Bosch GCO 20-14 Professional Heavy Duty Metal Cut-Off Grinder Saw Instruction Manual

BOSCH GCO 20-14 Professional Heavy Duty Metal Cut-Off Grinder Saw

Safety Notes

General Power Tool Safety Warnings

WARNING When using electric tools basic safety precautions should always be followed to reduce the risk of fire, electric shock and personal injury including the following.
Read all these instructions before attempting to operate this product and save these instructions.
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 jewelry. 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 Cut-off Grinder

• Never stand on the power tool. Serious injuries could occur when the power tool tips over or when accidentally coming into contact with the cutting disc.
• Always use the blade guard. A blade guard protects the user against broken off parts of the cutting disc and against accidental touching of the cutting disc.
• Make sure that the guard operates properly and that it can move freely. Never lock the guard in place when opened.
• Use the power tool only for dry cutting. Water penetrating into a power tool increases the risk of an electric shock.
• Keep the mains cable away from rotating application tools. The mains cable can be cut through or get caught.
• Keep handles dry, clean, and free from oil and grease. Greasy, oily handles are slippery causing loss of control.
• Never remove cutting remainders, metal chips, etc. from the cutting area while the machine is running. Al-ways guide the tool arm back to the neutral position first and then switch the machine off.
• Guide the cutting disc against the workpiece only when the machine is switched on. Otherwise, there is danger of kickback, when the cutting disc becomes wedged in the workpiece.
• Operate the power tool only when the work area to the workpiece is clear of any adjusting tools, metal chips, etc. Small pieces of metal or other objects that come in contact with the rotating cutting disc can strike the operator with high speed.
• Always firmly clamp the workpiece. Do not cut work pieces that are too small to clamp. Otherwise, the clearance of your hand to the rotating cutting disc is too small.
• If the cutting disc becomes jammed, switch the machine off and wait until the cutting disc comes to a complete stop. Never attempt to remove a still running cut-ting disc from the cut, otherwise there is danger of kickback. Determine and correct the cause for the jam-ming.
• After switching off, do not stop the cutting disc by applying lateral pressure to it. The cutting disc can become damaged, break or lead to kickback.
• Do not force the cutting disc into the workpiece and do not apply too much pressure when using the power tool. Particularly avoid jamming or wedging the cutting disc when working corners or sharp edges. When the cutting disc is damaged due to abuse, cracks can form that can lead to breakage without prior warning.
• Wear a work apron. Pay attention that other persons are not put at risk from sparking. Remove flammable materials in close vicinity. Sparking occurs when cutting metal.
• Use the cut-off grinder only for cutting materials mentioned under “Intended Use”. Otherwise, the cut-off grinder can be subject to overload.
• Do not use damaged, out-of-centre or vibrating cutting discs. Damaged cutting discs cause increased friction, binding of the cutting disc and kickback.
• Always use cutting discs with correct size and shape (diamond versus round) of arbor holes. Cutting discs that do not match the mounting hardware of the cut-off grinder will run eccentrically, causing loss of control.
• Do not attach a saw chain woodcarving blade or toothed saw blade. Such blades create frequent kickback and loss of control.
• Observe the operating instructions of the cut-off wheel manufacturer for assembly and use of the cut-off wheel. Cut-off wheels that do not fit can lead to injury as well as to jamming, breaking or kickback.
• Do not use accessories which are not specifically designed and recommended by the tool manufacturer. Just because the accessory can be attached to your power tool, it does not assure safe operation.
• Do not touch the cutting disc after working before it has cooled. The cutting disc becomes very hot while working.
• Check the cable regularly and have a damaged cable re-paired only through an authorised customer service agent for Bosch power tools. Replace damaged extension cables. This will ensure that the safety of the power tool is maintained.
• Store the machine in a safe manner when not being used. The storage location must be dry and lockable. This prevents the machine from storage damage, and from being operated by untrained persons.
• Secure the workpiece. A workpiece clamped with clamping devices or in a vice is held more secure than by hand.
• Never leave the machine before it has come to a complete stop. Cutting tools that are still running can cause injuries.
• Never use the machine with a damaged cable. Do not touch the damaged cable and pull the mains plug when the cable is damaged while working. Damaged cables increase the risk of an electric shock.

Products sold in GB only: Your product is fitted with a
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 sock-et elsewhere.
Products sold in AUS and NZ only: Use a residual current device (RCD) with a rated residual current of 30 mA or less.

Symbols

The following symbols can be important for the operation of your power tool. Please memorise the symbols and their meanings. The correct interpretation of the symbols helps you operate the power tool better and more secure.

• Symbol/Meaning
• Keep hands away from the cutting area while the machine is running. Dan-ger of injury when coming into contact with the cutting disc.
• Wear ear protectors. Exposure to noise can cause hearing loss.
• Wear safety goggles.
• Wear a dust respirator.
• Wear protective gloves.

Product Description and Specifications

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

Intended Use

The machine is intended for stationary use with cutting discs to perform lengthways and crossways straight cuts or mitre cuts to 45° in metal materials without the use of water.

Product Features

The numbering of the components shown refers to the representation of the power tool on the graphic pages.

1. Lock-off button for On/Off switch
2. On/Off switch
3. Handle
4. Retracting blade guard
5. Spindle lock
6. Cutting disc
7. Angle stop
8. Clamping spindle
9. Quick-release button
10. Spindle handle
11. Mounting holes
12. Hex key (8 mm)
13. Base plate
14. Locking screw for angle stop
15. Transport safety-lock
16. Tool arm
17. Transport handle
18. Blade guard
19. Spark guard
20. Tool spindle
21. Clamping flange
22. Washer
23. Hexagon bolt

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

Permissible workpiece dimensions (maximum/minimum) see page 18.
The values given are valid for a nominal voltage [U] of 230 V. For differ-ent voltages and models for specific countries, these values can vary.

Noise/Vibration Information

Sound emission values determined according to
EN 61029-2-10.
Typically the A-weighted noise levels of the product are: Sound pressure level 100.5 dB(A); Sound power level 113.5 dB(A). Uncertainty K =3 dB.
Wear hearing protection!
Vibration total values ah (triax vector sum) and uncertainty K determined according to EN 61029-2-10: ah=2.5 m/s2, 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 61029 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.

Assembly

Avoid unintentional starting of the machine. During assembly and for all work on the machine, the power plug must not be connected to the mains supply.

Delivery Scope

Carefully remove all parts included in the delivery from their packaging.
Remove all packaging material from the machine and the accessories provided.
Before starting the operation of the machine for the first time, check if all parts listed below have been supplied:

• Cut-off grinder with mounted cutting disc
  Hex key 12

Note: Check the power tool for possible damage.
Before further use of the machine, check that all protective devices are fully functional. Any lightly damaged parts must be carefully checked to ensure flawless operation of the tool. All parts must be properly mounted and all conditions fulfilled that ensure faultless operation.
Damaged protective devices and parts must be immediately replaced by an authorised service centre.

Stationary or Flexible Mounting

To ensure safe handling, the machine must be mounted on a level and stable surface (e. g., workbench) prior to using.

Mounting to a Working Surface (see figure A)

Fasten the power tool with suitable screw fasteners to the working surface. The mounting holes 11 serve for this purpose.

Flexible Mounting (not recommended!)
In the exceptional case that it should not be possible to firmly bench-mount the power tool, you can provisionally place the legs of base plate 13 on a suitable surface (e. g. a workbench, level floor, etc.) without bolting the machine down.

Changing the Tool (see figures B1–B2)

• Before any work on the machine itself, pull the mains plug.
• Actuate the spindle lock 5 only when the tool spindle 20 is stopped. Otherwise, the machine can become damaged.
• Do not touch the cutting disc after working before it has cooled. The cutting disc becomes very hot while working.

Use only cutting discs that have an equal or higher maximal allowable speed than the no-load speed of your power tool.
Use only cutting discs that correspond to the characteristic data given in these operating instructions and are checked according to EN 12413 and marked appropriately.
Place unused cutting discs in an enclosed container or in the original packaging. Store cutting discs lying flat.

Removing the Cutting Disc

• – Bring the power tool into the working position. (see “Re- leasing the Machine (Working Position)”, page 17)
• Swing back the retracting blade guard 4 to the stop.
• Turn the hexagon bolt 23 using the hex key provided 12 and at the same time press the spindle lock 5 until it engages.
• Hold the spindle lock pressed and unscrew the hexagon bolt 23.
• Remove the washer 22 and the clamping flange 21.
• Remove the cutting disc 6.

Installing the Cutting Disc

If required, clean all parts to be mounted prior to assembly.

• Mount the new cutting disc onto the tool spindle 20 in such a manner that its label faces away from the tool arm.
• Mount the clamping flange 21, the washer 22 and the hex-agon bolt 23.
  Press the spindle lock 5 until it engages and retighten the hexagon bolt 23 turning in clockwise direction. (Tightening torque approx. 18–20 Nm)
• Slowly guide the retracting blade guard 4 down until the cutting disc is covered off.
• Make sure that the retracting blade guard 4 operates properly.
  After mounting the cutting disc and before switching on, check whether the cutting disc is properly mounted and if it can rotate freely.
• Make sure that the cutting disc does not graze against the retracting blade guard 4, the blade guard 18 or against other parts.
• Run the machine for approx. 30 seconds.
  Should significant vibrations occur, switch off the machine immediately; remove and install the cutting disc again.

Operation

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

Transport Safety (see figure C)The transport safety-lock 15 enables easier handling of the machine when transporting to various working locations.

Releasing the Machine (Working Position)

• Push the tool arm by the handle 3 down a little in order to relieve the transport safety lock 15.
• Pull the transport safety-lock 15 completely outward.
• Guide the tool arm slowly upward.

Note: When working, pay attention that the transport safety-lock is not pushed inwards. Otherwise, the tool arm cannot be lowered to the requested depth.

Securing the Machine (Transport Position)

• Guide the tool arm downward until the transport safety- lock 15 can be pushed completely inward.
  For additional information on transport, see page 19.

Adjusting the Cutting Angle (see figure D)The mitre angle can be set in a range from 0° to 45°. Frequently used mitre angles are identified on the angle stop 7 with appropriate markings. The 0° and 45° position are set at the respective end stop.

• Loosen the locking screws 14 for the angle stop using the hex key provided 12 (8 mm).
• Adjust the desired angle and firmly tighten both locking screws 14 again.

Displacing the Angle Stop (see figure D and E)

You can displace the angle stop 7 backward.

• Completely unscrew the locking screws 14 using the hex key provided 12 (8 mm).
• Move the angle stop 7 toward the rear by one or two holes to the desired clearance.
• Adjust the desired angle and firmly tighten both locking screws 14 again.

Clamping the Workpiece (see figure E)
To ensure optimum working safety, the workpiece must always be firmly clamped.
Do not saw workpieces that are too small to clamp.
Long workpieces must be underlaid or supported at their free end.

• Place the workpiece against the angle stop 7.
• Slide the clamping spindle 8 against the workpiece and firmly clamp the workpiece with the spindle handle 10.

Loosening the Workpiece

• Loosen the spindle handle 10.
• Tilt up the quick release 9 and pull the clamping spindle 8 away from the workpiece.

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.
• Check the cutting disc before using. The cutting disc must be properly mounted and must rotate freely. Carry out a 30 second (min.) test run with no load. Do not use damaged, out-of-centre or vibrating cutting discs. Damaged cutting discs can burst and cause injuries.

Dust from materials such as lead-containing coatings, minerals and metal can be harmful to one’s health. Contact with or inhaling the dustcan trigger allergic reactions to the operator or bystanders and/or lead to respiratory infections. Certain metal dust is considered hazardous, especially in conjunction with alloys such as zinc, aluminium or chromium. Materials containing asbestos may only be worked by specialists.

• Provide for good ventilation of the working place.
• It is recommended to wear a P2 filter-class respirator.

Observe the relevant regulations in your country for the mate-rials to be worked.
The blade can be blocked by dust, chips or workpiece fragments in the slot of the base plate 13.

• Switch the machine off and pull the mains plug from the socket outlet.
• Wait until the cutting disc has come to a complete stop.
• Tilt the machine toward the rear, so that small workpiece fragments can fall out of the opening intended for this purpose.
  If required, use a suitable tool to remove all workpiece fragments.

Prevent dust accumulation at the workplace. Dust can easily ignite.

Position of the Operator (see figure F)

Do not stand in a line with the cutting disc in front of the machine. Always stand aside of the cutting disc. This measure provides for better protection of your body against possible splinters in case of cutting disc breakage.

Switching On and Off (see figure G)

To save energy, only switch the power tool on when using it. –To start the machine, firstly press the lock-off button 1. Then press the On/Off switch 2 and keep it pressed.
Note: For safety reasons, the On/Off switch 2 cannot be locked; it must remain pressed during the entire operation.

• To switch off the machine, release the On/Off switch 2.

Working Advice

General Cutting Instructions

• Do not touch the cutting disc after working before it has cooled. The cutting disc becomes very hot while working.
• Make sure that the spark guard 19 is properly mounted. Sparking occurs when cutting metal.

Protect the cutting disc against impact, shock and grease. Do not subject the cutting disc to lateral pressure.
Do not strain the power tool so heavily that it comes to a standstill.
Excessive feed considerably reduces the performance capability of the machine and shortens the service life of the cutting disc.
Use only cutting discs that are suitable for the material to be worked.

Permissible Workpiece Dimensions
Maximum workpiece sizes:

Minimum workpiece sizes
(= all workpieces that can be clamped via the clamping spin-dle 8): Length 80 mm
Cutting depth, max. (0°/0°): 129 mm
Cutting Metal

• Set the desired mitre angle.
• Firmly clamp the workpiece as appropriate for its dimensions.
• Switch on the machine.
• Slowly guide the tool arm downward with the handle 3.
• Cut the workpiece applying uniform feed.
• Switch the machine off and wait until the cutting disc comes to a complete stop.
• Guide the tool arm slowly upward.

Transport

• Always carry the power tool by its transport handle 17.
  • The power tool should always be carried by two persons in order to avoid back injuries.
  • When transporting the power tool, use only the transport devices and never use the protective devices.

Maintenance and Service

Maintenance and Cleaning

• Before any work on the machine itself, pull the mains plug.
• Clean the ventilation slots of your power tool regularly with a soft brush. The motor fan draws dust into the housing, and a large accumulation of metal dust can lead to electrical hazards.
• In extreme conditions, always use dust extraction as far as possible. Blow out ventilation slots frequently and install a portable residual current device (PRCD). When working metals, conductive dust can settle in the interior of the power tool. The total insulation of the power tool can be impaired.
• Have maintenance and repair work performed only by qualified specialists. In this manner, it can be ensured that the safety of the power tool is maintained.

The retracting blade guard must always be able to move freely and retract automatically. Therefore, always keep the area around the retracting blade guard clean.
If the replacement of the supply cord is necessary, this has to be done by Bosch or an authorized Bosch service agent in or-der to avoid a safety hazard.

Accessories

Cutting discs for all metal materials
Cutting disc 355 x 25.4 mm/2 608 600 543/2 608 600 208

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. Exploded views and information on spare parts can al-so be found under:
www.bosch-pt.com
Bosch’s application service team will gladly answer questions concerning 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
E-Mail:
Ireland
Origo Ltd.
Unit 23 Magna Drive
Magna Business Park
City West
Dublin 24
Tel. Service: (01) 4666700
Fax: (01) 4666888
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: (01300) 307044
Fax: (01300) 307045
Inside New Zealand:
Phone: (0800) 543353
Fax: (0800) 428570
Outside AU and NZ:
Phone: +61 3 95415555
www.bosch.com.au