Bosch Power Tools 1803EVS, 1801, 1800, 1806E User Manual

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IMPORTANT: IMPORTANT : IMPORTANTE:

Read Before Using Lire avant usage Leer antes de usar

Operating/Safety Instructions Consignes de fonctionnement/sécurité

Instrucciones de funcionamiento y seguridad

1800 1801 1803EVS 1806E

Call Toll Free for

Consumer Information

& Service Locations

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

For English Version Version française Versión en español

See page 2

Pour obtenir des informations

et les adresses de nos centres

de service après-vente,

appelez ce numéro gratuit

Voir page 14 Ver la página 26

Llame gratis para

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ubicaciones de servicio

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General Safety Rules

WARNING

all of the warnings listed below refers to your mains-operated (corded) power tool or batteryoperated (cordless) power tool.

Read all instructions. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.

The term “power tool” in

SAVE THESE INSTRUCTIONS

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.

tools create sparks which may ignite the dust or fumes.

Keep children and bystanders away while operating a power tool.

cause you to lose control.

Distractions can

Power

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.

and matching outlets will reduce risk of electric shock.

Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges and refrigerators.

is an increased risk of electric shock if your body is earthed or grounded.

Do not expose power tools to rain or wet conditions.

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.

entangled cords increase the risk of electric shock.

When operating a power tool outdoors, use an extension cord suitable for outdoor use.

outdoor use reduces the risk of electric shock.

Do not use AC only rated tools with a DC power supply.

work, the electrical components of the AC rated tool are likely to fail and create a hazard to the operator.

Water entering a power tool will

Use of a cord suitable for

While the tool may appear to

Unmodified plugs

There

Damaged or

If operating the power tool in damp locations is unavoidable a Ground Fault Circuit Interrupter (GFCI) must be used to supply the power to your tool.

personal protection devices like electrician’s rubber gloves and footwear will further enhance your personal safety.

GFCI and

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.

inattention while operating power tools may result in serious personal injury.

Use safety equipment. Always wear eye protection.

mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.

Avoid accidental starting. Ensure the switch is in the off-position before plugging in.

finger on the switch or plugging in power tools that have the switch on invites accidents.

Remove any adjusting key or wrench before turning the power tool on.

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.

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.

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.

related hazards.

Safety equipment such as dust

Carrying power tools with your

Loose clothes, jewelry or long hair can

Use of these devices can reduce dust-

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A moment of

A wrench

This enables

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Keep handles dry, clean and free from oil and grease.

control the power tool.

Slippery hands cannot safely

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.

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.

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 tools operation. If damaged, have the power tool repaired before use.

poorly maintained power tools.

Many accidents are caused by

Any power tool

Such preventive safety

SAVE THESE INSTRUCTIONS

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 i

nstructions and in the manner intended for the particular type of power tool, 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.

Use clamps or other practical way to secure and support the workpiece to a stable platform.

or against your body is unstable and may lead to loss of control.

Holding the work by hand

Service

Have your power tool serviced by a qualified repair person using only identical replacement parts.

safety of the power tool is maintained.

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 improperly mounted.

gasoline, carbon tetrachloride, ammonia, etc. may damage plastic parts.

Certain cleaning agents such as

This will ensure that the

Angle Grinder Safety Rules

Always use proper guard with grinding wheel.

broken wheel fragments. When using grinding wheel attachments, the guard must always be attached to the tool and positioned for maximum safety, so the least amount of wheel is exposed from the side the tool is being operated.

Use clamps or other practical way to secure and support the workpiece to a stable platform.

or against your body is unstable and may lead to loss of control.

A guard protects operator from

Holding the work by hand

Accessories must be rated for at least the speed recommended on the tool warning label.

Wheels and other accessories running over rated speed can fly apart and cause injury. Grinding wheels or any other accessory must have a maximum safe operating speed greater than the “no load RPM” marked on the tool’s nameplate.

Hold tool by insulated gripping surfaces when performing an operation where the cutting tools may contact hidden wiring or its own cord.

will make exposed metal parts of the tool “live” and shock the operator.

Contact with a “live” wire

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Always use auxiliary handle for maximum control over torque reaction or kick-back.

peration of the grinder without the side

andle could cause loss of control of the grinder, resulting in possible serious personal injury.

Before using a grinder or installing a new wheel, inspect the grinding wheel for chips and cracks. Remove bad wheels immediately. Run the tool at no load for one minute, holding the tool in the direction away from people.

flaws will normally break apart during this time.

Carefully handle both the tool and individual grinding wheels to avoid chipping or cracking. Install a new wheel if tool is dropped while grinding. Do not use a wheel that may be damaged.

from a wheel that bursts during operation will fly away at great velocity possibly striking you or bystanders.

Do not use grinding wheel that is larger than the maximum recommended size for your tool, or worn down damaged wheels from larger grinders.

large angle sander/grinders are not suitable for the high speed of a small angle sander/grinder, these wheels may easily burst and the fragments strike you or bystanders.

Do not use depressed hub grinding wheels for cut-off operations.

wheels or type 27 wheels are not intended for side loading and may shatter under overload.

Do not use this tool with “Woodcarving”

Such blades create frequent kick-back

blade.

and loss of control.

Wear proper apparel while using a sander/grinder.

goggles, dust mask, leather gloves and shop apron capable of stopping small wheel or workpiece fragments.

Position the cord clear of the spinning grinding wheel or any other sanding accessory. Do not wrap the cord around your arm or wrist.

have the cord wrapped around your arm or wrist it may entrap you and cause injury.

Wheels intended for

Face shield or at least safety

If you lose control and

Wheels with

Fragments

Depressed hub

Avoid bouncing and snagging the wheel, especially when working corners, sharp e

dges etc.

ick-back.

Regularily clean the tool’s air vents by compressed air.

powdered metal inside the motor housing may cause electrical failures.

Do not grind or sand near flammable materials.

these materials.

This tool can be converted to a sander. When grinding is resumed the proper guard and wheel flanges MUST be reinstalled before proceeding with grinding. The guard must always be attached to the tool and positioned for maximum safety, so the least amount of wheel is exposed from the side the tool is being operated.

cannot be used for most sanding operations or for wire brushing.

When sanding, do not use oversized sanding disc.

beyond the sanding pad causing snagging, tearing of the disc or kick-back. Extra paper extending beyond the sanding pad can also cause serious lacerations.

grinding, 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 chemicallytreated lumber.

Your risk from these exposures varies, depending 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 approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

his can cause loss of control and

Excessive accumulation of

Sparks from the wheel could ignite

The grinding wheel guard

Larger sanding disc will extend

WARNING

Some dust created by power sanding, sawing,

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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 Name Designation/Explanation

V Volts Voltage (potential)

A Amperes Current

Hz Hertz Frequency (cycles per second)

W Watt Power

kg Kilograms Weight

min Minutes Time

s Seconds Time

Diameter Size of drill bits, grinding wheels, etc.

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

0 Off position Zero speed, zero torque...

1, 2, 3, ... Selector settings Speed, torque or position settings.

I, II, III, Higher number means greater speed

No load speed Rotational speed, at no load

orbits etc. per minute

Infinitely 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

Earthing terminal Grounding terminal

Warning symbol Alerts user to warning messages

Ni-Cad RBRC seal Designates Ni-Cad battery recycling

Designates Double Insulated Construction tools.

program

This symbol designates that this tool is listed by Underwriters Laboratories.

This symbol designates that this tool is listed by the Canadian Standards Association.

This symbol designates that this tool is listed to Canadian Standards by Underwriters Laboratories.

This symbol designates that this tool is listed by Underwriters Laboratories, and listed to Canadian Standards by Underwriters Laboratories.

This symbol

designates that this tool complies to NOM Mexican Standards.

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Functional Description and Specifications

WARNING

Disconnect the plug from the power source before making any a

ssembly, adjustments or changing accessories.

measures reduce the risk of starting the tool accidentally.

Angle Grinders

FIG. 1

RELEASE / ADJUSTMENT

GUARD

BUTTON

SPINDLE LOCK

SWITCH

BUTTON

uch preventive safety

VENTILATION

OPENINGS

VARIABLE SPEED

WITH DIAL SETTING

(Model 1803EVS only)

VIBRATION

CONTROL

GRINDING

WHEEL

WHEEL GUARD

SIDE HANDLE

Model number 1800 1801 & 1803EVS 1806E Max. wheel diameter 4 1/2" (115mm) 5" (125mm) 6" (150mm) Spindle thread 5/8"-11 UNC 5/8 "-11 UNC 5/8 "-11 UNC Max. wire wheel 4" Dia. 4" Dia. 4" Dia. Max. wire cup brush 3" Dia. 3" Dia. 3" Dia. Max. sanding disc 4 1/2" Dia. 5" Dia. 6" Dia. Max. cut off wheel 4 1/2" Dia. 5" Dia. 6" Dia. Max. dry diamond wheel 4 1/2" Dia. 5" Dia. 6" Dia.

NOTE: For tool specifications refer to the nameplate on your tool.

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Assembly

HEEL GUARD INSTALLATION

WARNING

Wheel guard must be

attached when using disc grinding wheels. Always keep wheel guard between you and your work while grinding.

The position of the guard can be adjusted to accommodate the operation being performed.

To attach wheel guard DISCONNECT tool from power source.

Position wheel guard on spindle neck so that the arrow on guard lines up with the arrow on the spindle neck. Rotate wheel guard clockwise 90º until it clicks in place (Fig. 2).

TO ADJUST GUARD: depress guard release button (Fig. 1), rotate guard to desired position, release button and let it click in place.

O REMOVE GUARD: Depress release button, rotate guard until arrow on guard lines up with arrow on spindle neck, and remove guard from spindle neck.

WHEEL GUARD

SPINDLE

NECK

FIG. 2

LOCK NUT AND BACKING FLANGE

Your tool is equipped with a threaded spindle for mounting accessories. Always use the supplied lock nut (and backing flange) that has same thread size as spindle.

Disc Grinding Wheel Assembly

(Models 1800, 1801 & 1803EVS only)

Disconnect tool from power source. Be sure that wheel guard is in place for grinding. Place BACKING FLANGE and GRINDING WHEEL on the spindle. Thread on the lock nut and tighten nut using the supplied lock nut wrench, while holding the spindle lock in (Fig. 3).

SPINDLE

GRINDING

WHEEL

BACKING

FLANGE

LOCK NUT

The side handle used to guide and balance the

SIDE HANDLE

tool can be threaded into the front housing on either side of the tool, depending on personal preference and comfort. Use the side handle for safe control and ease of operation.

FIG. 3

SPINDLE

WHEEL GUARD

BACKING

FLANGE

GRINDING

WHEEL

LOCK NUT

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Disc Grinding Wheel Assembly

Disconnect tool from power source. Be sure that wheel guard is in place for grinding.

When using spin-on grinding wheels, thread directly onto the spindle.

When using mounting wheels, thread BACKING FLANGE onto spindle, then place GRINDING WHEEL on the spindle. Thread on the lock nut and tighten nut using a lock nut wrench provided with adapter kit, while holding the spindle lock in (Fig. 4).

TO REMOVE: Reverse procedure.

(Model 1806 only)

Masonry Cutting Wheel Assembly

For cutting masonry materials like brick, tile, stone, etc., it is best to use a dry diamond cutting wheel. Use only lock nut and flange with equal diameters. The wheel guard must be used with a dry diamond cutting wheel.

WARNING

cutting. Disconnect tool from power source. Be sure

that wheel guard is in place for grinding. Place BACKING FLANGE and DRY DIAMOND WHEEL on the spindle. Thread on the lock nut and tighten nut using the supplied lock nut wrench, while holding the spindle lock in (Fig. 5).

Do not use water or other cooling fluid with this tool for

FIG. 4

SPINDLE

WHEEL

GUARD

BACKING

FLANGE

GRINDING

WHEEL

LOCK NUT

TO REMOVE: Reverse procedure.

FIG. 5

SPINDLE

WHEEL GUARD

BACKING

FLANGE

DRY

DIAMOND

WHEEL

SPINDLE

BACKING

FLANGE

LOCK NUT

DRY

DIAMOND

WHEEL

LOCK NUT

When cutting, make only small passes through workpiece at a time. Be aware that “Kickback” can occur at any time. Keep both hands on tool for maximum control.

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Sanding Accessories Assembly

BACKING PAD

WARNING

safe operating speed is not exceeded by the nameplate speed of the tool.

WARNING

operations. Always reinstall wheel guard when converting back to grinding operations.

TO INSTALL BACKING PAD AND

Disconnect tool from power source. Set the tool on its top side (spindle up). Place the rubber backing pad onto the spindle shaft. Center the sanding disc on top of the backing pad. Insert the lock nut through the disc and thread onto the spindle as far as you can with your fingers. Press in the spindle lock, then tighten the backing pad securely with lock nut wrench (Fig. 6).

TO REMOVE BACKING PAD AND

Disconnect tool from power source. Using the lock nut wrench unscrew the nut from the spindle, while holding spindle lock in.

Before assembling wire brush to this tool, disconnect from the power source. Wire

Before attaching a backing pad be sure its maximum

Wheel guard may not be used for most sanding

SANDING DISC

WIRE BRUSH ASSEMBLY

brushes are equipped with their own threaded hub, simply thread on to spindle (

Fig. 6). Be sure to seat against shoulder

efore turning tool “ON”.

FIG. 6

PINDLE

BACKING

PAD

SANDING

DISC

LOCK NUT

WIRE

BRUSH

Operating Instructions

SLIDE ON-OFF SWITCH WITH LOCK

The tool is switched “ON” by the switch button located at the side of the motor housing. The switch can be locked in the “ON” position, a convenience for long grinding operations.

TO TURN THE TOOL “ON” without locking it, slide the switch button forward by applying pressure ONLY at the REAR portion of the button. When pressure is released the switch button will snap to “OFF” position.

TO LOCK THE SWITCH “ON”, slide the switch button forward and press “IN” the FRONT portion.

TO UNLOCK THE SWITCH, simply press and release the REAR portion of the button. Switch is spring loaded and will snap back automatically.

WARNING

torque from the motor can cause the tool to twist.

Start the tool before applying to work and let the tool come to full speed before contacting the workpiece. Lift the tool from the work before releasing the switch. DO NOT turn the switch “ON” and “OFF” while the tool is under load; this will greatly decrease the switch life.

Hold the tool with both hands while starting the tool, since

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ELECTRONIC FEEDBACK CIRCUITRY (EFC)

(Models 1803EVS & 1806E only)

The internal electronic feedback system provides a "soft start", which will reduce the stresses that occur from a high torque start. The system also helps to keep the no load speed virtually constant between no-load and l

oad conditions.

KICKBACK STOP

Your tool is equipped with a kickback stop feature. This feature shuts of the tool automatically if the tool stalls, or the wheel encounters excessive force. To resume operation, TURN ON/OFF SWITCH TO THE OFF POSITION, THEN RESTART THE TOOL.

RESTART PROTECTION

The restart protection feature was designed to help prevent accidental startups after the power has been interrupted. To resume operation if this occurs, TURN ON/OFF SWITCH TO THE OFF POSITION, THEN RESTART THE TOOL.

OVERLOAD PROTECTION

(Models 1803EVS & 1806E only)

Your tool is equipped with overload protection to protect the motor. If the tool stops during operation TURN OFF SWITCH IMMEDIATELY and allow the motor to cool for about 30 seconds by running at no-load. If the overload protection stops the tool

repeatedly, excessive force is causing the tool to overload. Don't press so hard and let the tool do the work.

ARIABLE SPEED WITH DIAL SETTING

(1803EVS ONLY)

Your tool is also equipped with a variable speed dial. The grinder’s RPM can be preset from zero to maximum nameplate rated RPM by rotating the dial on the motor housing. If tool is running at a set speed for extended periods of time, it may be necessary to run the tool at no- load full speed to cool the motor.

ial Setting Application Approx. RPM Material Attachment

Polishing Plastic Lambswool bonnet

1 or buffing disc.

(2800)

2-3 Solid wood & Sanding disc

(5300-7500) paint removal

(7500) Removing rust Sanding disc

4-6 Grinding metal Grinding disc

(8800-11000) or stone

(11000) Cutting stone Cutting disc

Precision grinding Grinding disc of metal tools

Brushing wood

from metal

Roughing metal

felt polishing disc,

Cup brush

Roughing disc

Grinding Operations

SELECTING GRINDING WHEELS

WARNING

maximum safe operating speed is not exceeded by the nameplate speed of the grinder. Do not exceed the recommended wheel diameter.

Grinding wheels should be carefully selected in order to use the grinder most efficiently. Wheels vary in type of abrasive, bond, hardness, grit size and structure. The correct type of wheel to use is determined by the job. Use disc grinding wheels for fast grinding of structural steel, heavy weld beads, steel casting, stainless steel and other ferrous metals.

Before using a grinding wheel, be certain that its

DISC GRINDING WHEELS

Efficient grinding is achieved by controlling

GRINDING TIPS

the pressure and keeping the angle between wheel and workpiece at 10° to 15°. If the wheel is flat, the tool is difficult to control. If the angle is too steep, the pressure is concentrated on a small area causing burning to the work surface.

WARNING

Excessive or sudden pres-

sure on the wheel will slow grinding action and put dangerous stresses on the wheel.

When grinding with a new wheel be certain to grind while pulling tool backwards until wheel becomes rounded on its edge. New wheels have sharp corners which tend to “bite” or cut into workpiece when pushing forward.

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Sanding Operations

SELECTING SANDING DISC

Sanding discs are made of extremely hard and sharp aluminum oxide grits, phenol-resin bonded to a sturdy fiber backing for fast heavy-duty service and long life. The discs vary as to size and spacing of the abrasive grits. OPEN COAT (type H) — used for soft materials and on paint or varnish. CLOSED COAT (type K) —used for metal, hardwood, stone, marble and other materials.

Sanding discs range in grit from 16 (very coarse) to 180 (very fine). To obtain best results, select sanding discs carefully. Many jobs require the use of several grit sizes and

SANDING TIPS

For best results, tilt the Disc Sander at a 10° to 15° angle while sanding so that only about 1" of the surface around the edge of the disc contacts the work.

WARNING

If the disc (accessory) is held

flat or the back edge of the disc comes in contact with the work, a violent thrust to the side may result.

If sander is tilted too much, sanding action will be too great and a rough cut surface or gouging and snagging will result.

Guide the Disc Sander with crosswise strokes. Be careful not to hold the sander in one spot too long. Do not use a circular motion, as this makes swirl marks. Test before use on scrap stock.

Do not force or apply pressure when sanding. Use only the weight of the tool for pressure. Excess pressure actually slows the tool down. If faster stock removal is desired, change to a coarser grit disc.

Remove gummy paint from metal with an “open coat” disc. Sand until sparks start to

at times both “open coat and closed coat” discs are required to get the job done faster. See chart for application examples.

peration:Refinishing painted wood or metal surfaces.

REMARKS GRIT

To remove paint and to smooth Coarse

urface irregularities. 16-24-30

o smooth Medium

he rough sanding. 36-50-80

o remove scratches left by Fine

revious discs. 100-120

To smooth surfaces for painting, Very Fine polishing or waxing. 1

50-180

appear, then stop and change to a “closed coat” disc to remove any remaining paint.

SANDING WOOD

When sanding wood the direction of the disc motion at the contact point should parallel the grain as much as possible. The rapid cut of discs and the swirl type scratch pattern they occasionally create generally prohibit their use for producing the final finish.

Scratches and circular marks are usually the result of using too coarse a grit. When changing to a finer grit, move across the sanding lines that were made by a previous coarser disc.

SANDING METAL

When sanding automobiles or appliances, wipe the metal clean with a non-flammable solvent or commercial cleaner to remove all wax and grease. By doing this first, the sanding discs will sand better and last longer.

For heavy duty work, use a coarse grit disc first. Follow-up with a medium grit to remove scratches. To produce smooth finish, use fine grit disc.

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Wire Brush Operations

Wire brushes are intended to “clean” structural steel, castings, sheet metal, stone and concrete. They are used to remove rust, s

cale and paint.

WARNING

when working corners, sharp edges etc. This c

an cause loss of control and kick-back.

Avoid bouncing and snagging the wire brush, especially

1. Remember, the tips of a wire brush do the

BRUSHING PRESSURE

work. Operate the brush with the lightest pressure so only the tips of the wire come in contact with the work.

2. If heavier pressures are used, the wires will be overstressed, resulting in a wiping

CORRECT:

Wire tips doing

the work.

Maintenance

action; and if this is continued, the life of the brush will be shortened due to wire fatigue.

3. Apply the brush to the work in such a way that as much of the brush face as possible is in full contact with the work. Applying the side or edge of the brush to the work will result in wire breakage and shortened brush life.

INCORRECT:

Excessive

pressure can

cause wire

breakage.

Service

WARNING

personnel may result in misplacing of internal wires and components which could cause serious hazard.

recommend that all tool service be performed by a Bosch Factory Service Center or Authorized Bosch Service Station.

Your Bosch tool has been properly lubricated and is ready to use. It is recommended that tools with gears be regreased with a special gear lubricant at every brush change.

Preventive maintenance performed by unauthorized

TOOL LUBRICATION

The brushes and commutator in your tool

CARBON BRUSHES

have been engineered for many hours of dependable service. To maintain peak efficiency of the motor, we recommend every two to six months the brushes be examined. Only genuine Bosch replacement brushes specially designed for your tool should be used.

BEARINGS

After about 300-400 hours of operation, or at every second brush change, the bearings should be replaced at Bosch Factory Service Center or Authorized Bosch Service Station. Bearings which become noisy (due to heavy load or very abrasive material cutting) should be replaced at once to avoid overheating or motor failure.

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