GCM 800 SJ - Saw BOSCH - Free user manual and instructions

USER MANUAL GCM 800 SJ BOSCH

OBJ_BUCH-2154-004.book Page 3 Wednesday, June 14, 2017 5:06 PM1 609 92A 3BW | (14.6.17) Bosch Power Tools 4 |

GCM 80 SJ GCM 800 SJ GCM 8000 SJ OBJ_BUCH-2154-004.book Page 4 Wednesday, June 14, 2017 5:06 PM| 5 Bosch Power Tools 1 609 92A 3BW | (14.6.17)

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C3 C4 OBJ_BUCH-2154-004.book Page 6 Wednesday, June 14, 2017 5:06 PM| 7 Bosch Power Tools 1 609 92A 3BW | (14.6.17)

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signed to properly support round material such as rods or tubing. Rods have a tendency to roll while being cut, causing the blade to “bite” and pull the work with your hand into the blade. Let the blade reach full speed before contacting the workpiece. This will reduce the risk of the workpiece be- ing thrown. If the workpiece or blade becomes jammed, turn the mitre saw off. Wait for all moving parts to stop and dis- connect the plug from the power source and/or remove the battery pack. Then work to free the jammed mate- rial. Continued sawing with a jammed workpiece could cause loss of control or damage to the mitre saw. After finishing the cut, release the switch, hold the saw head down and wait for the blade to stop before remov- ing the cut-off piece. Reaching with your hand near the coasting blade is dangerous. Keep your workplace clean. Blends of materials are par- ticularly dangerous. Dust from light alloys can burn or ex- plode. Do not use dull, cracked, bent or damaged saw blades. Unsharpened or improperly set saw blades produce nar- row kerf causing excessive friction, blade binding and kick- back. Do not use high speed steel (HSS) saw blades. Such saw blades can easily break. Always use blades with correct size and shape (dia- mond versus round) of arbour holes. Blades that do not match the mounting hardware of the saw will run eccentri- cally, causing loss of control. Never remove cutting remainders, wood chips, etc. from the sawing area while the machine is running. Al- ways guide the tool arm back to the neutral position first and then switch the machine off. OBJ_BUCH-2154-004.book Page 21 Wednesday, June 14, 2017 5:06 PM22 | English 1 609 92A 3BW | (14.6.17) Bosch Power Tools Do not touch the saw blade after working before it has cooled. The saw blade becomes very hot while working. 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 author- ised 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. 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 safely. Product Description and Specifica- tions Read all safety warnings and all instruc- tions. Failure to follow the warnings and in- structions may result in electric shock, fire and/or serious injury. Intended Use The power tool is intended as a stationary machine for making straight lengthways and crossways cuts in wood. Horizontal mitre angles of –47° to +47° as well as vertical bevel angles of 0° to 45° are possible. The machine is designed with sufficient capacity for sawing hard and softwood as well as press and particle board. When using appropriate saw blades, sawing aluminium pro- files and plastic is also possible. Product Features The numbering of the components shown refers to the repre- sentation of the power tool on the graphic pages. 1 Mounting holes 2 Clamping screw for saw-table extension 3 Saw-table extension 4 Recessed handles 5 Scale for mitre angle 6 Adjustable fence 7 Material clamp 8 Stop for 45° bevel angle 9 Stop screw for 45° bevel angle 10 Bevel lock lever 11 Locking screw for slide device 12 Slide device 13 Chip ejector 14 Chip deflector 15 On/Off switch 16 Handle 17 Locking switch for releasing the tool arm 18 Blade guard Symbols and their meaning Keep hands away from the cutting area while the machine is running. Danger of injury when coming in con- tact with the saw blade. Wear a dust respirator. Wear safety goggles. Wear ear protectors. Exposure to noise can cause hearing loss. Danger area! Keep hands, fingers or arms away from this area. Sawing bevel angles: The middle locking screw has to be loos- ened to move the adjustable fence. The two outer fixing screws must not be loosened! Observe the dimensions of the saw blade. The hole diameter must match the tool spindle without play. If it is necessary to use reducers, ensure that the dimensions of the reducer are suitable for the base blade thickness and the saw blade hole di- ameter, as well as the tool spindle diame- ter. Wherever possible, use the reducers provided with the saw blade. Symbols and their meaning

OBJ_BUCH-2154-004.book Page 22 Wednesday, June 14, 2017 5:06 PMEnglish | 23 Bosch Power Tools 1 609 92A 3BW | (14.6.17) 19 Retracting blade guard 20 Roller 21 Fence 22 Saw table 23 Insert plate 24 Mitre angle indicator 25 Locking knob for various mitre angles 26 Mitre detent lever 27 Tilt protector 28 Detents for standard mitre angles 29 Spindle lock 30 Transport safety-lock 31 Scale for bevel angle 32 Indicator for bevel angle 33 Stop screw for 0° bevel angle 34 Stop for 0° bevel angle 35 Hex key (size 5 mm)/cross-head screwdriver 36 Hex socket screw for mounting of saw blade 37 Clamping flange 38 Interior clamping flange 39 Saw blade 40 Locking screw of the adjustable fence 41 Mounting holes for material clamp 42 Threaded rod 43 Screws for insert plate 44 Screw for bevel angle indicator 45 Screw for mitre angle indicator Accessories shown or described are not part of the standard deliv- ery scope of the product. A complete overview of accessories can be found in our accessories program. Technical Data Noise Information Sound emission values determined according to EN 62841-3-9. Typically the A-weighted noise levels of the product are: Sound pressure level 93 dB(A); Sound power level 106 dB(A). Uncertainty K =3 dB. Wear hearing protection! The noise emission value given in these instructions has been measured in accordance with a standardised measuring pro- cedure 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 applica- tions of the power tool. However, if the power tool is used for other applications, with different accessories or is poorly maintained, the noise emission value may differ. This may sig- nificantly increase noise emissions over the total working pe- riod. 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 significant- ly reduce noise emissions over the total working period. Assembly Avoid unintentional starting of the machine. During as- sembly and for all work on the machine, the power plug must not be connected to the mains supply. Delivery Scope Before starting the operation of the machine for the first time, check if all parts listed below have been supplied: – Sliding mitre saw with mounted saw blade –Material clamp 7 – Saw-table extension 3 Clamping screw 2 x 2, cross-head screw x 2 to prevent the saw table extensions from being pulled out of the saw table – Hex key/cross-head screwdriver 35 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. Mounting Saw-table Extensions (see figure A) The saw table can be extended left and right with the saw-ta- ble extensions 3. – Slide the saw table extensions in as far as they will go through the holes provided in the saw table. – Turn the power tool upside down so that you can screw in the two cross-head screws provided to prevent the saw ta- ble extensions from being pulled out of the saw table. Screw the cross-head screws into the threaded holes pro- vided in the saw table extensions 3 and use a cross-head screwdriver 35 to tighten them. Sliding Mitre Saw GCM 80 SJ GCM 800 SJ GCM 8000 SJ Article number 3 601 M19 ...

Reduced starting current

Weight according to EPTA- Procedure 01:2014 kg 14.1 14.1 Protection class /II /II Permissible workpiece dimensions (maximum/minimum) see page 26. 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. Dimension of suitable saw blades Saw blade diameter mm 216 Blade body thickness mm 1.3–1.8 Max. cutting width mm 3.3 Mounting hole diameter mm 30 OBJ_BUCH-2154-004.book Page 23 Wednesday, June 14, 2017 5:06 PM24 | English 1 609 92A 3BW | (14.6.17) Bosch Power Tools – Turn the power tool the right way round again and screw the clamping screws 2 for fastening the saw table exten- sions 3 in place into the threaded holes provided in the saw table 22. 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 B1) – Fasten the power tool with suitable screw fasteners to the working surface. The mounting holes 1 serve for this pur- pose. Mounting to a Bosch Saw Stand With the height-adjustable legs, Bosch GTA saw stands pro- vide firm support for the power tool on any surface. The work- piece supports of the saw stand are used for underlaying long workpieces. Read all safety warnings and instructions included with the worktable. Failure to observe safety warnings and in- structions can lead to electrical shock, fire and/or cause serious injuries. Assemble the worktable properly before mounting the power tool. Perfect assembly is important in order to pre- vent the risk of collapsing. – Mount the power tool in transport position on the saw stand. Flexible Mounting (not recommended!) (see figure B2) In exceptional cases, when it is not possible to mount the ma- chine onto a level and stable work surface, it can be set up us- ing the tilt protector. Without the use of the tilt protector, the machine does not stand safely and can tip over, especially when saw- ing at maximum mitre/bevel angles. – Screw the tilt protector 27 in or out until the machine is po- sitioned level on the working surface. Dust/Chip Extraction Dust from materials such as lead-containing coatings, some wood types, minerals and metal can be harmful to one’s health. Touching or breathing-in the dust can cause allergic reactions and/or lead to respiratory infections of the user or bystanders. Certain dust, such as oak or beech dust, is considered carci- nogenic, especially in connection with wood-treatment addi- tives (chromate, wood preservative). Materials containing as- bestos may only be worked by specialists. – Always use dust extraction. – 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. Prevent dust accumulation at the workplace. Dust can easily ignite. The dust/chip extraction can be blocked by dust, chips or workpiece fragments. – Switch the machine off and pull the mains plug from the socket outlet. – Wait until the saw blade has come to a complete stop. – Determine the cause of the blockage and correct it. External Dust Extraction For dust extraction, a vacuum hose (size Ø 35 mm) can also be connected to the chip ejector 13. – Connect the vacuum hose with the chip ejector 13. The vacuum cleaner must be suitable for the material being worked. When vacuuming dry dust that is especially detrimental to health or carcinogenic, use a special vacuum cleaner. Changing the Saw Blade (see figures C1 – C4) When mounting the saw blade, wear protective gloves. Danger of injury when touching the saw blade. Use only saw blades whose maximum permitted speed is higher than the no-load speed of the power tool. Use only saw blades that correspond with the characteristic data given in these operation instructions and that are tested and marked in accordance with EN 847-1. Use only saw blades recommended by the tool manufacturer, and suitable for sawing the materials to be cut. This prevents overheating of the saw teeth during sawing. Removing the Saw Blade – Bring the power tool into the working position. –Turn the hex socket screw 36 with the hex key (5 mm) 35 and at the same time press the spindle lock 29 until it en- gages. – Hold the spindle lock 29 pressed and unscrew the hex socket screw 36 in clockwise direction (left-hand thread!). – Remove the clamping flange 37. – Press locking switch 17 and swing back the retracting blade guard 19 to the stop. – Hold the retracting blade guard in this position and remove the saw blade 39. – Slowly guide the retracting blade guard downward again. Mounting the Saw Blade If required, clean all parts to be mounted prior to assembly. – Press locking switch 17, swing back the retracting blade guard 19 to the stop and hold it in this position. – Place the new saw blade onto the interior clamping flange

When mounting the saw blade, pay attention that the cutting direction of the teeth (arrow direction on the saw blade) corresponds with the direction of the arrow on the blade guard! – Slowly guide the retracting blade guard downward again. – Place on the clamping flange 37 and the screw 36. Press the spindle lock 29 until it engages and tighten the screw turning in anticlockwise direction. OBJ_BUCH-2154-004.book Page 24 Wednesday, June 14, 2017 5:06 PMEnglish | 25 Bosch Power Tools 1 609 92A 3BW | (14.6.17) Operation Before any work on the machine itself, pull the mains plug. Transport Safety (see figure D) The transport safety-lock 30 enables easier handling of the machine when transporting to various working locations. Releasing the Machine (Working Position) – Push the tool arm by the handle 16 down a little in order to relieve the transport safety-lock 30. – Pull the transport safety-lock 30 completely outward. – Guide the tool arm slowly upward. Securing the Machine (Transport Position) – Loosen the locking screw 11 if tightened. Pull the tool arm completely to the front and tighten the locking screw again. – To lock the saw table 22, tighten the locking knob 25. – Press locking switch 17 and slowly guide the tool arm downward by the handle 16. – Guide the tool arm downward until the transport safety- lock 30 can be pushed completely inward. Preparing for Operation Moving the Fence (see figure E) You have to move the adjustable fence 6 to saw bevel angles. – Loosen the locking screw 40 using the supplied hex key

The two outer fixing screws must not be loosened! – Pull the adjustable fence 6 completely outward. – Retighten the locking screw 40. After sawing the bevel angles, slide the adjustable fence 6 back again (loosen the locking screw 40; slide the fence 6 completely inward; retighten the locking screw). Extending the Saw Table (see figure F) Long workpieces must be underlaid or supported at their free end. The saw table can be extended left and right with the saw-ta- ble extensions 3. – Loosen the clamping screw 2. – Pull out the saw-table extension 3 to the desired length. – Retighten the clamping screw 2 to fix the saw-table exten- sion. Clamping the Workpiece (see figure G) To ensure optimum working safety, the workpiece must al- ways be firmly clamped. Do not saw workpieces that are too small to clamp. – Press the workpiece firmly against the fences 6 and 21. – Insert the material clamp 7 provided into one of the holes 41 intended for it. – Adapt the threaded rod 42 of the screw clamp to the work- piece height. – Firmly tighten the threaded rod 42, thus fastening the workpiece. Adjusting the Cutting Angle To ensure precise cuts, the basic adjustment of the machine must be checked and adjusted as necessary after intensive use (see “Checking and Adjusting the Basic Adjustment”, page 26). Always tighten the locking knob 25 firmly before saw- ing. Otherwise the saw blade can become wedged in the workpiece. Adjusting Mitre Angles (see figure H) The mitre angle can be set in the range from 47° (left side) to 47° (right side). – Loosen the locking knob 25 in case it is tightened. – Pull the lever 26 and turn the saw table 22 until the desired mitre angle is indicated on the angle indicator 24. – Tighten the locking knob 25 again. For quick and precise setting of often used mitre angles, detents 28 are provided on the saw table: – Loosen the locking knob 25 in case it is tightened. – Pull lever 26 and rotate the saw table 22 left or right to the requested detent. – Release the lever again. The lever must be felt to engage in the detent. – Tighten the locking knob 25 again. Adjusting Bevel Angles (see figure I) The bevel angle can be set in the range from 0° to 45°. – Pull the adjustable fence 6 completely outward. – Loosen the lock lever 10. – Tilt the tool arm by the handle 16 until the angle indicator 32 indicates the desired bevel angle. – Hold the tool arm in this position and retighten the clamp- ing lever 10. For quick and precise setting of the standard angles 0° and 45°, end stops are provided on the housing. – Pull the adjustable fence 6 completely outward. – Loosen the lock lever 10. – To do so, swivel the tool arm by the handle 16 to the stop 34 to the right (0°) or to the stop 8 to the left (45°). – Retighten the lock lever 10 again. Starting Operation Observe correct mains voltage! The voltage of the pow- er 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. Products sold in AUS and NZ only: Use a residual current de- vice (RCD) with a rated residual current of 30 mA or less. Switching On (see figure J) To save energy, only switch the power tool on when using it. –To start the machine, press the On/Off switch 15 and keep it pressed. Left Right

45° 22.5° 15° 15° 22.5° 45° OBJ_BUCH-2154-004.book Page 25 Wednesday, June 14, 2017 5:06 PM26 | English 1 609 92A 3BW | (14.6.17) Bosch Power Tools Note: For safety reasons, the On/Off switch 15 cannot be locked; it must remain pressed during the entire operation. The tool arm can only be guided downward by pressing lock- ing switch 17. –For sawing, the locking switch 17 must be therefore pushed in addition to pressing the On/Off switch 15. Switching Off –To switch off the machine, release the On/Off switch 15. Working Advice General Sawing Instructions For all cuts, it must first be ensured that the saw blade at no time can come in contact with the fence, screw clamps or other machine parts. Remove any mounted auxiliary stops or adjust them accordingly. Only saw materials which are permitted within the scope of the intended use. Protect the saw blade against impact and shock. Do not sub- ject the saw blade to lateral pressure. Do not saw warped/bent workpieces. The workpiece must al- ways have a straight edge to face against the fence. Make sure that the retracting blade guard operates properly and that it can move freely. The retracting blade guard must open when the tool arm is guided downward. When the tool arm is guided upward, the retracting blade guard must close again over the saw blade and lock in the uppermost position of the tool arm. Position of the Operator (see figure K) Do not stand in a line with the saw blade in front of the machine. Always stand aside of the saw blade. This pro- tects your body against possible kickback. – Keep hands, fingers and arms away from the rotating saw blade. – Do not cross your arms when operating the tool arm. Permissible Workpiece Dimensions Maximum workpiece sizes: Minimum workpiece sizes (= all workpieces that can be clamped left or right from the saw blade with the supplied ma- terial clamp 7): 100 x 40 mm (length x width) Cutting depth, max. (0°/0°): 70 mm Replacing Insert Plates (see figure L) The red insert plates 23 can become worn after prolonged use of the machine. Replace defective insert plates. – Bring the power tool into the working position. –Unscrew the screws 43 with a hex key (4 mm) and remove the old insert plates. – Insert the new right-hand insert plate. – Screw the insert plate as far as possible to the right with the screws 43 so that the saw blade does not come into contact with the insert plate over the complete length of the possible slide motion. – Repeat the work steps in the same manner for the left-hand insert plate. Sawing Always tighten the locking knob 25 firmly before saw- ing. Otherwise the saw blade can become wedged in the workpiece. Sawing without Slide Movement (Cutting Off) (see figure M) – For cuts without slide movement (small workpieces), loos- en the locking screw 11 if it is tightened. Push the tool arm all the way towards the fences 6 and 21 and retighten the locking screw 11. – Adjust the requested mitre and/or bevel angle. – Press the workpiece firmly against the fences 6 and 21. – Firmly clamp the workpiece as appropriate for its dimen- sions. – Switch on the machine. – Press locking switch 17 and slowly guide the tool arm downward by the handle 16. – Saw through the workpiece applying uniform feed. – Switch off the machine and wait until the saw blade has come to a complete stop. – Guide the tool arm slowly upward. Sawing with Slide Movement – For cuts using the slide device 12 (wide workpieces), loos- en the locking screw 11 in case it is tightened. – Adjust the requested mitre and/or bevel angle. – Press the workpiece firmly against the fences 6 and 21. – Firmly clamp the workpiece as appropriate for its dimen- sions. – Pull the tool arm away from the fences 6 and 21 until the saw blade is in front of the workpiece. – Switch on the machine. – Press locking switch 17 and slowly guide the tool arm downward by the handle 16. – Now push the tool arm toward the fences 6 and 21 and saw through the workpiece with uniform feed. – Switch off the machine and wait until the saw blade has come to a complete stop. – Guide the tool arm slowly upward. Special Workpieces When sawing curved or round workpieces, these must be es- pecially secured against slipping. At the cutting line, no gap may exist between workpiece, fence and saw table. Provide for special fixtures, if required. Checking and Adjusting the Basic Adjustment Before any work on the machine itself, pull the mains plug. To ensure precise cuts, the basic adjustment of the machine must be checked and adjusted as necessary after intensive use. Mitre/Bevel Angle Height x Width [mm] Horizontal Vertical 0° 0° 70 x 270 45° 0° 70 x 190 0° 45° 45 x 270 OBJ_BUCH-2154-004.book Page 26 Wednesday, June 14, 2017 5:06 PMEnglish | 27 Bosch Power Tools 1 609 92A 3BW | (14.6.17) A certain level of experience and appropriate specialty tools are required for this. A Bosch after-sales service station will handle this mainte- nance task quickly and reliably. Setting the Standard Bevel Angle 0° (Vertical) – Bring the power tool into the working position. – Turn the saw table 22 to the 0° detent 28. The lever 26 must be felt to engage in the detent. Checking: (see figure N1) – Adjust an angle gauge to 90° and position it on the saw ta- ble 22. The leg of the angle gauge must be flush with the saw blade 39 over the complete length. Adjusting: (see figureN2) – Loosen the lock lever 10. – Loosen the lock nut of the stop screw 33 using a commer- cial box-end or open-end spanner (size 10 mm). – Screw the stop screw in or out until the leg of the angle gauge is flush with the saw blade over the complete length. – Retighten the lock lever 10 again. – Afterwards, retighten the lock nut of the stop screw 33 again. In case the angle indicator 32 is not in a line with the 0° mark of the scale 31 after the adjustment, loosen the screw 44 us- ing a commercial cross-head screwdriver and align the angle indicator along the 0° mark. Setting the Standard Bevel Angle 45° (Vertical) – Bring the power tool into the working position. – Turn the saw table 22 to the 0° detent 28. The lever 26 must be felt to engage in the detent. – Loosen the lock lever 10 and tilt the tool arm leftward to the stop (45°) by the handle 16. Checking: (see figure O1) – Adjust an angle gauge to 45° and position it on the saw ta- ble 22. The leg of the angle gauge must be flush with the saw blade 39 over the complete length. Adjusting: (see figure O2) – Loosen the lock lever 10. – Loosen the lock nut of the stop screw 9 using a commercial box-end or open-end spanner (size 10 mm). – Screw the stop screw in or out until the leg of the angle gauge is flush with the saw blade over the complete length. – Retighten the lock lever 10 again. – Afterwards, retighten the lock nut of the stop screw

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