Bosch PBS 75 A, PBS 75 AE, 0 603 2A1 030 Manual

Product description and specifications

Read all the safety and general instructions. Failure to observe the safety and general instructions may result in electric shock, fire and/or serious injury.
Please observe the illustrations at the beginning of this operating manual.

Intended Use
The power tool is intended for dry surface sanding of wood, plastic, metal, filler and varnished surfaces with a high material removal rate.

Product Features
The numbering of the product features refers to the diagram of the power tool on the graphics page.

1. Auxiliary handle (insulated gripping surface)
2. Sanding belt ^a)
3. Clamping lever for sanding belt
4. Belt speed preselection thumbwheel (PBS 75 AE)
5. On/off switch
6. Complete dust box (microfilter system)
7. Lock-on button for on/off switch
8. Handle (insulated gripping surface)
9. Extraction adapter
10. Extraction outlet
11. Locking lever for dust box
12. Filter element (microfilter system)
13. Adjusting screw for belt running
14. Protective cap
15. Dust channel

1. This accessory is not part of the standard scope of delivery.

Technical Data

Belt sander		PBS 75 A	PBS 75 AE
Article number		3 603 BA1 0..	3 603 BA1 1..
Rated power input	W	710	750
No-load belt speed	m/min	350	200–350
Sanding belt length	mm	533	533
Sanding belt width	mm	75	75
Belt speed preselection		–	●
Self-generated/external dust extraction connection		●	●
Weight A)	kg	3,4	3.5
Protection class		/ II	/ II

1. Weight without mains connection cable and without mains plug
   The specifications apply to a rated voltage [U] of 230 V. These specifications may vary at different voltages and in country-specific models.

Noise/Vibration Information
Noise emission values determined according to EN 62841‑2‑4.
Typically, the A-weighted noise level of the power tool is: Sound pressure level 96 dB(A); sound power level 104 dB(A). Uncertainty K = 3 dB.

Wear hearing protection!
Vibration total values a_h (triax vector sum) and uncertainty K determined according to EN 62841‑2‑4:
a_h = 3.5 m/s², K = 1.5 m/s².
The vibration level and noise emission value given in these instructions have been measured in accordance with a standardised measuring procedure and may be used to compare power tools. They may also be used for a preliminary estimation of vibration and noise emissions.
The stated vibration level and noise emission value represent the main applications of the power tool. However, if the power tool is used for other applications, with different accessories or is poorly maintained, the vibration level and noise emission value may differ. This may significantly increase the vibration and noise emissions over the total working period.
To estimate vibration and noise emissions accurately, the times when the tool is switched off or when it is running but not actually being used should also be taken into account. This may significantly reduce vibration and noise emissions over the total working period.
Implement additional safety measures to protect the operator from the effects of vibration, such as servicing the power tool and accessories, keeping their hands warm, and organising workflows correctly.

Assembly

• Pull the plug out of the socket before carrying out any work on the power tool.

Dust/Chip Extraction
The dust from materials such as lead paint, some types of wood, minerals and metal can be harmful to human health. Touching or breathing in this dust can trigger allergic reactions and/or cause respiratory illnesses in the user or in people in the near vicinity.
Certain dusts, such as oak or beech dust, are classified as carcinogenic, especially in conjunction with wood treatment additives (chromate, wood preservative). Materials containing asbestos may only be machined by specialists.

• Use a dust extraction system that is suitable for the material wherever possible.
• Provide good ventilation at the workplace.
• It is advisable to wear a P2 filter class breathing mask.

The regulations on the material being machined that apply in the country of use must be observed.

• Avoid dust accumulation at the workplace. Dust can easily ignite.

Self-generated dust extraction with dust box (see figures A1–A4)
Place the dust box (6) on the extraction adapter (9) until it engages. Attach the extraction adapter (9) to the extraction outlet (10).
To empty the dust box (6), remove the dust box (6) with the extraction adapter (9).
Before opening the dust box (6), knock the dust box against a firm surface as shown in the figure to loosen the dust from the filter element.
Take hold of the dust box (6) by the recessed grip, fold the filter element (12) upwards out of the way and empty the dust box. Use a soft brush to clean the flaps of the filter element (12).
Note: The belt sander has a high material removal rate. Therefore, to ensure optimum dust extraction, empty the dust box (6) at regular intervals after every five minutes of operation and clean the filter element (12) regularly.

External Dust Extraction
Fit a dust extraction hose onto the extraction outlet (10).
Connect the dust extraction hose to an extractor. You will find an overview of connecting to various dust extractors at the end of these operating instructions.
The dust extractor must be suitable for the material being worked.
When extracting dry dust that is especially detrimental to health or carcinogenic, use a special dust extractor.

Changing the Sanding Belt (see figures B–D)

• Swivel the clamping lever (3) all the way out. The sanding belt (2) is now slack and can be removed.
• Fit the new sanding belt(2). Ensure that the arrow directions on the inner surface of the sanding belt and the housing of the power tool match.
• Swivel the clamping lever(3) back to the starting position.
• Lift up the power tool and switch it on. The belt running is centred automatically when the tool is switched on and during the sanding process.

If the belt running is not centred after switching the power tool on, it may have to be manually adjusted. To do this, turn the adjusting screw (13) on the front roller until the sanding belt (2) runs at a distance of 2–3 mm from the aluminium housing, see figure (D). Should the belt running still not be centred after doing this, then the sanding belt (2) must be replaced.

Selecting a Sanding Belt
Different sanding belts are available, depending on the material you are working with and the required surface removal rate:

	Grit
		40–240
For processing all wood and wood-based materials
For pre-sanding, e.g. of rough and uneven beams and boards	Coarse 40, 60
For surface sanding and levelling of slight irregularities	Medium 80, 100,	120
For finishing and fine sanding of hard woods	Fine	180, 240

Operation

Starting Operation

• Pay attention to the mains voltage. The voltage of the power source must match the voltage specified on the rating plate of the power tool.
• Products that are only sold in AUS and NZ: Use a residual current device (RCD) with a nominal residual current of 30 mA or less.

Switching On and Off

• Make sure that you are able to press the On/Off switch without releasing the handle.

To switch on the power tool, press and hold the on/off switch (5).
To lock the on/off switch (5) press and hold it while also pushing the lock-on button (7).
To switch off the power tool, release the on/off switch (5). If the on/off switch (5) is locked, press the switch first and then release it.

Preselecting the Belt Speed (PBS 75 AE)
You can even preselect the necessary belt speed during operation using the belt speed preselection thumbwheel (4). The required belt speed is dependent on the material and the work conditions and can be determined using practical tests.

Practical advice

• Pull the plug out of the socket before carrying out any work on the power tool.

The material removal rate when sanding and the surface quality are primarily determined by the choice of sanding belt and the preselected belt speed (PBS 75 AE). The higher the belt speed, the higher the removal rate and the finer the sanded surface becomes.
Only sanding belts in perfect condition achieve good sanding performance and make the power tool last longer.
Apply as little contact pressure as possible while working in order to increase the service life of the sanding belts. The weight of the power tool alone is enough to ensure good sanding performance. Excessively increasing the contact pressure will not lead to increased sanding performance, rather it will cause more severe wear of the power tool and of the sanding belt.
Place the running power tool on the surface you wish to work on. Work with moderate feed and carry out sanding in parallel and overlapping with the sanding path. Sand with the grain; sanding marks that run against the grain result in bothersome sanding effects.
Especially when sanding off paint residue, the residue could merge together, resulting in smears on the workpiece surface and the sanding belt. Therefore, do not work without dust extraction.
A sanding belt that has been used to work on metal should no longer be used to work on other materials. Use only original Bosch-sanding accessories.
Only ever store sanding belts hanging up and do not fold them as this makes them unusable.
The sanding frame (accessory) enables an even, adjustable material removal rate while sanding large wooden surfaces.

Maintenance and Service

Maintenance and Cleaning

• Pull the plug out of the socket before carrying out any work on the power tool.
• To ensure safe and efficient operation, always keep the power tool and the ventilation slots clean.

In order to avoid safety hazards, if the power supply cord needs to be replaced, this must be done by Bosch or by an after-sales service centre that is authorised to repair Bosch power tools.

Cleaning the Dust Channel (see figure E)
Remove the protective cover (14) from time to time and clean the dust channel (15) to maintain optimal suction power.

After-Sales Service and Application Service
Our after-sales service responds to your questions concerning maintenance and repair of your product as well as spare parts. You can find explosion drawings and information on spare parts at: www.bosch-pt.com
The Bosch product use advice team will be happy to help you with any questions about our products and their accessories.
In all correspondence and spare parts orders, please always include the 10‑digit article number given on the nameplate of the product.

Great Britain
Robert Bosch Ltd. (B.S.C.)
P.O. Box 98
Broadwater Park
North Orbital Road
Denham Uxbridge
UB 9 5HJ
At www.bosch-pt.co.uk you can order spare parts or arrange the collection of a product in need of servicing or repair.
Tel. Service: (0344) 7360109
E-Mail: boschservicecentre@bosch.com
You can find further service addresses at: www.bosch-pt.com/serviceaddresses

Safety Instructions

General Power Tool Safety Warnings

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.
Save all warnings and instructions for future reference. The term "power tool" in the warnings refers to your mainsoperated (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 English dust. Power tools create sparks which may ignite the dust or fumes.
• Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

Electrical safety

• Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.
• Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
• Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
• Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock.
• When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
• If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.

Personal safety

• Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.
• Use personal protective equipment. Always wear eye protection. Protective equipment such as a dust mask, non-skid safety shoes, hard hat or hearing protection used for appropriate conditions will reduce personal injuries.
• Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energising power tools that have the switch on invites accidents.
• Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.
• Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
• Dress properly. Do not wear loose clothing or jewellery. Keep your hair and clothing away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts.
• If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards.
• Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.

Power tool use and care

• Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.
• Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
• Disconnect the plug from the power source and/or remove the battery pack, if detachable, 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 and accessories. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool's operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
• Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
• Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.
• Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

Service

• Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

Safety Warnings for Sander

• Hold the power tool by insulated gripping surfaces, because the sanding surface may contact its own cord. Cutting a "live" wire may make exposed metal parts of the power tool "live" and could give the operator an electric shock.
• Only use the power tool for dry sanding. Water entering a power tool will increase the risk of electric shock.
• Switch the power tool on before making contact with the workpiece and only switch the power tool off after you have removed it from the workpiece. The power tool can move suddenly.
• Never touch the sanding belt while it is running. This poses a risk of injury.
• Wear protective gloves and never touch the sanding belt while it is running. This poses a risk of injury.
• Ensure that no persons are at risk due to flying sparks. Remove combustible materials from the surrounding area. Flying sparks are created when sanding metals.
• Do not use any worn, torn or severely clogged sanding belts. Damaged sanding belts can tear, fly off and injure someone.
• 
  Danger of fire! Avoid overheating the workpiece and the sander. Always empty the dust collector before taking a break from work. Sanding dust in the dust bag, microfilter, paper bag (or in the filter bag or vacuum cleaner filter) can spontaneously combust under certain conditions, for example if flying sparks are created when sanding metals. This risk is increased if the sanding dust is mixed with paint or polyurethane residue or with other chemical substances and if the workpiece is hot as a result of prolonged work.
• Clean the air vents on your power tool regularly. The motor's fan will draw the dust inside the housing and excessive accumulation of powdered metal may cause electrical hazards.

Products sold in GB only:
Your product is fitted with an BS 1363/A approved electric plug with internal fuse (ASTA approved to BS 1362).
If the plug is not suitable for your socket outlets, it should be cut off and an appropriate plug fitted in its place by an authorised customer service agent. The replacement plug should have the same fuse rating as the original plug.
The severed plug must be disposed of to avoid a possible shock hazard and should never be inserted into a mains socket elsewhere.

• Secure the workpiece. A workpiece clamped with clamping devices or in a vice is held more secure than by hand.
• Always wait until the power tool has come to a complete stop before placing it down. The application tool can jam and cause you to lose control of the power tool.
• Hold the power tool firmly with both hands and make sure you have a stable footing. The power tool can be more securely guided with both hands.