Bosch Power Tools 1994-6D, 1994-6, 1974-8D, 1974-8 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

1974-8 1974-8D 1994-6 1994-6D

Call Toll Free for

Consumer Information

& Service Locations

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

Pour obtenir des informations

et les adresses de nos centres

de service après-vente,

appelez ce numéro gratuit

Llame gratis para

obtener información

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ubicaciones de servicio

For English Version Version française Versión en español

See page 2 Voir page 17 Ver la página 32

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General Power Tool Safety Warnings

WARNING

follow the warnings and instructions may result in electric shock, fire and/or serious injury.

SAVE ALL WARNINGS AND

INSTRUCTIONS FOR FUTURE

The term “power tool” in all of the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

a) Ke ep wo rk area clean and well lit.

Cluttered or dark areas invite accidents.

b) 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.

c) Keep childre n and bystanders aw ay

while operating a power tool. Distractions

can cause you to lose control.

a) Power tool plugs must match the outlet.

Never modify the plug in any way. Do not use an y adapter pl ugs with ear thed (grounded) power tools. Unmodified plugs

and matching outlets will reduce risk of electric shock.

b) Avo id bo dy contact w ith earthe d or

gr oun ded sur faces such as pi pes, radiators, 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.

Damaged or entangled cords increase the risk of electric shock.

e) When operating a power tool outdoors,

us e an ext ension cord suitab le for outdoor use. Use of a cord suitable for

outdoor use reduces the risk of electric shock.

Read all safety warnings and instructions. Failure to

REFERENCE

1) Work area safety

2) Electrical safety

f) If ope ratin g a power tool i n a damp

location is unavoidable, use a Ground Fault Circuit Interrupter (GFCI) protected supply. Use of an 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 influence of dru gs, alco hol or medica tion. A

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

b) Use personal p rotective equi pment.

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.

c) Prevent unintentional starting. Ensure

the switch is in the off-position before connecting to power source and / or battery pack, picking up or carrying the tool. Carrying power tools with your finger

on the switch or energizing power tools that have the switch on invites accidents.

d) Remove any adjusting key or wrench

befo re turning t he power too l 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

bette r cont rol of the power to ol in unexpected situations.

f) Dr ess pro perl y. Do not wea r loose

clothing or jewelry. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair

can be caught in moving parts.

g) If de vic es ar e pr ovided f or t he

co nne ctio n of du st extr acti on and collection facilities, ensure these are connected and properly used. Use of dust

collection can reduce dust-related hazards.

4) Power tool use and care

a) 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.

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) 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 the battery pack from the po wer to ol bef ore ma kin g any adjustments, changing accessories, 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

ch ild ren and do not allow per sons unfamiliar with the power tool or these instructions to operate the power tool.

Power tools are dangerous in the hands of untrained users.

e) Ma int ain power tools. Check for

misalignment or binding of moving parts, br eak age of pa rts an d any other condit ion that ma y affect th e power

ool’s operation. If damaged, have the

t power tool repaired before use. Many

accidents are caused by poorly maintained power tools.

f) Keep cutting t ools sharp and cl ean.

Properly 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

bi ts etc . in acco rdan ce wit h these instructions, taking into account the working conditions and the work to be pe rfo rmed. Use of t he pow er tool for

operations different from those intended could result in a hazardous situation.

a) Have your power t ool serviced by a

qu ali fied re pair person usi ng only identical replacement parts. This will

ensure that the safety of the power tool is maintained.

5) Service

Power Tool-Specific Safety Warnings

Safety Warnings Common for Grinding,

Sanding, Wire Brushing, and Abrasive

Cutting-Off Operations:

a) This power tool is intended to function

as a grinder, sander, wire brush or cutof f tool . Read all saf e ty war ning s , in struc tion s , il lustr atio n s an d specifications provided with this power tool. Failure to follow all instructions listed

below may result in electric shock, fire and/or serious injury.

b) This power tool is not recommended for

polishing. Operations for which the power

tool was not designed may create a hazard and cause personal injury.

c) Do not use accessories which are not

specifically designed and recommended by the tool manufacturer. Just because

the accessory can be attached to your po wer to ol, it d oes not a ssur e safe operation.

d) 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 fly apart.

e) The outside diameter and the thickness

of your accessory must be within the ca paci ty ratin g o f y our pow er tool .

Incorrectly sized accessories cannot be adequately guarded or controlled.

f) Th e arbo r size of wheel s, fla nges,

backing pads or any other accessory must pr ope rly fi t the spind le of th e power tool. Accessories with arbor holes

that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively and may cause loss of control.

g) 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 wire s. If power to ol or access ory is dropped, inspect for damage or install an undamaged accessory. After inspecting and installing an accessory, position yourself and bystanders away from the plane of the rotating accessory and run the po wer tool at ma ximum no-l oad sp eed for one minute . Damag ed

accessories will normally break apart during this test time.

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ickback and Related Warnings

) Wear personal protective equipment.

Dependi ng on appl ica tio n, us e fac e shield, safety goggles or safety glasses. As appropriate, wear dust mask, hearing protectors, gloves and workshop apron capable of stopping small abrasive or workpiece fragments. The eye protection

must be capable of stopping flying debris generated by various operations. The eye protection must be capable of stopping flying debris generated by various operations. The dust mask or respirator must be capable of filtr atin g particle s gener ated by yo ur operation. Prolonged exposure to high intensity noise may cause hearing loss.

i) 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 fly away and cause injury beyond immediate area of operation.

j) Hold power tool by insulated gripping

su rfa ces only, when p erformi ng an operation where the cutting accessory 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 shock the operator.

k) 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.

l) 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.

m)Do not run the power tool while carrying

it at your side. Accidental contact with the

spinn ing accessor y coul d snag y our clothing, pulling the accessory into your body.

n) Regul arly clean th e power tool’s ai r

vents. The motor’s fan will draw the dust

insid e the h ousing an d excessi ve accumulation of powdered metal may cause electrical hazards.

o) Do not o perate th e power too l near

flammable materials. Sparks could ignite

these materials.

p) Do not use accessor ies that r equire

liquid coolants. Using water or other liquid

coolants may result in electrocution or shock.

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 kickout. The wheel may either jump toward or away from the operator, depen ding on directio n of the wheel’ s movement at the point of pinching. Abrasive wheels may also break under these conditions.

Kickback is the result of power tool misuse and/or inco rrect operating p rocedures or conditions and can be avoided by taking proper precautions as given below.

a) Maintain a firm grip on the power tool

and position your body and arm to allow you to resist kickback forces. Always use au xil iary hand le, i f pro vided, for ma xim um co ntro l over ki ckba ck or torque reactio n 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

direction 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 or toothed saw blade. Such blades

create frequent kickback and loss of control.

Safety Warnings Specific for Grinding and

Abrasive Cutting-Off Operations:

a) Us e on ly w hee l ty pes that are

recommended for your power tool and the specific gu ard d esi gne d for the selected wheel. Wheels for which the

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ool motionless until the wheel comes to

ower tool was not designed cannot be

p adequately guarded and are unsafe.

b) The guard must be securely attached to

th e po wer tool and positio ned for maximum safety, so the least amount of wheel is exposed towards the operator.

The guard helps to protect operator from broken wheel fragments and accidental contact with wheel.

c) Wh eel s must be use d o nly for

re com mend ed ap pli cati ons. 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.

d) Always use undamaged wheel flanges

that are of correct size and shape for your selected wheel. Proper wheel flanges

suppo rt the whe el thus re duci ng the possibility of wheel breakage. Flanges for cut-off wheels may be different from grinding wheel flanges.

e) Do not u se worn down w heels f rom

larger power tools. Wheel intended for

larger power tool is not suitable for the higher speed of a smaller tool and may burst.

Additional Safety Warnings Specific for

Abrasive Cutting-Off Operations:

Do not attempt to cut large stock or sheets of metal as this machine is not designed to be a dedicated cut-off machine.

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

excessive pressure. Do not attempt to ma ke an exce ssiv e dep th of c ut.

Overstressing 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) Wh en whee l is bin ding o r when

interrupting a cut for any reason, switch off the power tool and hold the power

t a co mple te sto p. Nev er att emp t to remove the cut-off 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 reenter the cut. The wheel

may bind, walk up or kickback if the power tool is restarted in the workpiece.

e) Su ppo rt p anels o r any o vers ize d

workpiece to minimize the risk of wheel pinching and kickback. Large workpieces

tend to sag under their own weig ht. Suppo rts must be placed unde r t he workpiece near the line of cut and near the edge of the workpiece on both sides of the wheel.

f) Us e extra cau tion w hen maki ng 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.

Do not use type 1 abrasive wheels designed for straight grinding.

Safety Warnings Specific for Sanding

a) Do not use excessively oversized sanding

di sc p aper . Fol low manu fact ure r’s re com mend ations, when sele cting sandin g paper. La rger sanding paper

extending beyond the sanding pad presents a lacer ation haza rd and may cause snagging, tearing of the disc or kickback.

Safety Warnings Specific for Wire Brushing

a) Be aware that wire bristles are thrown by

th e bru sh ev en du ring ordi nary operation. Do not overstress the wires by applying excessive load to the brush.

The wire bristles can easily penetrate light clothing and/or skin.

b) If the use of a guard is recommended for

wi re b rushi ng, do n ot a llow any interference of the wire wheel or brush with the guard. Wire wheel or brush may

expand in diameter due to work load and centrifugal forces.

Operations:

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Additional Safety Warnings

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

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

Keep handles dry, clean and free from oil and grease. Slippery hands cannot safely

control the power tool.

Use clamps or other practical way to secure and supp ort the wor kpiece to a stable platform. Holding the work by hand or against

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

Develop a periodic maintenance schedule for your tool. When cleaning a tool b e careful not to disassemble any portion of th e tool since int erna l wire s may be misplaced or pinched or safety guard return sp rin gs may be improper ly mounted.

Certain cleaning agents such as gasoline, carb on tetrachlor ide, ammonia, etc. may damage plastic parts.

Risk of injury to user. The power cord must only be serviced by a Bosch Factory Service Center or Autho rized Bosch Service Station.

Us e han d gua rd whe n san ding and brushing.

Do not u se t ype 1 A whe els f or f ace grinding. Side forces applied to type 1 wheels

may cause them to shatter or burst.

WARNING

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.

Yo u r ris k fro m thes e exp osures vari e s, 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.

Some dust created by power sanding, sawing, grinding,

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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 Designates Double Insulated

Construction tools.

Earthing terminal Grounding terminal

Warning symbol Alerts user to warning messages

Li-ion RBRC seal Designates Li-ion battery recycling

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 by the Intertek Testing

This symbol designates that this tool is listed by the Canadian Standards Association, to United States and Canadian Standards.

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

This symbol

designates that this tool complies to NOM Mexican Standards.

Services, to United States and Canadian Standards.

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Functional Description and Specifications

WARNING

Di s conn e ct t h e p l ug f r om t he p o wer sou r ce b efore maki n g a n y assembly, adjustments or changing accessories. Such preventive safety

measures reduce the risk of starting the tool accidentally.

Angle Grinders

VENTILATION

VIBRATION CONTROL

SPINDLE LOCK

KEYS

SPINDLE

OPENINGS

SWITCH

MOTOR HOUSING

RELEASE LEVER

(Model 1994-6 &

1994-6D only)

GUARD

RELEASE / LOCK

LATCH

VIBRATION

CONTROL

SIDE HANDLE

WHEEL GUARD

NOTCHES

Model number 1974-8 & 1974-8D 1994-6 & 1994-6D

No load speed n08,500/min n06,500/min Spindle thread 5/8"-11 UNC 5/8"-11 UNC Max. spindle length 3/4" 3/4" Max. grinding wheel (Type 27) 7" Dia. 9" Dia. Max. wire wheel 4-1/2" Dia. 6" Dia. Max. wire cup brush 4" Dia. 6" Dia. Max. sanding disc 7" Dia. 9" Dia. Max. type 1A and 27A cutting wheel 7" Dia. 9" Dia.

ADJUSTMENT SCREW

HAND GUARD

(Optional Accessory)

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Functional Description and Specifications (Continued)

NOTE: Always use appropriate size wheel guard.

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

NOTE: Not recommended for use with type 11 cup wheels.

Assembly

WHEEL GUARD INSTALLATION

WARNING

close the latch to secure the guard. Keep the guard between you and the wheel. Do not direct guard opening toward your body.

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

To attach wheel guard DISCONNECT tool from power source.

Open guard release/lock latch and position guard on spindle neck so that the notched on guard, line up with the keys on the spindle neck (Fig. 2).

The tightening tension of the clamp from the protection guard can be changed by loosening or tightening the adjustment screw. Ensure that the protection guard is tighly seated and check regularly.

Ro tate gu ard eith er dire ction to de sire d position, and close latch to secure guard in place.

TO REMOVE GUARD: Open guard release/lock lat ch, ro tate guard un til the

Use wheel guard with disc gr indin g whe els. Alway s

notches on guard line up with the keys on the spindle neck, and lift guard off the spindle neck (Fig. 2).

FIG. 2

KEYS

GUARD

RELEASE / LOCK

LATCH

NOTCHES

ADJUSTMENT

SCREW

SPINDLE

WHEEL GUARD

LOCK NUT AND BACKING FLANGE

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

VIBRATION CONTROL SIDE HANDLE

The side handle is used to control and balance the tool. The handle must be thread ed into the fr ont hous ing on eithe r si de of t he tool, de pendi ng on per sonal pr efere nce and comfort. Use the side handle for safe control and ease of operation (Fig. 1).

The hand guard is to be used with backing

OPTIONAL HAND GUARD

pads and sanding discs to keep fingers and hand away from work surface, sharp edges, burrs and debris. When using the optional hand guard accessory insert side handle through hole in guard and then thread into housing (Fig. 1).

Ensure that hand guard is positioned between hand and backing pad or sanding disc.

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YPE 27, 28 & 29 GRINDING

WHEEL ASSEMBLY

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

When using m o u n t i n g wh e e l s , th r e a d BACKING FLANGE all the way down onto spindle, then place GRINDING WHEEL on the spin dle. Th read on th e l ock nut a nd tighten nut using a lock nut wrench provided with flange kit, while holding the spindle lock in (Fig. 3).

TO REMOVE: Reverse procedure. When using spin-on grinding wheels, thread

directly onto the spindle.

ABRASIVE TYPE 1A & 27A

WHEEL ASSEMBLY

Using the optional type 1A wheel guard, it is possible to perform limited cutting on small stock such as metal tubes, piping or rebar.

WARNING

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

TO REMOVE: Reverse procedure.

TYPE 1 ABRASIVE

STRAIGHT GRINDING WHEELS

WARNING

st raig h t/di e g rind i ng. Th is tool is no t desi gne d for u se wi th ty pe 1 abras ive straight/die grinding wheels.

Do not attempt to cut large stock or sheets of metal as this tool is not designed to be a dedicated cutting tool.

lways use type 1A protection

A guard for cutting.

Do not use type 1 abrasive wh eels d e sign e d for

FIG. 3

SPINDLE

TYPE 27

SPIN-ON

GRINDING

WHEEL

TYPE 27

WHEEL GUARD

BACKING

FLANGE

TYPE 27

GRINDING

WHEEL

LOCK NUT

TYPE 1A

WHEEL

FIG. 4

SPINDLE

TYPE 1A

WHEEL GUARD

BACKING

FLANGE

LOCK NUT

TYPE 27A

WHEEL

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OUNTING TYPE 28 OR TYPE 29

GRINDING WHEELS

On l y u s e sm a ll f lange set (av a ilabl e as accessory) when mounting type 28 or type 29 wheels (Fig. 5).

FLANGE SET PART NO. 1 607 000 380

FLANGE WITH SHOULDER

FIG. 6

FLANGE WITH SHOULDER

SPINDLE

efer to figure s 6 or 7 for pr oper wheel

R assembly when using the small flange set. For use with type 27 wheel guard

FIG. 5

FLANGE OR LOCK NUT

TYPE 28

GRINDING WHEEL

FIG. 7

SPINDLE

FLANGE OR LOCK NUT

FLANGE WITH SHOULDER

TYPE 29

GRINDING

WHEEL

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SANDING DISC ASSEMBLY

BACKING PAD

efore attaching a backing

WARNING

pad b e s ure its m aximum safe operating speed is not exceeded by the nameplate speed of the tool.

WARNING

Whe e l guard m a y not b e

used for most sanding operations. Always reinstall wheel guard when converting back to grinding operations.

TO INSTALL BACKING PAD AND

SANDING DISC

Disconnect tool from power source. Attach hand guard (Fig. 1). Set the tool on its top side (spindle up). Place the rubber backing pad o n t o the spindle shaft. C e n t e r the sanding disc on top of the backi ng pad. Inser t t he lock nu t throu gh 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. 8).

WIRE BRUSH ASSEMBLY

WARNING

Before attaching a wire

brush be sure its maximum safe operating speed is not exceeded by the nameplate speed of the tool.

Before assembling wire brush to this tool, disconnect from the power source. Attach hand g u a r d (Fig. 1). Wire b r u s h e s are equipped with their own threaded hub, simply thread on to spindle. Be sure to seat against shoulder before turning tool “ON”.

TO REMOVE: Reverse procedure.

FIG. 8

SPINDLE

SPIN-ON

WIRE

BRUSH

SPINDLE

LOCK

RUBBER

BACKING

PAD

SANDING

DISC

LOCK NUT

TO REMOVE: Reverse procedure.

WIRE WHEEL ASSEMBLY

Before assembling wire wheel to this tool, disconnect from the power source. Attach Type 27 guard (Fig. 2). Wire wheels are equipped with their own threaded hub, simply thread on to spindle. Be sure to seat against shoulder before turning tool “ON”.

TO REMOVE: Reverse procedure.

MOTOR HOUSING RELEASE LEVER

(Model 1994-6 & 1994-6D only)

Your tool is equipped with a motor housing release lever that will allow you to rotate the spindle in either direction 90˚. To use this feature, pull release lever in direction of arrow to release housing, and rotate housing until it clicks into place (Fig. 9)

FIG. 9

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Operating Instructions

WARNING

torque from the motor can cause the tool to twist.

tart the tool before applying to work and let

S 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.

"TRI-CONTROL" PADDLE SWITCH

(Models 1974-8 & 1994-6 only)

The “Tri-Control” Paddle Switch enables the operator to control the switch functions of

"Lock-OFF", "ON/OFF" and "Lock-ON".

TO UNLOCK SWITCH AND TURN TOOL "ON": Push paddle lever FORWARD (toward the spindle) then squeeze the paddle lever.

TO SWITCH TOOL "OFF": Release pressure on paddle lever. The switch is spring loaded and w i l l return to " O F F " position automatically.

The "Lock-ON" feature, incorporated into the paddle switch, is a convenience for long operations.

TO LOCK SWITCH "ON": After paddle switch has been activated push pa d dle le v e r completely FORWARD and release paddle lever.

TO SWITCH TOOL "OFF": Squeeze and then release paddle lever. The switch is spring loaded and will r e t u r n to "OFF" position automatically.

(Models 1974-8D & 1994-6D only)

The Paddle switch enables the operator to control the switch functions of "Lock-OFF", and "ON/OFF".

TO UNLOCK SWITCH AND TURN TOOL "ON": Push paddle lever FORWARD (toward the spindle) then squeeze the paddle lever.

TO SWITCH TOOL "OFF": Release pressure on paddle lever. The switch is spring loaded and will return to "OFF" position automatically.

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

PADDLE SWITCH WITH "LOCK-OFF "FEATURE

SELECTING GRINDING WHEELS

WARNING

safe operating speed is not exceeded by the na mepl ate speed of the gri nder. Do no t exceed the recom mended wheel diameter.

Grinding wheels should be carefully selected in order to use the grinder most efficiently. Wh e e ls va r y in t ype o f abras i v e, bo n d , 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.

Efficient grinding is achieved by controlling the pressure and keep ing the angle between wheel and workpiece at 10° to 15°. If the wheel is flat, the tool is difficult to control. If the angle i s too s t e e p , the p r e s s u r e is concent r a t e d on a small area causing burning to the work surface.

WARNING

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 work piece when pushing forward.

Using the optional Type 1A wheel guard, it is possible to perform limited cutting on small stock such as metal tubes, piping or rebar. When cutti ng, work with moder ate feed, adapted to the material being cut. Do not exert side pressure onto the cutting disc, tilt or oscillate the tool. When cutting profiles and square bar, it is best t o s tar t a t t he smallest cross section.

Always follow precautions for kickback. Do not apply side pressure to cutting wheel

to reduce wheel speed. The t ool should always be used so t hat

sparks are directed away from user.

Before using a grinding wheel, be certain that its maximum

DISC GRINDING WHEELS

GRINDING TIPS

Excessive or sudden pressure on the wheel will slow

CUTTING METAL

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BM 1609929T61 07-09:BM 1609929T61 07-09 7/8/09 1:37 PM Page 14

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

Operation: Refinishing painted wood or metal surfaces.

REMARKS GRIT

To remove paint and to smooth Coarse surface irregularities. 16-24-30

To smooth Medium the rough sanding. 36-50-80

To remove scratches left by Fine previous discs. 100-120

To smooth surfaces for painting, Very Fine polishing or waxing. 150-180

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.

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

nd snagging will result.

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

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 sand ing 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 mediu m grit to remove scratches. To produce smooth finish, use fine grit disc.

SANDING WOOD

Wire Brush Operations

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

WARNING

cially when working corners, sharp edges et c. T h is c an c a use loss of c ontrol and kickback.

Avoid bouncing and snagging the wire brush, espe-

WARNING

Be aware that wire bristles

are thrown by t he br ush even during ordinary operation. Do not overstress the wires by applying excessive load to the brush. The wire bristles can easily

penetrate light clothing and/or skin.

BRUSHING PRESSURE

1. Remember, the tips of a wire brush do the work. Operate the brush with the lightest

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BM 1609929T61 07-09:BM 1609929T61 07-09 7/8/09 1:37 PM Page 15

ressure so only the tips of the wire come in

p contact with the work.

2. If heavier pressures are used, the wires will be overstressed, resulting in a wiping action; and if this is continued, the life of the brush will be shortened due to wire fatigue.

WIRE WHEEL BRUSH

CORRECT:

Wire tips doing

the work.

WIRE CUP BRUSH

CORRECT:

Wire tips doing

the work.

Maintenance

Service

WARNING

orized per so n nel may result in misplacing of internal wires and components which could cause serious hazard . We

recommend that all tool service be performed by a Bosch Factory Service Center or Autho rized 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.

The brushes and commutator in your tool have been engineered for many hours of dependa b l e service. To m a i n t a i n peak efficiency of the motor, we recommend every two to six months the brush es be examined. Only genuine Bosch replace ment brushes specially designed for your tool should be used.

After about 300-400 hours of operation, or at every second brush change, the bearings

Pr even t ive mai nten ance perform e d b y unauth-

TOOL LUBRICATION

CARBON BRUSHES

BEARINGS

. Apply the brush to the work in such a way

3 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.

INCORRECT:

Excessive

pressure can

cause wire

breakage.

should be replaced at Bosch Factory Service Center or Au thorized Bosch Service Station. Bearings which become noisy (due to heavy load or very abrasive material cut ting) should be replaced at once to avoid overheating or motor failure.

Cleaning

WARNING

th e power suppl y before clea n i n g or performing any main tenance. The tool may

be cleaned most effectively with compressed dry air. Always wear safety gog gles when

cleaning tools with compressed air.

Ventilation openings and switch levers must be kept clean and free of foreign matter. Do not at tempt to clean by inserting pointed objects through openings.

CAUTION

plastic parts. Some of these are: gasoline, carbon tetrachlo ride, chlo rinated cleaning solvent s , ammonia and house hold detergents that contain ammonia.

To avoid accidents always

dis connect the tool from

Ce rtai n cl e anin g ag ents

and s o l ve n t s d a m a g e

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