover (3), remove the table insert (23) and place the riving knife (4) in the bottom position. Reinsert the table insert (23).
Turn the crank (15) anticlockwise until the teeth of the saw blade (24) lie below the saw table (21).
Push the saw table expansion (6) in fully.
Push the clamping handle (13) down. This fixes the saw table expansion in place.

Work Position

Position the riving knife (4) in the top position directly over the center of the saw blade, insert the table insert (23) and fit the protective cover (3).
Turn the crank (15) clockwise until the top teeth of the saw blade (24) are approx. 3-6 mm above the workpiece.

Extending the Saw Table

The free end of long and heavy workpieces must have something placed underneath it or be supported.

Saw Table Expansion
The saw table expansion (6) increases the width of the saw table (21) on the right.

Pull the clamping handle (13) for the saw table expansion all the way up.
Pull out the saw table expansion (6) to the required length.
Push the clamping handle (13) down. This fixes the saw table expansion in place.

Setting Mitre and Bevel Angles

To ensure precise cuts, the basic settings of the power tool must be checked and adjusted as necessary after intensive use.

Setting Bevel Angles (Saw Blade)
The bevel angle can be set between 0° and 45°.

Loosen the locking lever (18) by turning it anticlockwise.

Note: When the locking lever is fully loosened, gravity causes the saw blade to tilt into a position that corresponds to approximately 30°.

Pull or push the hand wheel (14) along the slotted link until the angle indicator (52) shows the required bevel angle.
Hold the hand wheel in this position and retighten the locking lever (18).

For quick and precise setting of the standard bevel angles of 0° and 45°, there are preset stops ((20)),((17)).

Setting Mitre Angles (Angle Guide)
Note: Use appropriate equipment for making tapering cuts (long tapers).
The mitre angle can be set between 30° (left-hand side) and 30° (right-hand side).

Loosen the locking knob (53) if it is tightened.
Turn the angle guide until the angle indicator (54) shows the desired mitre angle.
Retighten the locking knob (53).

Adjusting the Parallel Guide

The parallel guide (5) can be positioned on the left or the right of the saw blade. The marking in the magnifying glass (55) indicates the set distance of the parallel guide to the saw blade on the scale (1).
Position the parallel guide on the required side of the saw blade.

Adjusting the parallel guide when the saw table is not pulled out

Loosen the clamping handle (39) of the parallel guide (5). Move the parallel guide until the marking in the magnifying glass (55) indicates the desired distance from the saw blade.
When the saw table is not pulled out, the lower marking on the silver scale applies (1).
To secure it in place, push the clamping handle (39) back down.

Adjusting the parallel guide when the saw table is pulled out

Position the parallel guide on the right of the saw blade. Move the parallel guide until the marking in the magnifying glass (55) shows 29 cm on the lower scale.
To secure it in place, push the clamping handle (39) back down.
Pull the clamping handle (13) for the saw table expansion all the way up.
Pull out the saw table expansion (6) until the spacing indicator (56) shows the desired distance from the saw blade on the upper scale.
Push the clamping handle (13) down.
This fixes the saw table expansion in place.

Adjusting the Additional Parallel Guide

To saw narrow workpieces and bevel angles, you must fit the additional parallel guide (41) on the parallel guide (5). The additional parallel guide can be fitted on the left or right of the parallel guide (5) as required.
When sawing, workpieces can become jammed between the parallel guide and the saw blade, caught in the saw blade as it rises and ejected.
You should therefore set the additional parallel guide so that the end of the guide is between the front tooth of the saw blade and the front edge of the riving knife.

To do so, loosen all wing nuts of the fastening set (42) and move the additional parallel guide until only the front two screws are used for attachment.
Retighten the wing nuts.

Adjusting the Riving Knife

The riving knife (4) prevents the saw blade (24) from becoming jammed in the kerf. Otherwise there is a risk of kick-back occurring if the saw blade catches in the workpiece. It is therefore important to ensure that the riving knife is set up correctly:

The radial clearance between the saw blade and the riving knife must not exceed 3-8 mm (max.).
The thickness of the riving knife must be smaller than the cutting width and larger than the base blade thickness.
The riving knife must always be aligned with the saw blade.
For normal cuts, the riving knife must always be in the highest possible position.

Adjusting the Riving Knife Height
The height of the riving knife must be adjusted in order to saw grooves.

Only use the power tool for grooving or routing if a suitable protective guard (e.g. tunnel blade guard, feather board) is in place.
Open the clamping lever (37) and pull the protective cover (3) out of the groove on the riving knife (4).
To prevent damage to the protective guard, store it in the bracket (11) provided on the housing.
Turn the crank (15) clockwise as far as possible so that the saw blade (24) is in the highest possible position above the saw table.
Release the clamping lever (34) clockwise until it points upwards.
Pull the riving knife off the pins (35) (pull the clamping lever (34) outwards slightly) and push the riving knife (4) down as far as possible.
Allow both pins (35) to engage in the upper bore holes in the riving knife and then retighten the clamping lever (34).
The markings (33) on the clamp and clamping lever (34) must be aligned as shown.

Start-up

Pay attention to the mains voltage. The voltage of the power source must match the voltage specified on the rating plate of the power tool.
Products that are only sold in AUS and NZ: Use a residual current device (RCD) with a nominal residual current of 30 mA or less.

Switching on

To start, press the green “on” button (57).

Switching off

Press the safety flap (16).

Power Outage
The on/off switch acts as a zero-voltage switch that prevents the power tool from starting up again following a power outage (e.g. if the mains plug is removed during operation). To restart the power tool following a power outage, press the green “on” button (57) again.

Protection Against Unauthorized Use
To protect against unauthorized use, you can lock the safety flap of the on/off switch (16) with a padlock.

Slide the viewing window (58) all the way up and gently press on the safety flap.
Fit a padlock through the two eyelets in the viewing window and the eyelet in the base plate of the on/off switch.

Practical Advice

General Sawing Instructions

Before making any cuts, first make sure that the saw blade cannot come into contact with the stops or any other parts of the tool at any time.
Only use the power tool for grooving or routing if a suitable protective guard (e.g. tunnel blade guard, feather board) is in place.
Do not use the power tool for cutting slots (stopped grooves).

Protect the saw blade against impact and shock. Do not subject the saw blade to lateral pressure.
The riving knife must be aligned with the saw blade in order to prevent the workpiece from jamming.
Do not saw workpieces that have become bent or twisted out of shape. The workpiece must always have a straight edge to face against the parallel guide.
Always store the push stick on the power tool.

Position of The Operator

Never stand directly in line with the saw blade. Always position your body on the same side of the saw blade as the fence. Kickback may propel the workpiece at high velocity towards anyone standing in front and in line with the saw blade.
Keep hands, fingers and arms away from the rotating saw blade.

Pay attention to the following instructions:

Hold the workpiece firmly with both hands and press it securely against the saw table.
When using narrow workpieces or sawing bevel angles, always use the push stick (12) and the additional parallel guide (41) provided.

Sawing

Making Straight Cuts

Adjust the parallel guide (5) to the desired cutting width.
Place the workpiece on the saw table in front of the protective cover (3).
Use the crank (15) to raise or lower the saw blade as far up or down as needed to position the top teeth of the saw blade (24) approx. 3-6 mm above the workpiece.
Switch on the power tool.
Saw through the workpiece applying uniform feed.
If you apply too much pressure, the tip of the saw blade could overheat and damage the workpiece.
Switch off the power tool and wait until the saw blade has come to a complete stop.

Sawing a Bevel Angle

Set the required saw blade bevel angle.
If the saw blade is tilted to the left, the parallel guide (5) must be to the right of the blade.
Follow the work steps set out in the section.

Sawing Mitre Angles

Set the desired mitre angle on the angle guide (2).
Place the workpiece against the angle guide (2).
Raise or lower the saw blade using the crank (15) until the upper saw teeth lie approx. 5 mm above the surface of the workpiece.
Switch the power tool on.
Hold the workpiece against the angle guide with one hand; place your other hand on the locking knob (53) and slide the angle guide slowly forwards in the guide groove (28).
Switch off the power tool and wait until the saw blade has come to a complete stop.

Checking and Adjusting the Basic Settings

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

Adjusting the stops for a standard bevel angle 0°/45°

Bring the power tool into the work position.
Set the saw blade to a bevel angle of 0°.
Remove the blade guard (3).

Checking

Remove the table insert (23).
Set an angle gauge to 90° and place it on the saw table (21).

The leg of the angle gauge must be flush with the saw blade (24) along its entire length.

Setting

Loosen the screw (59). This enables the 0° stop (20) to be moved.
Loosen the locking lever (18).
Slide the hand wheel (14) towards the 0° stop until the leg of the angle gauge is flush with the saw blade along its entire length.
Hold the hand wheel in this position and retighten the locking lever (18).
Retighten the screw (59).
Refit the table insert (23).

If the angle indicator (52) is not aligned with the 0° mark on the scale (19) following adjustment, loosen the screw (60) using a conventional cross-headed screwdriver and align the angle indicator along the 0° mark.
Repeat the above work steps for the bevel angle of 45°
(loosen the screw (61); move the 45° stop (17)). The angle indicator (52) must not be repositioned when doing this.

Parallelism of the saw blade with the guide grooves of the angle guide

Bring the power tool into the work position.
Remove the blade guard (3).

Checking

Use a pencil to mark the first left-hand saw tooth that is visible at the back above the table insert.
Set an angle gauge to 90° and place it on the edge of the guide groove (28).
Move the leg of the angle gauge until it touches the marked saw tooth and read the distance between the saw blade and the guide groove.
Turn the saw blade until the marked tooth at the front lies above the table insert.
Move the angle gauge along the guide groove up to the marked saw tooth.
Measure the distance between the saw blade and the guide groove again.

The two measured distances must be identical.

Setting

Loosen the hex socket screws (62) at the front beneath the saw table and the hex socket screws (63) at the rear beneath the saw table using the hex key (10) provided.
Carefully move the saw blade until it lies parallel with the guide groove (28).
Retighten all screws (62) and (63).

Adjusting the saw table spacing indicator

Position the parallel guide on the right of the saw blade. Move the parallel guide until the marking in the magnifying glass (55) shows 29 cm on the lower scale.
To secure it in place, push the clamping handle (39) back down.
Pull the clamping handle (13) all the way up and pull the saw table expansion (6) out as far as possible.

Checking
The upper scale (1) of the spacing indicator (56) must show the same value as the marking in the magnifying glass (55) on the lower scale (1).

Setting

Pull the saw table expansion (6) out fully.
Loosen the screw (64) with a cross-headed screwdriver and align the spacing indicator (56) along the 29 cm mark on the upper scale (1).

Adjusting the parallelism of the parallel guide

Bring the power tool into the work position.
Remove the blade guard (3).
Loosen the clamping handle (39) of the parallel guide and move it until it touches the saw blade.

Checking
The parallel guide (5) must touch the saw blade along its entire length.

Setting

Loosen the hex socket screws (65) using the hex key (10) provided.
Carefully move the parallel guide (5) until it touches the saw blade along its entire length.
Hold the parallel guide in this position and push the clamping handle (39) down again.
Retighten the hex socket screws (65).

Adjusting the clamping force of the parallel guide
The clamping force of the parallel guide (5) can deteriorate after frequent use.

Tighten the adjusting screw (22) until the parallel guide can be securely fixed to the saw table again.

Adjusting the magnifying glass of the parallel guide

Bring the power tool into the work position.
Remove the protective cover (3).
Move the parallel guide (5) from the right until it touches the saw blade.

Checking
The marking in the magnifying glass (55) must be in line with the 0 mm mark on the scale (1).

Setting

Loosen the screw (66) using a cross-headed screwdriver and align the marking along the 0 mm mark.

Adjusting the level of the table insert

Checking
The front side of the table insert (23) must lie flush with or a little below the saw table; the rear must lie flush with or a little above the saw table.

Setting

Use the tip of the ring spanner (9) to set the adjusting screws (67) to the correct level.

Storage and Transport

Storing Tool Elements
You can attach certain tool elements to the power tool to store them.

Detach the additional parallel guide (41) from the parallel guide (5).
Place all loose components of the tool in their storage compartments on the housing.

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

Bring the power tool into the transport position. Remove all accessories that cannot be securely fitted to the power tool.
If possible, transport unused saw blades in an enclosed container.
Slide the saw table expansion (6) in fully and push the clamping handle (13) down to secure it in place.
Wrap the power cable around the cable holder (26).
Use the carrying handles (27) to lift or transport the tool.

Only use the transport devices to transport the power tool and never the protective devices.

Maintenance and Servicing

Maintenance and Cleaning

Pull the plug out of the socket before carrying out any work on the power tool.
To ensure safe and efficient operation, always keep the power tool and the ventilation slots clean.

In order to avoid safety hazards, if the power supply cord needs to be replaced, this must be done by Bosch or by an after-sales service centre that is authorised to repair Bosch power tools.

Cleaning
Always remove dust and chips after working by blowing out with compressed air or using a brush.

Noise Reduction Measures
Measures implemented by the manufacturer:

Soft start
Provided with a saw blade specially developed for noise reduction

Measures implemented by the operator:

Low-vibration mounting on a stable work surface
Use of saw blades with noise-reducing functions
Regular cleaning of the saw blade and power tool

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

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

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

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Bosch GTS 635-216 Professional Table Saw Instruction Manual

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