Bosch Tg503 Assembly instructions

Operating / Safety Instructions

Consignes d’utilisation / de sécurité

Instrucciones de funcionamiento y seguridad

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IMPORTANT

Read Before Using ●IMPORTANT

Lire avant usage ●IMPORTANTE

Leer antes de usar

1-877-BOSCH99 (1-877-267-2499) www.boschtools.com

TG503

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The definitions below describe the level of severity for each signal word.

Please read the manual and pay attention to these symbols.

This is the safety alert symbol. It is used to alert you to potential per-

sonal injury hazards. Obey all safety messages that follow this symbol

to avoid possible injury or death.

DANGER indicates a hazardous situation which, if not avoided, will

result in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could

result in death or serious injury.

CAUTION indicates a hazardous situation which, if not avoided, could

result in minor or moderate injury.

Table of Contents

Safety Symbols

Safety Symbols .......................2

General Power Tool Safety Warnings .......3

Cut-Off Machine Safety Warnings..........5

Additional Safety Warnings ..............8

Intended Use .........................8

Symbols.............................9

Functional Description.................11

Specications .......................12

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

Tuckpointing Guard Assembly .........13

Installing Tuckpointing Guard .........14

Reverting to Grinding Applications .....14

Installing and Removing Wheels on a

Spindle Grinder ................15

Basic X-Lock Operation..............16

Mounting and Removing X-Lock

Wheels .......................17

Operating Instructions .................21

Adjustable Depth Stop ..............21

Tuckpointing Guard ................21

Dust Extraction....................21

Auxiliary Handle ...................21

Tuckpointing......................21

Diamond Wheels ..................22

Maintenance ........................23

Service ..........................23

Tool Lubrication ...................23

Cleaning.........................23

Accessories .........................23

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General Power Tool Safety Warnings

Read all safety warnings, instructions, illustrations and speciﬁcations pro-

vided with this power tool. Failure to follow all instructions listed below may

result in electric shock, re 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.

1. Work area safety

a. Keep work area clean and well lit. Clut-

tered or dark areas invite accidents.

b. Do not operate power tools in explosive

atmospheres, such as in the presence of

ammable liquids, gases or dust. Power

tools create sparks which may ignite the

dust or fumes.

c. Keep children and bystanders away while

operating a power tool. Distractions can

cause you to lose control.

2. Electrical safety

a. 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. Unmodied plugs

and matching outlets will reduce risk of

electric shock.

b. Avoid body contact with earthed or

grounded surfaces, such as pipes, radia-

tors, ranges and refrigerators. There is an

increased risk of electric shock if your body

is earthed or grounded.

c. Do not expose power tools to rain or wet

conditions. Water entering a power tool

will increase the risk of electric shock.

d. 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. Dam-

aged or entangled cords increase the risk of

electric shock.

e. 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.

f. If operating a power tool in a damp loca-

tion is unavoidable, use a Ground Fault

Circuit Interrupter (GFCI) protected

supply. Use of a GFCI reduces the risk of

electric shock.

3. Personal safety

a. 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 inuence of

drugs, alcohol or medication. A moment

of inattention while operating power tools

may result in serious personal injury.

b. Use personal protective equipment.

Always wear eye protection. Protective

equipment such as a dust mask, non-skid

safety shoes, hard hati or hearing protec-

tion used for appropriate conditions will

reduce personal injuries.

c. Prevent unintentional starting. Ensure the

switch is in the off-position before con-

necting to power source and/or BATTERY

pack, picking up or carrying the tool. Car-

rying power tools with your nger on the

switch or energizing power tools that have

the switch on invites accidents.

d. Remove any adjusting key or wrench be-

fore 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.

e. Do not overreach. Keep proper footing and

balance at all times. This enables better

control of the power tool in unexpected

situations.

f. Dress properly. Do not wear loose cloth-

ing or jewelry. Keep your hair and clothing

away from moving parts. Loose clothes,

jewelry or long hair can be caught in mov-

ing parts.

g. If devices are provided for the connec-

tion of dust extraction and collection

SAVE THESE INSTRUCTIONS

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SAVE THESE INSTRUCTIONS

General Power Tool Safety Warnings

facilities, ensure these are connected and

properly used. Use of dust collection can

reduce dust-related hazards.

h. Do not let familiarity gained from fre-

quent use of tools allow you to become

complacent and ignore tool safety prin-

ciples. A careless action can cause severe

injury within a fraction of a second.

4. Power tool use and care

a. Do not force the power tool. Use the cor-

rect power tool for your application. The

correct power tool will do the job bet-

ter and safer at the rate for which it was

designed.

b. 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.

c. Disconnect the plug from the power

source and/or remove the BATTERY pack,

if detachable, from the power tool before

making any adjustments, changing ac-

cessories, or storing power tools. Such

preventive safety measures reduce the risk

of starting the power tool accidentally.

d. 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.

e. 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.

f. Keep cutting tools sharp and clean. Prop-

erly maintained cutting tools with sharp

cutting edges are less likely to bind and are

easier to control.

g. Use the power tool, accessories and tool

bits etc. in accordance with these instruc-

tions, taking into account the working

conditions and the work to be performed.

Use of the power tool for operations differ-

ent from those intended could result in a

hazardous situation.

h. Keep handles and grasping surfaces dry,

clean and free from oil and grease. Slip-

pery handles and grasping surfaces do not

allow for safe handling and control of the

tool in unexpected situations.

5. Battery tool use and care (cord-

less only)

a. Recharge only with the charger speciﬁed

by the manufacturer. A charger that is

suitable for one type of BATTERY pack may

create a risk of re when used with another

BATTERY pack.

b. Use power tools only with speciﬁcally

designated BATTERY packs. Use of any

other BATTERY packs may create a risk of

injury and re.

c. When BATTERY pack is not in use, keep it

away from other metal objects, like paper

clips, coins, keys, nails, screws or other

small metal objects, that can make a

connection from one terminal to another.

Shorting the BATTERY terminals together

may cause burns or a re.

d. Under abusive conditions, liquid may be

ejected from the BATTERY; avoid contact.

If contact accidentally occurs, ush with

water. If liquid contacts eyes, additionally

seek medical help. Liquid ejected from the

BATTERY may cause irritation or burns.

e. Do not use a BATTERY pack or tool that is

damaged or modiﬁed. Damaged or modi-

ed batteries may exhibit unpredictable

behavior resulting in re, EXPLOSION or

risk of injury.

f. Do not expose a BATTERY pack or tool to

ﬁre or excessive temperature. Exposure to

re or temperature above 265 °F / 130 °C

may cause explosion.

g. Follow all charging instructions and do

not charge the BATTERY pack or tool

outside the temperature range speciﬁed

in the instructions. Charging improperly or

at temperatures outside the specied range

may damage the BATTERY and increase the

risk of re.

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General Power Tool Safety Warnings

SAVE THESE INSTRUCTIONS

1. Safety warnings common for

grinding or cutting-off operations

a. This power tool is intended to function as

a cut-off tool. Read all safety warnings, in-

structions, illustrations and speciﬁcations

provided with this power tool. Failure to

follow all instructions listed below may

result in electric shock, re and/or serious

injury.

b. Operations such as grinding, sanding, wire

brushing, polishing or hole cutting are not

to be performed with this power tool. Op-

erations for which the power tool was not

designed may create a hazard and cause

personal injury.

c. Do not convert this power tool to operate

in a way which is not speciﬁcally designed

and speciﬁed by the tool manufacturer.

Such a conversion may result in a loss of

control and cause serious personal injury.

d. Do not use accessories which are not

speciﬁcally designed and speciﬁed by the

tool manufacturer. Just because the acces-

sory can be attached to your power tool, it

does not assure safe operation.

e. The rated speed of the accessory must

be at least equal to the maximum speed

marked on the power tool. Accessories

running faster than their rated speed can

break and y apart.

f. The outside diameter and the thickness of

your accessory must be within the capac-

ity rating of your power tool. Incorrectly

sized accessories cannot be adequately

guarded or controlled.

g. The dimensions of the accessory mounting

must ﬁt the dimensions of the mounting

hardware of the power tool. Accessories

that do not match the mounting hardware

of the power tool will run out of balance,

vibrate excessively and may cause loss of

control.

h. Do not use a damaged accessory. Before

each use inspect the accessory such as

abrasive wheels for chips and cracks,

backing pad for cracks, tear or excess

wear, wire brush for loose or cracked

wires. If power tool or accessory is

dropped, inspect for damage or install

an undamaged accessory. After inspect-

ing and installing an accessory, position

yourself and bystanders away from the

plane of the rotating accessory and run

the power tool at maximum no-load speed

for one minute. Damaged accessories will

normally break apart during this test time.

i. Wear personal protective equipment.

Depending on application, use face shield,

safety goggles or safety glasses. As ap-

propriate, wear dust mask, hearing protec-

tors, gloves and workshop apron capable

of stopping small abrasive or workpiece

fragments. The eye protection must be

capable of stopping ying debris generated

by various applications. The dust mask or

respirator must be capable of ltrating par-

ticles generated by the particular applica-

tion. Prolonged exposure to high intensity

noise may cause hearing loss.

j. Keep bystanders a safe distance away

from work area. Anyone entering the

work area must wear personal protective

equipment. Fragments of workpiece or of

a broken accessory may y away and cause

injury beyond immediate area of operation.

k. Hold the power tool by insulated grip-

ping surfaces only, when performing an

operation where the cutting accessory

Cut-Off Machine Safety Warnings

6. Service

a. Have your power tool serviced by a quali-

ﬁed repair person using only identical

replacement parts. This will ensure that

the safety of the power tool is maintained.

b. Never service damaged BATTERY packs.

Service of BATTERY packs should only be

performed by the manufacturer or autho-

rized service providers. (cordless only)

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SAVE THESE INSTRUCTIONS

Cut-Off Machine Safety Warnings

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 opera-

tor an electric shock. (corded only)

l. Hold the power tool by insulated grip-

ping surfaces only, when performing an

operation where the cutting accessory

may contact hidden wiring. Contact with a

"live" wire will also make exposed metal

parts of the power tool "live" and could

give the operator an electric shock. (cord-

less only)

m. Position the cord clear of the spinning

accessory. If you lose control, the cord may

be cut or snagged and your hand or arm

may be pulled into the spinning accessory.

n. Never lay the power tool down until the

accessory has come to a complete stop.

The spinning accessory may grab the

surface and pull the power tool out of your

control.

o. Do not run the power tool while carrying

it at your side. Accidental contact with the

spinning accessory could snag your cloth-

ing, pulling the accessory into your body.

p. Regularly clean the power tool’s air vents.

The motor’s fan will draw the dust inside

the housing and excessive accumulation

of powdered metal may cause electrical

hazards.

q. Do not operate the power tool near am-

mable materials. Sparks could ignite these

materials.

r. Do not use accessories that require liquid

coolants. Using water or other liquid cool-

ants may result in electrocution or shock.

2. Kickback and related warnings

Kickback is a sudden reaction to a pinched or

snagged rotating wheel, backing pad, brush

or any other accessory. Pinching or snagging

causes rapid stalling of the rotating accessory

which in turn causes the uncontrolled power

tool to be forced in the direction opposite of

the accessory’s rotation at the point of the

binding.

For example, if an abrasive wheel is snagged

or pinched by the workpiece, the edge of the

wheel that is entering into the pinch point can

dig into the surface of the material causing the

wheel to climb out or kick out. The wheel may

either jump toward or away from the operator,

depending on direction of the wheel’s move-

ment at the point of pinching. Abrasive wheels

may also break under these conditions.

Kickback is the result of power tool misuse

and/or incorrect operating procedures or con-

ditions and can be avoided by taking proper

precautions as given below.

a. Maintain a ﬁrm grip with both hands on

the power tool and position your body

and arms to allow you to resist kickback

forces. Always use auxiliary handle, if pro-

vided, for maximum control over kickback

or torque reaction during start-up. The

operator can control torque reactions or

kickback forces, if proper precautions are

taken.

b. Never place your hand near the rotating

accessory. Accessory may kickback over

your hand.

c. Do not position your body in the area

where power tool will move if kickback

occurs. Kickback will propel the tool in di-

rection opposite to the wheel’s movement

at the point of snagging.

d. Use special care when working corners,

sharp edges, etc. Avoid bouncing and

snagging the accessory. Corners, sharp

edges or bouncing have a tendency to snag

the rotating accessory and cause loss of

control or kickback.

e. Do not attach a saw chain woodcarving

blade, segmented diamond wheel with

a peripheral gap greater than 10 mm

(13/32”) or toothed saw blade. Such

blades create frequent kickback and loss of

control.

3. Safety warnings speciﬁc for

grinding and cutting-off opera-

tions

a. Use only wheel types that are speciﬁed

for your power tool and the speciﬁc guard

designed for the selected wheel. Wheels

for which the power tool was not designed

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SAVE THESE INSTRUCTIONS

Cut-Off Machine Safety Warnings

cannot be adequately guarded and are

unsafe.

b. The grinding surface of center depressed

wheels must be mounted below the plane

of the guard lip. An improperly mounted

wheel that projects through the plane of

the guard lip cannot be adequately pro-

tected.

c. The guard must be securely attached to

the power tool and positioned for maxi-

mum safety, so the least amount of wheel

is exposed towards the operator. The

guard helps to protect the operator from

broken wheel fragments, accidental contact

with wheel and sparks that could ignite

clothing.

d. Wheels must be used only for speciﬁed

applications. For example: do not grind

with the side of cut-off wheel. Abrasive

cut-off wheels are intended for peripheral

grinding, side forces applied to these

wheels may cause them to shatter.

e. Always use undamaged wheel anges

that are of correct size and shape for your

selected wheel. Proper wheel anges sup-

port the wheel thus reducing the possibil-

ity of wheel breakage. Flanges for cut-off

wheels may be different from grinding

wheel anges.

f. Do not use worn down wheels from larger

power tools. A wheel intended for larger

power tool is not suitable for the higher

speed of a smaller tool and may burst.

g. When using dual purpose wheels always

use the correct guard for the application

being performed. Failure to use the correct

guard may not provide the desired level

of guarding, which could lead to serious

injury.

4. Additional safety warnings spe-

ciﬁc for cutting-off operations

a. Do not “jam” the cut-off wheel or apply

excessive pressure. Do not attempt to

make an excessive depth of cut. Over-

stressing the wheel increases the loading

and susceptibility to twisting or binding of

the wheel in the cut and the possibility of

kickback or wheel breakage.

b. Do not position your body in line with

and behind the rotating wheel. When the

wheel, at the point of operation, is moving

away from your body, the possible kickback

may propel the spinning wheel and the

power tool directly at you.

c. When the wheel is binding or when inter-

rupting a cut for any reason, switch off

the power tool and hold it motionless

until the wheel comes to a complete stop.

Never attempt to remove the cutoff wheel

from the cut while the wheel is in motion

otherwise kickback may occur. Investigate

and take corrective action to eliminate the

cause of wheel binding.

d. Do not restart the cutting operation in the

workpiece. Let the wheel reach full speed

and carefully re-enter the cut. The wheel

may bind, walk up or kickback if the power

tool is restarted in the workpiece.

e. Support panels or any oversized work-

piece to minimize the risk of wheel pinch-

ing and kickback. Large workpieces tend

to sag under their own weight. Supports

must be placed under the workpiece near

the line of cut and near the edge of the

workpiece on both sides of the wheel.

f. Use extra caution when making a “pocket

cut” into existing walls or other blind

areas. The protruding wheel may cut gas

or water pipes, electrical wiring or objects

that can cause kickback.

g. Do not attempt to do curved cutting. Over-

stressing the wheel increases the loading

and susceptibility to twisting or binding of

the wheel in the cut and the possibility of

kickback or wheel breakage, which can lead

to serious injury.

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SAVE THESE INSTRUCTIONS

Intended Use

This tuckpointing guard and respective small

angle grinder is intended for use in cutting mor-

tar or masonry type materials.

The guard includes a dust port which allows it

to be connected to a vacuum hose which can

be connected to an appropriate dust extractor

vacuum. (See OSHA Silica Regulation concern-

ing vacuum, CFM and lter requirements for

tuckpointing applications / mortar removal.)

The TG503 tuckpointing guard is designed for

use with two types of Bosch small angle grind-

ers, the type having threaded spindle (model

GWS) and the X-LOCK (model GWX). This guard

is intended for use with Type 1A/41 diamond

wheels, or specially designed sandwiched dia-

mond wheels, available with X-LOCK or 7/8”

arbor, for mounting on the two types of Bosch

angle grinders.

Use this tuckpointing guard with a Bosch 4-1/2 inch, 5 inch, or 6 inch small

angle grinder only as intended. Unintended use may result in personal injury

and property damage.

GFCI and personal protection devices like elec-

trician’s rubber gloves and footwear will further

enhance your personal safety.

Do not use AC only rated tools with a DC pow-

er supply. While the tool may appear to work,

the electrical components of the AC rated tool

are likely to fail and create a hazard to the op-

erator.

Keep handles dry, clean and free from oil and

grease. Slippery hands cannot safely control

the power tool.

Develop a periodic maintenance schedule for

your tool. When cleaning a tool be careful not

to disassemble any portion of the tool since

internal wires may be misplaced or pinched

or safety guard return springs may be improp-

erly mounted. Certain cleaning agents such as

gasoline, carbon tetrachloride, ammonia, etc.

may damage plastic parts.

Wear hearing protection. Prolonged exposure

to high intensity noise can cause hearing loss.

Use thick cushioned gloves and limit the ex-

posure time by taking frequent rest periods.

Vibration caused by the use of power tools may

be harmful to your hands and arms.

This tool must be used with Respiratory Pro-

tection sufﬁcient to block dusts including

silica from concrete cutting. N-95 rated masks

minimum or full respirator protection for the

operator and others in the work area.

Dust collection is required with a vacuum or

other suitable dust collection system for con-

crete/masonry applications.

Do not use vacuum or other dust collection

system when cutting metal. Sparks from metal

cutting can cause re in the collector.

Some dust created by pow-

er sanding, sawing, grind-

ing, 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, depend-

ing 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 ap-

proved safety equipment, such as those dust

masks that are specially designed to lter out

microscopic particles.

Additional Safety Warnings

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Symbols

Important: Some of the following symbols may be used on your tool. Please study them and learn

their meaning. Proper interpretation of these symbols will allow you to operate the tool better

and safer.

Symbol Designation/Explanation

V Volts (voltage)

A Amperes (current)

Hz Hertz (frequency, cycles per second)

W Watt (power)

kg Kilograms (weight)

min Minutes (time)

s Seconds (time)

⌀Diameter

n0No load speed (rotational speed, at no load)

n Rated speed (maximum attainable speed)

.../min Revolutions or reciprocation per minute (revolutions, strokes, surface speed,

orbits etc. per minute)

0Off position (zero speed, zero torque...)

1, 2, 3, ...

I, II, III,

Selector settings (Speed, torque or position settings. Higher number means

greater speed.)

Innitely variable selector with off (Speed is increasing from 0 setting.)

Arrow (action in the direction of arrow)

Alternating current (type or a characteristic of current)

Direct current (type or a characteristic of current)

Alternating or direct current (type or a characteristic of current)

Class II construction (Designates Double Insulated Construction tools.)

Earthing terminal (grounding terminal)

Designates Li-ion battery recycling program.

Alerts user to read manual.

Alerts user to wear eye protection.

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Symbols

Important: Some of the following symbols may be used on your tool. Please study them and learn

their meaning. Proper interpretation of these symbols will allow you to operate the tool better

and safer.

Symbol Designation/Explanation

Alerts user to wear respiratory protection.

Alerts user to wear hearing protection.

Alerts user to wear eye, respiratory, and hearing protection.

Alerts user to hold tool with both hands.

The protective guard must not be used for cutting. With a suitable adapter, the

protective guard can also be used for cutting.

This symbol designates that this tool is listed by Underwriters Laboratories, to

United States and Canadian Standards.

This symbol designates that this tool is listed by the Canadian Standards Associa-

tion.

This symbol designates that this tool is listed by the Canadian Standards Associa-

tion, to United States and Canadian Standards.

This symbol designates that this tool is listed by the Intertek Testing Services, to

United States and Canadian Standards.

Designates Li-ion battery recycling program.

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Disconnect the plug from the power source before making any assembly,

adjustments or changing accessories. Such preventive safety measures reduce

the risk of starting the tool accidentally.

Functional Description

TG503 Tuckpointing Guard

(Compatible with GWS Spindle Grinders and GWX X-Lock Grinders)

1 Spindle Grinder

2 Slide Switch

3 Spindle Lock

4 Dust Port

5 Adjustable Depth Stop Button

6 Depth Scale

7 Depth Adjust Lock Knob

8 Guard Cover Knob

9 Stability Bracket

10 Auxiliary Handle

11 Ventillation Openings

12 X-Lock Grinder

13 TG503 Tuckpoint Guard

14 Wheel

15 Wheel's X-Lock Mounting Hub

16 Wheel's X-Lock Alignment Contours

17 X-Lock Accessory Mount

18 Viewing Window

19 Threaded Spindle Accessory Mount

20 Guide Plate

Fig. 1

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Specifications

Model number TG503

Flanges/Nuts 1600A002TP Backing Flange

1600A002TR Lock Nut

Wheel diameter and type: 5" (125mm) Tuckpointing wheel

5" (125mm) diamond cutoff wheel

5" (125mm) crack chaser wheel

Recommended Bosch small angle grinders: Threaded spindle: GWS13-50, GWS13-60,

GWS18V-13 series grinders

X-Lock: GWX13-50, GWX13-60, GWX18V-13

series grinders

NOTE: For tool specications refer to the nameplate on your tool.

TG503 Tuck Point Grinder Guard OSI Final 20230606.indd 12TG503 Tuck Point Grinder Guard OSI Final 20230606.indd 12 6/6/2023 1:42:59 PM6/6/2023 1:42:59 PM

-13-

lease Lever 23 when re-attaching the Gear

Housing 21 for the Guard Release Lever 23

to operate properly.

6. Attach a proper dust collection guard with

foot and wheel.

Assembly

Tuckpointing Guard Assembly

(Fig. 2, Fig. 3, Fig. 4)

The type 27 grinding wheel

guard must be removed. Re-

tain Type 27 guard for future use. Always rein-

stall Type 27 wheel guard when converting back

to grinding operations.

The TG503 Tuckpointing Guard is for both GWS

threaded spindle grinders and GWX X-Lock

grinders.

To improve ergonomics of your grinder when

cutting masonry, gearbox must be rotated rela-

tive to the position of the switch as the tool

was assembled at the factory.

Rotate gearbox:

1. Unplug tool from power source.

2. Completely unscrew the four screws

between the Gear Housing 21 and Motor

Body 22 .

NOTE: Retain the Guard Release Lever 23

with the Spring 24 for reassembling gear

housing in step 4.

3. Rotate the Gear Housing 21 to the proper

orientation without removing the motor

from the housing .

• For a grinder with a Slide Switch 2,

rotate the Gear Housing 21 180 degrees

in the direction indicated in Fig. 3 ,

so the Slide Switch 2 is 90 degrees

from the spindle.

• For a grinder with a Paddle Switch 27,

rotate the Gear Housing 21 90 degrees

in the direction indicated in Fig. 4 ,

so the Paddle Switch 27 is facing the

workpiece.

4. Screw in and tighten the three short

screws you removed .

5. The screw holding the Guard Release Lever

23 is longer than the other screws. This

long screw must stay with the Guard Re-

Disconnect the plug from the power source before making any assembly,

adjustments or changing accessories. Such preventive safety measures reduce

the risk of starting the tool accidentally.

Disconnect battery pack from tool before making any assembly, adjustments

or changing accessories. Such preventive safety measures reduce the risk of

starting the tool accidentally.

(3x)

21 22

Fig. 2

180°

Fig. 3

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-14-

Installing Tuckpointing Guard

(Fig. 5, Fig. 6)

To Attach Guard

1. Unplug tool from power source.

2. Position the Guard 13 on the spindle neck

so that the Arrow on the Guard 25 and the

Arrow on the Spindle Neck 26 align.

3. Slide the Guard 13 on the spindle neck,

and rotate the Guard 13 until the Stabil-

ity Bracket and the hole for the auxiliary

handle are aligned.

4. Screw in the auxiliary handle to secure the

Guard 13 on the tool.

5. Always position Wheel Guard 13 between

operator and work piece and direct sparks

away from operator.

To Remove Wheel Guard

1. Unscrew the auxiliary handle.

2. Rotate the Guard 13 until the Arrow on the

Guard 25 and the Arrow on the Spindle

Neck 26 are aligned.

3. Remove the Guard 13 from the spindle

neck.

Reverting to Grinding Applications

(Fig. 2)

Return the Gear Housing 21 to original position

and replace Type 27 grinding guard. See manu-

al for grinder for details.

Assembly

Fig. 5

Fig. 6

90°

(under

tool)

90°

Fig. 4

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-15-

Installing and Removing Wheels on

a Spindle Grinder

(Fig. 7, Fig. 8, Fig. 9)

Backing ange and lock nut

that is provided with the

tuckpointing guard MUST be used together

with tuckpointing guard. Retain original ang-

es for grinding use.

1. Loosen and remove the Guard Cover Knob

8(Fig. 7).

2. Push the Raised Portion of the Guard

Cover 28 near the Locking Clip 29 (Fig.

7) in the direction of the arrow to unlock

the Guard Cover 30, and swing the Guard

Cover 30 out of the way (Fig. 9).

3. Place the Backing Flange 31 (provided

together with the guard) on the Spindle 32

Assembly

Fig. 8

Fig. 9

830

Fig. 7

(Fig. 8). Turn the Backing Flange 31 until

it is securely in place at the base of the

Spindle 32.

4. Place the Wheel 14 onto the Spindle 32

and align the Arbor Hole of the Wheel 33

with the shoulder of the Lock Nut 34 (pro-

vided together with the guard).

5. Tighten the Lock Nut 34 with the supplied

lock nut wrench while holding the Spindle

Lock 3.

6. Return the Guard Cover 30 back to its origi-

nal position and push into the Locking Clip

29 to secure the Guard Cover 30 in place

(Fig. 7).

7. Replace the Guard Cover Knob 8and se-

curely tighten the Knob 8(Fig. 7).

To remove reverse procedure.

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-16-

Basic X-Lock Operation

(Fig. 10, Fig. 11)

The X-Lock system is a combination of patented

tool mount and Wheel 14 designs that provide

the operator with fast Wheel 14 changes. Avail-

able on select Bosch angle grinders, X-Lock al-

lows tool free installation and removal of grind-

er Wheels 14 (grinding, cut-off wheels, wire

brushes, sanding discs, etc.). The X-Lock sys-

tem is a replacement for the traditional method

of attaching grinder Wheels 14.

Traditional grinders have 5/8”-11 threaded

spindles that require a nut and backing ange

to hold the Wheel 14 in place. To replace a

Wheel 14, a wrench is used to loosen or tighten

the nut. X-Lock equipped grinders have a tool

free interface system, eliminating the spindle,

backing ange and lock nut.

The X-Lock interface has a tool component – X-

Lock Wheel Mount 17, and a Wheel 14 compo-

nent – typically a Wheel X-Lock Mounting Hub

15. The two components have keyed Alignment

Contours 16, which help to ensure correct as-

sembly of the wheel to the tool.

The X-Lock Wheel Mount 17 on the tool consists

of a round Base 37, Clamping Height Gages 35

and a locking mechanism, which activates the

Clamping Tabs 36. X-Lock-equipped grinders

can only use X-Lock Wheels 14 since the spe-

cially designed X-Lock Mounting Hub on Wheels

15 matches the contours of the X-Lock Wheel

Mount 17 on the tool. (See Fig. 10.) However,

select X-Lock Wheel 14 are backward compat-

ible with the traditional threaded spindle de-

sign.

Attachment of the X-Lock Wheel 14 to the X-

Lock Wheel Mount 17 on the grinder requires

alignment of the Wheel's X-Lock Mounting Hub

15 with the X-Lock Wheel Mount 17 on the tool.

Once the Wheel's X-Lock Mounting Hub 15 is

aligned, and pressed against the base of the

X-Lock Wheel Mount 17, the locking mecha-

nism is activated. This causes the two opposing

Clamping Tabs 36 to lock the Wheel 14 to the

grinder. An audible ‘click’ in combination with

the alignment of the at surface of the Wheel's

X-Lock Mounting Hub 15 with the Clamping

Height Gauges 35 means the Wheel 14 is rm-

ly attached to the tool. To remove the Wheel

14, the X-Lock Release Lever 38 on the grinder

gearhead is actuated which will release the

Clamping Tabs 36, allowing the Wheel 14 to be

Assembly

detached from the tool (Fig. 11). To activate the

X-Lock Release Lever 38, push down while

simultaneously pulling up (Fig. 11).

38 14

Fig. 11

Fig. 10

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-17-

Verify that the Wheel 14 and the X-Lock Wheel

Mount 17 on the tool are not deformed and

are free from dirt. If necessary, clean the area

around the two X-Lock Clamping Tabs 36.

Verify that both Clamping Tabs 36 are open (Fig.

10) before tting the X-Lock Wheel 14 (Fig. 13).

Assembly

Mounting and Removing X-Lock

Wheels

(Fig. 10, Fig. 12, Fig. 13, Fig. 15)

Only use Bosch or Bosch li-

censed X-LOCK accesso-

ries. Incompatible accessories may not clamp

properly resulting in personal injury and/or

property damage.

Conﬁrm proper clamping

by ensuring that top of the

accessories's X-Lock mounting hub surface is

not above the top of the clamping height gage.

Accessories that are above the clamping height

gauge may not be xed properly and separate

from the the tool causing personal injury and/

or property damage.

Always inspect accessory

mount and accessory

clamping ange before use. Do not use the

tool or accessory if the accessory mount or ac-

cessory is damaged or deformed. Accessoies

that are not clamped properly may cause per-

sonal injury and/or property damage.

Check for presence or

buildup of foreign material

on clamping surfaces and remove before use.

Unwanted material can cause incomplete

clamping and may cause personal injury and/or

property damage.

Never actuate X-Lock Re-

lease Lever while accessory

is moving. Make sure that the accessory has

come to a complete stop before removing the

accessory. Releasing an accessory while still

spinning could cause personal injury and/or

property damage.

Do not use a damaged ac-

cessory. Before each use in-

spect the accessory such as abrasive wheels for

chips and cracks, backing pad for cracks, tear

or excess wear, wire brush for loose or cracked

wires. If power tool or accessory is dropped,

inspect for damage or install an undamaged ac-

cessory. After inspecting and installing an ac-

cessory, position yourself and bystanders away

from the plane of the rotating accessory and

run the power tool at maximum no-load speed

for one minute. Damaged accessory will nor-

mally break apart during this test time.

Fig. 12

28 29

Fig. 13

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-18-

Assembly

Mounting an X-Lock Wheel to the

Tool

(Fig. 12, Fig. 13, Fig. 14, Fig. 15, Fig. 16)

1. Loosen and remove the Guard Cover Knob

8(Fig. 12) .

2. Push the Raised Portion of the Guard

Cover 28 near the Locking Clip 29 in the

direction of the arrow to unlock the Guard

Cover 30, and swing the Cover 30 out of

the way (Fig. 12) .

3. Place the Wheel 14 on the X-Lock Wheel

Mount 17. Align the Alignment Contours

16 on the Wheel's X-Lock Mounting Hub 15

with the Contours 16 on the X-Lock Wheel

Mount 17 on the grinder (Fig. 13).

4. Push the Wheel 14 into the X-Lock Wheel

Mount 17. The Wheel 14 audibly clicks as

the Clamping Tabs 36 lock into place (Fig.

14).

5. Check that the edge of the Wheel's X-Lock

Mounting Hub 15 is correctly engaged in

the slots of the X-Lock Clamping Tabs 36

(Fig. 13, Fig. 14). If the top surface of the

Wheel's X-Lock Mounting Hub 15 is higher

than the Clamping Height Gauges 35

(located on each side of the X-Lock Wheel

Mount 17), the X-Lock Wheel 14 must not

be used until this condition is eliminated

by cleaning the X-Lock Wheel Mount 17 or

replacing the Wheel 14 (Fig. 13, Fig. 14,

Fig. 15).

6. Return the Guard Cover 30 back to its origi-

nal position, and push it into the Locking

Clip 29 to secure the Guard Cover 30 in

place (Fig. 16) .

7. Replace the Guard Cover Knob 8and se-

curely tighten the Knob 8 (Fig. 16) . 8

Fig. 16

CLICK!

Fig. 14

CORRECT: Height of Accessory's X-Lock

Mounting Hub is equal or less than

X-Lock Accessory Mount.

INCORRECT: Height of Accessory's

X-Lock Mounting Hub is greater than

X-Lock Accessory Mount.

X-Lock Accessory

Mount

X-Lock Accessory

Mount

Accessory's X-Lock

Mounting Hub

Accessory's X-Lock

Mounting Hub

Fig. 15

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-19-

Assembly

Removing an X-Lock Wheel

(Fig. 17, Fig. 18, Fig. 19, Fig. 20)

Never actuate the X-Lock

Release Lever while the ac-

cessory is moving. Make sure that the acces-

sory has come to a complete stop before re-

moving the wheel. Releasing an accessory

while still spinning could cause personal injury

and/or property damage.

Do not touch grinding and

cutting discs until they have

cooled down. The discs can become very hot

while working.

Do not allow accessories to

fall uncontrollably after re-

lease. Falling accessories can become damaged

and may cause personal injury and/or property

damage.

Before removing the accessory, make sure that

the power tool has come to a complete stop

and is disconnected from power.

1. Loosen and remove the Guard Cover Knob

8(Fig. 17) .

2. Push the Raised Portion of the Guard

Cover 28 near the Locking Clip 29 in the

direction of the arrow to unlock the Guard

Cover 30, and swing the Cover 30 out of

the way (Fig. 17) .

3. Orient the tool to prevent the wheel from

being dropped during release.

4. Open the X-Lock Release Lever 38 (Fig.

18):

• Press on the backside of the lever .

• Lift the front side of the lever .

5. Remove the Wheel 14 from the tool with

care, preventing it from being dropped

(Fig. 19, Fig. 20).

Fig. 18

28 29

Fig. 17

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-20-

Assembly

Fig. 19

Fig. 20

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