Bosch Power Tools AG60-125PD, AG50-10TG, AG50-125PD, AG50-11VSPD, AG40-85PD-2P User Manual

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Operating/Safety Instructions Consignes d’utilisation/de sécurité

Instrucciones de funcionamiento y seguridad

AG40-85 AG40-85P AG40-85PD AG40-11P AG40-11PD AG50-10 AG50-11VS AG50-11VSPD AG50-125PD AG60-125 AG60-125PD

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General Power Tool Safety Warnings

WARNING

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

SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE

The term “power tool” in all of 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 wi t h earthed (grounded) power tools. Unmodified plugs

an d ma tchi ng o utlet s wi ll r educ e ri sk o f electric shock.

Avoid body contact with ea r t h e d 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 or moving parts. Damaged or

entangled cords increase the risk of electric shock.

When operating a power tool outdoors, use an e x t e n s i o n cord suitable f o r outdoor use. Use of a cord suitable fo r

ou tdoo r us e re d uces the ris k of ele c tric shock.

If operating a power tool in a damp location is unavoidable, use a Ground Fault Circuit Interrupter (GFCI) protected supply. Use of a GFCI reduces the risk of

electric shock.

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 ra ted too l a r e l i kely to fai l a n d c reate a hazard to the operator.

If an extension cord is necessary, a cord with adequate size conductors that is capable of carrying the current necessary for your tool must b e used. T h i s will

pr event exc e ssiv e vol tage dro p, l oss of power or overheating. Grounded tools must use 3-wire extension cords that have 3-prong plugs and receptacles.

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

eq uip ment such a s d ust 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 i n the off-position before co nnecting to powe r sourc e 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.

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. Th is enable s

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, jewelry or long hair can

be caught in moving parts.

-2-

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

ca nno t be cont roll ed 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. U se of t he pow er tool for

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

If the “Lock-ON” button is continuously being depressed, the trigger cannot be released.

Never leave the trigger locked "ON". Before plugging the tool in, check that the trigger lock is "OFF". Accidental start-ups could

cause injury.

Be aware of the location and setting of the switch "Lock-ON" button. If the switch is

locked "ON" during the use, be ready for emergency situations to switch it "OFF".

Always hold the tools with both hands while starting. Torque from the motor can cause the

tool to twist and slip from your hands.

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 support the workpiece to a stable platform. Holding the work by hand or against

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

If devices are provided for the connection to dust collection and extraction systems, be sure these are connected and used according to tool and vacuum instructions.

Proper use of dust collection can reduce dust related hazards.

If devices are provided for the connection of dust collection and extraction systems, empty the dust container before beginning work, frequently during work, after completion of work, and before storing the tool. Be extremely careful of dust disposal,

ma ter ials in fine parti cles form ma y be explosive.

Do not throw dust on an open fire.

Co mbu stio n fr om mixtu re of va rnis hes, lacquers, polyurethane, oil or water with dust particles can occur if there is a static discharge, electric spark, or excessive heat.

Do not use dust extraction for operations where dust may include burning, smoking or smoldering items like hot ashes or sparks. Fire inside the vacuum tank or bag

may occur. Dust may smolder and set vacuum on fire long after work is completed.

Do not use dust extraction with explosive dusts, varnish, polyurethane coatings, cleaners, or oil-based paints. Electric motors

create sparks which may ignite the dust or fumes.

Do not use dust extraction when working on metal. Swarf from sanding, grinding or cutting

metal may be hot and may spark which may melt plastic adaptors, vacuum hoses and may cause a fire inside the vacuum tank or bag.

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.

Preventative maintenance performed by unauthorized personnel 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 Authorized Bosch Service Station.

-3-

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. Certain cleaning agents such as gasoline, carbon tetrachloride, ammonia, etc. may damage plastic parts.

Safety Warnings Common for Grinding,

Sanding, Wire Brushing, and Abrasive

Cutting-Off Operations:

This power tool is intended to function as a grinder, sander, wire brush or cut-off tool. Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all

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

Operations such as polishing are not recommended to be performed with this power tool. Operations for which the power

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

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.

The rated speed of the accessory must be at least equal to the maximum speed marked on the power tool. Acces sories

running faster than their RATED SPEED can break and fly apart.

The outside diameter and the thickness of your accessory must be within the capacity rating of your power tool. Incorrectly sized

accessories cannot be adequately guarded or controlled.

The arbor size of wheels, flanges, backing pads or any other accessory must properly fit the spindle of the 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.

Do not use a damaged accessory. Before each use inspect the accessory such as abrasive wheels for chips and cracks, backing pad for cracks, tear or excess wear, wire brush for loose or cracked wires. If power tool or accessory is dropped, inspect for damage or install an undamaged accessory. After inspecting and installing an accessory, position yourself and bystanders away from the plane of the rotating accessory and run the power tool

at maximum no-load speed for one minute.

Damaged accessories will normally break apart during this test time.

Wear personal protective equipment. Depending on application, use face 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 dust mask or respirator must be capable of filtrating pa rti cles ge ner ated by your op erat ion. Prolonged exposure to high intensity noise may cause hearing loss.

Keep bystanders a safe distance away from work area. Anyone entering the work area must wear personal protective equipment.

Fr agm ents of workpi ece or of a bro ken accessory may fly away and cause injury beyond immediate area of operation.

Hold power tool by insulated gripping surfaces only, when performing 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.

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.

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.

Do not run the power tool while carrying it at your side. Accidental contact with the

spinning accessory could snag your clothing, pulling the accessory into your body.

Regularly clean the power tool’s air vents.

The motor’s fan will draw the dust inside the ho usi ng and exc essive accum ulat ion of powdered metal may cause electrical hazards.

Do not operate the power tool near flammable materials. Sparks could ignite

these materials.

Do not use accessories that require liquid coolants. Using water or other liquid coolants

may result in electrocution or shock.

Always use wheel guard with disc grinding wheels and ensure that it is securely latched to the tool. Always keep the guard between you and the wheel and do not

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direct guard opening or particles toward your body. Such preventive safety measures

reduce the risk of injury while operating the tool.

A type 27 guard must be used with all grinding wheels, bonded body sanding flap discs, wire brushes and wheels. The tool

may be use d wit hout a g uard o nly wh en sanding with conventional sanding discs.

Do not place excessive or sudden pressure on the wheel while grinding. Su dden

changes in pressure to the wheel may cause the wheel to burst.

Do not use accessories that run eccentrically. The tool will vibrate excessively

an d may cause loss of cont rol an d the accessory may burst.

Do not use type 1 abrasive wheels designed for straight/die grinding. This tool is not

de sig ned for use w ith t ype 1 a brasive straight/die grinding wheels.

Do not use type 1 cutting wheels for face grinding. Side forces applied to type 1 cutting

wheels may cause them to shatter or burst.

Do not use Type 11 abrasive (cup) wheels with this tool. This tool is not designed for use

with type 11 (cup) abrasive grinding wheels.

Kickback and Related Warnings:

Kickback is a sudden reaction to a pinched or snagged rotating wheel, backing pad, brush or any other accessory. Pinching or snagging causes rapid stalling of the rotating accessory which in turn causes the uncontrolled power tool to be forced in the direction opposite of the accessory’s rotation at the point of the binding.

For example, if an abrasive wheel is snagged or pinched by the workpiece, the edge of the wheel that is entering into the pinch point can dig into the surface of the material causing the wheel to climb out or kickout. The wheel may either jump toward or away from the operator, de pen ding on di rect ion of the wh eel’ 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 in correct op erating proce dures or conditions and can be avoided by taking proper precautions as given below.

Maintain a firm grip on the power tool and position your body and arm to allow you to resist kickback forces. Always use auxiliary handle, if provided, for maximum control over kickback or torque reaction during start-up. The operator can control torque

re act ions or kick back f orce s, if prope r precautions are taken.

Never place your hand near the rotating accessory. Accessory may kickback over your

hand.

Do not position your body in the area where power tool will move if kickback occurs.

Kickb ack will propel t he too l in dir ect ion opposite to the wheel’s movement at the point of snagging.

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.

Do not attach a saw chain woodcarving blade or toothed saw blade. Such blades

create frequent kickback and loss of control.

Do not use the switch "Lock-ON" feature in situations where kickback is likely, such as when working into a corner. When the wheel

binds, the t ool will ki ck- bac k in opposite direction of wheel rotation and the release of the trigger "Lock-ON" may be difficult.

Safety Warnings Specific for Grinding and

Abrasive Cutting-Off Operations:

Use only wheel types that are recommended for your power tool and the specific guard designed for the selected wheel. Wheels for which the power tool was

not designed cannot be adequately guarded and are unsafe.

The guard must be securely attached to the power tool and positioned 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.

Wheels must be used only for recommended applications. For example: do not grind with the side of cut-off wheel.

Abrasive c ut- off w hee ls are i nte nde d for peripheral grinding, side forces applied to these wheels may cause them to shatter.

Always use undamaged wheel flanges that are of correct size and shape for your selected wheel. Proper wheel flanges support

the wheel thus reducing the possibility of wheel breakage. Flanges for cut-off wheels may be different from grinding wheel flanges.

Do not use worn down wheels from larger power tools. Wheel intended for larger power

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

-5-

Additional Safety Warnings Specific for

Abrasive Cutting-Off Operations:

Do not “jam” the cut-off wheel or apply excessive pressure. Do not attempt to make an excessive depth of cut. 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.

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.

When wheel is binding or when interrupting a cut for any reason, switch off the power tool and hold the power tool motionless until the wheel comes to a complete stop. Never attempt 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.

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.

Support panels or any oversized workpiece to minimize the risk of wheel pinching and kickback. Large workpieces tend to sag under

their own weight. Supports must be placed under the workpiece near the line of cut and near the edge of the workpiece on both sides of the wheel.

Use extra caution when making a “pocket cut” into existing walls or other blind areas.

The protruding wheel may cut gas or water pipes, electrical wiring or objects that can cause kickback.

Always use type 1 cutting guard for cutting operations. Other guards or attachments may

not protect operator in the event of a wheel burst.

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

materials shift while cutting and cause wheel to burst.

Safety Warnings Specific for

Sanding Operations:

Do not use excessively oversized sanding disc paper. Follow manufacturer’s recommendations, when selecting sanding paper. Larger sanding paper extending beyond

the sanding pad presents a laceration hazard and may cause snagging, tearing of the disc or kickback.

A guard may not be used for all sanding operations. Do not discard guard when not in use. Use hand shield when sanding without

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

Safety Warnings Specific for

Be aware that wire bristles are thrown by the brush 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.

If the use of a guard is recommended for wire brushing, do not allow 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.

A guard may not be used for all wire brushing operations. Do not discard guard

when n ot in u se. Us e hand shiel d whe n brushing without a guard. Always reinstall wheel guard when converting back to grinding operations.

Do not use a knotted wire brush with this tool. This tool does not have a guard for

knotted brushes.

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

• Arsenic a nd chro mium fr om chemically-

Yo ur ris k from these exposure s vari es, depending on how often you do this type of work. T o redu ce your exp osure to the se 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.

Wire Brushing Operations:

Additional Warnings:

WARNING

other masonry products, and

treated lumber.

Some dust created by power sanding, sawing,

-6-

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.

n Rated speed Maximum attainable speed

.../min Revolutions or reciprocation 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

per minute 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

Ni-Cad RBRC seal Designates Ni-Cad battery recycling

program

Read manual symbol Alerts user to read manual

Wear eye protection symbol Alerts user to wear eye protection

-7-

Symbols (continued)

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.

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

This symbol designates that this component is recognized by Underwriters Laboratories.

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

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

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 the Intertek Testing Services, to United States and Canadian Standards.

This symbol designates that this tool complies to NOM Mexican Standards.

-8-

Angle Grinders with Paddle Switch

GUARD

RELEASE / ADJUSTMENT

BUTTON

SPINDLE LOCK

GRINDING

WHEEL

FIG. 1

TYPE 27

GRINDING GUARD

VIBRATION

CONTROL

SIDE HANDLE

VENTILATION

OPENINGS

LOCK-ON

SWITCH

(select models)

PADDLE SWITCH

"LOCK-OFF" SWITCH

RELEASE LEVER

TYPE 1

CUTTING GUARD

(Optional Accessory)

AG40-85P AG40-11P

Model number & AG40-85PD & AG40-11PD AG50-11VSPD AG50-125PD AG60-125PD

Amps 8.5 11 11 12.5 12.5 Volts 120 120 120 120 120 Rated speed (RPM) 11500 11500 2800-11500 11500 9300 Spindle thread 5/8"-11 5/8"-11 5/8"-11 5/8"-11 5/8"-11 Max. grinding wheel dia. 4-1/2" (115 mm) 4-1/2" (115 mm) 5" (125 mm) 5" (125 mm) 6" (150 mm) Max. cutting wheel 4-1/2" Dia. 4-1/2" Dia. 5" Dia. 5" Dia. 6" Dia. Max. sanding disc 4-1/2" Dia. 4-1/2" Dia. 5" Dia. 5" Dia. 6" Dia. Max. flap disc 4-1/2" Dia. 4-1/2" Dia. 5" Dia. 5" Dia. 6" Dia. Max. wire wheel 4" Dia. 4" Dia. 4" Dia. 4" Dia. 4" Dia. Max. wire cup wheel 3" Dia. 3" Dia. 3" Dia. 3" Dia 3" Dia Variable speed x Electronic clutch xx xx Constant response circuitry xx xx Restart protection xx xx Overload protection xx xx Soft start xx xx

HAND SHIELD

(Optional Accessory)

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Angle Grinders with Slide Switch

FIG. 2

GUARD

RELEASE / ADJUSTMENT

BUTTON

GRINDING

WHEEL

VENTILATION

OPENINGS

SPINDLE

LOCK

SLIDE SWITCH

TYPE 27

GRINDING GUARD

VIBRATION

CONTROL

SIDE HANDLE

TYPE 1

CUTTING GUARD

(Optional Accessory)

Model number AG40-85 AG50-10 AG50-11VS AG60-125

Amps 8.5 10 11 12.5 Volts 120 120 120 120 Rated speed (RPM) 11500 11500 2800-11500 9300 Spindle thread 5/8"-11 5/8"-11 5/8"-11 5/8"-11 Max. grinding wheel dia. 4-1/2" (115 mm) 5" (125 mm) 5" (125 mm) 6" (150 mm) Max. cutting wheel 4-1/2" Dia. 5" Dia. 5" Dia. 6" Dia. Max. sanding disc 4-1/2" Dia. 5" Dia. 5" Dia. 6" Dia. Max. flap disc 4-1/2" Dia. 5" Dia. 5" Dia. 5" Dia. Max. wire wheel 4" Dia. 4" Dia. 4" Dia. 4" Dia. Max. wire cup wheel 3" Dia. 3" Dia. 3" Dia. 3" Dia Variable speed x Electronic clutch xx Constant response circuitry xx Restart protection xx Overload protection xx Soft start xx

HAND SHIELD

(Optional Accessory)

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Application

Model number AG40-85 AG50-10 AG50-11VS AG60-125 AG40-85P(D)

Metal Grinding (Type 27) XXX X X Metal Grinding (Type 11) NNN N N Metal Grinding (Type 1) NNN N N Metal Cutting OOO X O Concrete Surfacing OOO O O Concrete/Masonry Cutting OOO O O Sanding OOO O O Wire Brushing (Wheel) XXX X X Wire Brushing (Cup) OOO O O

Model number AG40-11P(D) AG50-11VSPD AG50-125PD AG60-125PD

Metal Grinding (Type 27) XXXX Metal Grinding (Type 11) NNNN Metal Grinding (Type 1) NNNN Metal Cutting OOOX Concrete Surfacing OOOO Concrete/Masonry Cutting OOOO Sanding OOOO Wire Brushing (Wheel) XXXX Wire Brushing (Cup) OOOO

X = Tool is provided with attachments to perform this application. O = Tool can use optional attachments to perform this application. N = Tool is not capable of this application.

Accessory speed rating must be equal to or greater than the tool’s speed rating. Do not exceed the recommended wheel diameter.

WARNING

Do not use Type 11 abrasive (cup) wheels with this tool. This tool is not designed for use with type 11 (cup) abrasive grinding wheels.

-11-

Functional Descriptions

Electronic Clutch:

The electronics in the power tool de tects situations where the wheel or accessory may be at risk to bind. The electronics prevents further rotation of the drive spindle by switching th e power to o l off (it do e s not pre v ent kickback). To resume operation, turn on/off switch to the off position, then restart tool.

Constant Response Circuitry:

Helps maintain near constant RPMs between no-load and load conditions.

Soft Start:

Helps reduce stress on the motor that occurs from a high torque start. Helps bring accessory smoothly up to speed.

Automatic Restart Protection:

Helps prevent accidental startups after power ha s been int e rrup t ed, e.g. the tool was

Assembly Instructions

Lock Nut & Backing Flange

Your tool is equipped with a threaded spindle for mounting non-threaded hub accessories. Always use the supplied backing flange with a lock nut. Inner flange is keyed to output shaft. Always ensure that arbor diameter matches accessory diameter. Accessories that run eccentrically may burst. (Fig. 3)

Installing Side Handle

Th e side h a ndle i s used t o cont r o l and balance the tool. Securely thread handle into either side of gear housing, depending on pe rson al p refe renc e, c omfo rt, ope rati on being performed. The handle should always be installed onto the guard protected side of the tool. Use the side handle for safe control and ease of operation (Fig. 4).

Hand Shield

The hand shield is to be used with backing pads, sanding dis cs an d wire brush es to ke e p fing e r s and han d away fro m work su rfa ce, sharp edges, bur rs and debris . When using the hand shield accessory, insert side handle through hole in shield and then thread into housing (Fig. 4). Ensure that hand shi e l d is p o s i t i o ned betwe e n hand a n d backing pad, sanding disc or wire brush.

unplugged with the switch locked in the on position. To resume operation, turn on/off switch to the off position, then restart the tool.

Overload Protection:

Helps protect tool from excessive heat that may damage motor. If tool stops or slows during operation, allow motor to cool for 30 seconds by running no-load. If the overload protection stops the tool repeatedly, excessive force is causing the tool to overload. Stop excessive force and readjust work piece to reduce force applied.

Variable Speed:

Allows the grinders RPM to be adjusted for greater versatility to match needs of specific applications.

FIG. 3

SPINDLE

KEYED

BACKING

FLANGE

LOCK NUT

FIG. 4

SIDE

HANDLE

TO SHAFT

HAND SHIELD

(Optional Accessory)

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Installing Wheel Guards

(Type 27 & Type 1 Wheel Guards)

WARNING

wheels, bonded body sanding flap discs, wire brushes and wheels. The tool may be

used without a guard only when sanding with conventional sanding discs.

To attach guard (Fig. 5):

1. Unplug tool from power source.

2. Position appropriate guard on spindle neck so arrows on guard and spindle neck align.

3. Rotate wheel guard clockwise 90º until guard clicks in place.

4. Adjust guard by depressing guard release bu tton and rot ate to desi red posit ion. Al ways po siti on whe el guar d b etwe en operator and work piece and direct sparks away from operator, Fig. 6.

5. Allow guard release button to click in place.

To remove wheel guard:

1. Depress guard release button and rotate guard until arrows on guard and spindle neck align.

2. Remove guard from spindle neck.

A Type 27 guard must be used with all grinding

FIG. 5

SPINDLE

NECK

FIG. 6

WHEEL GUARD

GUARD

RELEASE

BUTTON

OPERATING ZONE

-13-

Abrasive Type 27 Grinding Wheel &

Sanding Flap Disk Assembly

Your tool is equipped with a threaded spindle for mounting non-threaded hub accessories. Always use the supplied backing flange with a lock nut. Always ensure that arbor diameter matches accessory diameter.

To install grinding wheel or flap disk (Fig. 7):

1. Unplug tool from power source.

2. Install and adjust type 27 grinding guard to the proper position for grinding as shown in figure 5.

3. Place the backing flange on the spindle. Turn flange until it locks with the base of the spindle.

4. Place the grinding wheel onto the spindle and align the arbor hole of the grinding wheel with the shoul der of the backing flange.

5. Thread the lock nut onto the spindle with the lock nut relief facing the accessory.

6. Ti ghten loc k nut with supplied lock nut wrench while holding spindle lock.

TO REMOVE: Reverse procedure.

When using spin-on wheels:

Follow steps 1 & 2, then thread wheel directly on t o sp i ndle wit hout usi ng t h e su p plied flanges.

TO REMOVE: Reverse procedure.

All parts of a spin-on wheel must be within lip of grinding guard (Fig. 8). If spin-on wheel is past lip of guard, do not use that wheel as it does not fit on this grinder.

WARNING

tool will vibrate excessively and may cause loss of control and the accessory may burst.

Do not use acce s sories that run eccentrically. The

FIG. 7

SPINDLE

BACKING

FLANGE

TYPE 27

GRINDING

WHEEL

TYPE 27

GRINDING

WHEEL

FIG. 8

LOCK NUT

TYPE 27

WHEEL GUARD

TYPE 27 SPIN-ON

GRINDING WHEEL

SPINDLE

BACKING

FLANGE

LOCK NUT

-14-

LIP OF

GUARD

SPIN-ON

WHEEL

Abrasive Type 1 & 27 Cutting

Wheel Assembly

WARNING

operations. Other guards or attachments may not protect operator in the event of a wheel burst.

WARNING

operations. Do not discard guard when not in use. Always reinstall wheel guard when

converting back to grinding operations.

To install cutting wheel (Fig. 9):

1.Unplug tool from power source.

2.Install and adjust type 1 cutting guard to

the proper position for cutting as shown in figure 5.

3.Place the backing flange on the spindle. Turn flange until it locks with the base of the spindle.

4.Place the cutting wheel onto the spindle

and align the arbor hole of the cutting wheel with the shoulder of the backi ng flange.

5.Thread the lock nut onto the spindle with

the lock nut relief facing the accessory.

6.Tighten l ock nut with supplied lock nut

wrench while holding spindle lock.

TO REMOVE: Reverse procedure.

Always use type 1 cutting guard for cutting

A type 27 wheel guard may not be used for all tool

FIG. 9

TYPE 1A

CUTTING

WHEEL

TYPE 27A

CUTTING

WHEEL

SPINDLE

TYPE 1

WHEEL GUARD

BACKING

FLANGE

LOCK NUT

TYPE 27A

CUTTING

WHEEL

SPINDLE

BACKING

FLANGE

-15-

LOCK NUT

Concrete Dust Extraction

Attachment for Surfacing Grinding

Assembly

WARNING

all tool operations. Do not discard guard when not in use. Always reinstall wheel

gu ard whe n co nver ting bac k to gri ndin g operations.

WARNING

do not use with bonded abrasive wheels.

Dust extraction attachment may not protect operator in the event of a wheel burst.

To install concrete dust extraction attachment (Fig. 10):

1.Unplug tool from power source.

2.Position appropriate attachment on spindle

neck with dust port pointing away from tool body.

3.Rot ate att achm ent clockw ise 90º unt il

guard clicks in place.

4.Adjust attachment by depressing guard

release button and rotate to desired position.

5.Allow guard release button to click in place.

6.Place the backing flange on the spindle.

7.Pl ace the di amond cup whee l ont o the

spindle and align with the flange.

8.Thread the lock nut onto the spindle with

the lock nut relief facing the accessory.

9.Tighten l ock nut with supplied lock nut

wrench while holding spindle lock.

When using spin on wheels, follow steps 1 5, then thread wheel directly onto spindle without using the supplied flanges.

TO REMOVE: Reverse procedure.

A type 27 grinding wheel guard may not be used for

Dust Extraction Attachment is not a guard,

FIG. 10

SPINDLE

CONCRETE DUST EXTRACTION

ATTACHMENT

WHEEL GUARD

SPINDLE

NECK

-16-

Sanding Assembly

WARNING

operations. Do not discard guard when not in use. Always reinstall wheel guard when

converting back to grinding operations.

The hand shield is to be used with backing pads, sanding discs and wire brushes to keep fingers and hand away from work surface, sharp edges, burs and debris. When using the hand shield accessory, insert side handle through hole in shield and then thread into housing (Fig 4). Ensure that hand shield is positioned between hand and backing pad, sanding disc or wire brush.

To install backing pad and sanding disc (Fig. 11):

1. Unplug tool from power source.

2. Attach hand shield.

3. Place the r ubber backing pad onto the spindle shaft.

4. Cen t er the san ding dis c o n t op of the backing pad.

5. Insert the lock nut through the disc and thread onto spindle.

A type 27 wheel guard may not be used for all tool

FIG. 11

SPINDLE

BACKING

PAD

6. Tighten lock nut with supplied lock nut wrench while holding spindle lock.

TO REMOVE: Reverse procedure.

HAND

SHIELD

SANDING

DISC

LOCK NUT

Wire Cup Brush Assembly

WARNING

operations. Do not discard guard when not in use. Always reinstall wheel guard

when converting back to grinding operations.

Do not use a knotted wire cup brush with this tool. This tool does not have a guard for

knotted wire cup brushes.

To install wire cup brush (Fig. 12):

1. Unplug tool from power source.

2. Attach hand shield.

A type 27 wheel guard may not b e used f o r all tool

FIG. 12

SPINDLE

WIRE CUP

BRUSH

3. Thread wire cup brush onto spindle until secure. Be sure to seat cup brush against shoulder before turning tool “ON”.

TO REMOVE: Reverse procedure.

HAND

SHIELD

-17-

Masonry Cutting Guard

0 mm

Assembly

WARNING

all tool operations. Do not discard guard when not in use. Always reinstall wheel

gu ard whe n co nver ting bac k to gri ndin g operations.

To improve ergonomics of your grinder when cutting masonry, gearbox must be rotated relative to the position of the switch as the tool was assembled at the factory.

Rotate gearbox (Fig. 13):

1. Unplug tool from power source.

2. Completely unscrew the four s c r e w s between the gear housing and motor body.

3. Rotate gear housing to the proper orientation without removing motor from the housing.

a. For the slide switch models, rotate gear

housing 180 degrees in the direction indicated in Fig 14a, so the switch is 90 degrees from the spindle.

b. For the paddle switch models, rotate

gear housing 90 degrees in the direction indicated in Fig 14b, so the switch is facing the work piece.

4. Screw in and tighten the four screws you removed.

5. The screw holding the quick release lever is longer than the other screws, this long screw must stay with the quick release lever when re-attaching gear housing for the qu i c k r e l e a s e button to op e r a t e properly.

6. Attach proper dust collection guard with foot and accessory.

Installing Masonry Type 1 Cutting Guard:

1. Use tool adjusted as show in figures 13

and 14a or 14b.

2. Unplug tool from power source.

3. Unscrew and remove side handle.

4. Sl ide du st extra ction guard on spindle

neck.

5. Rotate attachment until stability bracket

and hole for side handled are aligned.

A type 27 grinding wheel guard may not be used for

FIG. 13

FIG. 14a

180

DEGREES

FIG. 14b

DEGREES

SLIDE

SWITCH

180

DEGREES

PADDLE SWITCH

UNDER

TOOL

-18-

6. Screw in side handle to secure stability

brack et between t he tool hous ing and handle.

7. Adjust guard to desired depth of cut.

TO REMOVE: Reverse procedure.

Installing dry diamond wheel (Fig. 15):

1. Place the backing flange on the spindle.

Turn flange until it locks with the base of the spindle.

2. Pl ace the dry diamo nd wheel onto the spindle and align the arbor hole o f the grinding wheel with the shoulder of the backing flange.

3. Tighte n lock nut with supplied lock n ut wrench while holding spindle lock.

TO REMOVE: Reverse procedure.

BACKING

FLANGE

DRY

DIAMOND

WHEEL

SPINDLE

FIG. 15

DRY

DIAMOND

WHEEL

LOCK

NUT

SPINDLE

BACKING

FLANGE

LOCK NUT

Wire Wheel Assembly

To install wire wheel (Fig. 16):

1. Unplug tool from power source.

2. Install and adjust type 27 grinding guard to

the proper position as shown in figure 5.

3. Thread w i r e wheel o n t o spind l e until

secure.

NOTE: Be sure to seat wire wheel against shoulder before turning tool “ON”.

TO REMOVE: Reverse procedure.

FIG. 16

SPINDLE

TYPE 27

WHEEL GUARD

WIRE WHEEL

-19-

Operating Instructions

WARNING

depressed, the trigger cannot be released.

WARNING

plugging the tool in, check that the trigger lock is "OFF". Accidental start-ups could

cause injury.

WARNING

"Lock-ON" button. If the switch is locked "ON" during the use, be ready for emergency situations to switch it "OFF".

WARNING

situations where kickback is likely, such as when working into a corner. When the

wheel binds, the tool will kick-back in opposite direction of wheel rotation and the rele ase of t he trig ger "Lock-ON" may b e difficult.

If the “Lock-ON” button is continuously be i n g

Never leave the trigger locked " O N " . Before

Be aware of the location and setting of the switch

Do not u s e the switch "Lock-ON" feature in

Paddle Switch (Fig. 17)

The paddle switch has a lock-off feature to help prevent accidental startups. TO TURN TOOL “ON”, push lock-off switch backward to un lock th e pa ddle swi tch, then s quee ze pa d d l e switch . TO TURN TOOL “OFF” , re leas e p ress ure on pad dle switch . Th e switch is spring loaded and will return to the “OFF” position automatically.

If your tool ha s th e LO C K - O N fe a t u r e in c o r p o rated i n t o the p a ddle s w i t c h for extended operation, there will be a red button on the bottom of the tool directly behind the paddle switch. TO LOCK SWITCH “ON” after pa ddle swi tch has bee n ac tiva ted, pus h “L OCK -ON” button whi le simult aneo usl y releasing pressure from the paddle switch. TO TU R N T O O L “ O F F ” , s q u e e z e a n d release paddle switch.

LOCK-ON

SWITCH

FIG. 17

FIG. 18

Slide Switch (Fig. 18)

TO TUR N TOOL “ ON”, r o c ker b a c k the switch and slide forward towards the gear housing and into the on position. TO “LOCKON”, when the switch is slid into the “ON” position, roll the switch forward. TO TURN TOOL “OFF”, press the rear portion of the switch. The switch is spring loaded and will return to the “OFF” position automatically.

-20-

Metal Grinding

Grinding wheels should be carefully selected in order to use the grinder most efficiently. Wh e e l s vary in type of a b rasive, bon d , hardness, grit size and structure. The correct wheel to use is determined by the job. Use disc grinding wheels fo r fa st grindi ng of struct ural steel, he avy w eld beads, steel casting, stainless steel and other ferrous metals.

1. Allow the tool to reach full speed before touching the tool to the work surface.

2. Apply m i n i m u m pressure to t h e work surface, allowing the tool to operate at high speed. Grinding rate is greatest when the tool operates at high speed.

3. Maintain a 10° to 15° angle between the tool and work surface, (Fig. 19).

FIG. 19

4. Continuously move the tool at a moderate speed to avoid creating gouges in the work surface.

5. Remove the tool from work surface before tu rnin g to ol o ff. Allow the too l t o st o p rotating before laying it down.

Tip: When grindi ng with a new wheel be certain to grind while pulling tool backwards until the wheel becomes rounded on its edge. New wheels have sharp edges which tend to “bite” or cut into the work piece when pushed forward.

Metal Cutting

WARNING

tool but is required when using a cutting wheel. Cutting with a type 27 wheel guard

ma y not prov i de the opera t or suf f icien t protection in the event of a wheel burst.

With this grinder it is possible to perform cutting of limited small stock such as metal tubes, piping or rebar. When cutting, work with moderate feed, adapted to the material being cut. When cutting profiles and square bar, it is best to start at the smallest cross section.

Always follow precautions for kickback.

1. Allow the tool to reach full speed before touching the tool to the work surface.

2. The tool should always be used so that the sparks are directed away from user.

3. App l y mini m um pre s sure to the work surface, allowing the tool to operate at high speed. Cutting rate is greatest when the tool operates at high speed.

4. Do not exert side pressure onto the cutting disc. Do not tilt or oscillate the tool as wheel may burst, (Fig. 20).

5. Remove the tool from the work surface before turning the tool off. Allow the tool to stop rotating before laying it down.

A Type 1 wheel guard may not be included with this

FIG. 20

-21-

Masonry / Concrete Cutting

With this grinder it is possible to perform cutting of concrete and masonry materials. Wh en cuttin g, work wit h m oder ate fee d, adapted to the material being cut.

Always follow precautions for kickback.

Operate the tool with a dust extraction system and personal dust protection, e.g. respirator, dust mask, etc. The vacuum used for this application must be approved for the extraction of masonry and concrete dust. Bosch sells suitable vacuum cleaners.

WARNING

the material and KICKBACK will occur.

1. Allow the tool to reach full speed before touching the tool to the work surface.

2. If plunge cutting:

a. Tilt tool forward with wheel lined up with

the cut l ine a nd hold the t ool by the grinder body and the auxiliary handle (Fig. 21).

b. Gradually lower the rear of tool using the

front end of the foot as the hinge point.

c. When the foot rests flat on the surface

being cut, proceed cutting in forward direction to end of cut.

3. Always maintain contact between the guard foot and work piece.

4. Slide the tool forward at a moderate speed adapted to the material being cut. Always cut towar ds th e dus t ext raction port to ma ximiz e dust extra c tion and red uce likelihood of kickback (Fig. 22).

5. App l y mini m um pre s sure to the work surface, allowing the tool to operate at high speed. Cutting rate is greatest when the tool operates at high speed.

6. When the cut is completed, remove tool from work piece before turning off. Allow wheel to stop rotating before setting tool down.

Tip: When performing deep cuts, it is best to cut in several shallow passes. Each pass should be only to the segment depth of the wheel. Masonry dust is abrasive and may wear and weaken the segment bond.

Never pull the tool backward since blade will climb out of

FIG. 21

FIG. 22

When cutting especially hard material, e. g., concrete with high pebble content, the dry diamond wheel can overheat and become damaged. This is clearly indicated by circular sparking of the rotating dry diamond wheel. In this case, interrupt the cutting process and allow the dry diamond wheel to cool by running the too l f or a short per iod of ti me at the maximum speed with no-load.

Noticeable decreasing work progress and circular sparking are indications of a d ry diamond wheel that has become dull. Briefly cutting into abrasive materials (e. g. brick) can resharpen the wheel.

-22-

Concrete Surfacing

Diamond cup wheels should be carefully selected in order to use the grinder most efficiently. Wheels vary in type of material they are designed to remove and how aggressively they will remove material. The correct wheel to use is determined by the job.

1. Allow the tool to reach full speed before

touching the tool to the work surface.

2. Hold t he tool with two hands and keep

diamond wheel flat on the work surface.

3. Apply minimum pressure, allowing the tool to operate at high speed. Removal rate is greatest when the tool operates at high speed.

4. Continuously move the tool at a moderate speed to avoid creating gouges in the work surface.

5. Remove the tool from work surface before turning tool off. Allow the tool to stop rotating before laying it down.

Tip: For optimal dust collection, all sides of the surfacing dust collection guard must stay in contact with the surface and the surfacing guard must be connected to a vacuum. A dull diamond wheel can be sharpened by briefly surf acing an abrasive material (eg. sand stone).

Sanding

Sanding discs range in grit from 16 (very course) to 180 (very fine). They also vary in size and spacing of grit.

OPEN COAT (type H) is used for soft materials and on paint and varnish, CLOSED COAT (type K) is used for metal, hardwood, stone, marble and other materials. 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 complete the job. See chart for application examples.

1. Allow the tool to reach full speed before touching the tool to the work surface.

2. App l y mini m um pre s sure to the work surface, allowing the tool to operate at high speed. Sanding rate is greatest when the tool operates at high speed.

3. Maintain a 10° to 15° angle between the tool and work surface, (Fig. 23).

FIG. 23

4. Continuously move the tool at a moderate speed to avoid creating gouges in the work surface.

5. Remove the tool from work surface before turning tool off. Allow the tool to stop rotating before laying it down.

Tips: Guide the disc with crisscross strokes. Do not use a circular motion as this makes swirl marks.

Operation: Refinishing painted wood or metal surfaces.

REMARKS GRIT

To remove paint and to smooth surface irregularities.

To smooth the rough sanding.

To remove scratches left by previous discs.

To smooth surfaces for painting, polishing or waxing.

Coarse

16-24-30

Medium

36-50-80

Fine

100-120

Very Fine

150-180

-23-

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