Bosch PEX 400 AE Manual

Safety Notes

General Power Tool Safety Warnings

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 the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

1. Work area safety
   1. Keep work area clean and well lit. Cluttered or dark areas invite accidents.
   2. 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.
   3. Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.
2. Electrical safety
   1. 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.
   2. 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.
   3. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
   4. 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 and moving parts. Damaged or entangled cords increase the risk of electric shock.
   5. 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.
   6. 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.
3. Personal safety
   1. 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.
   2. Use personal protective equipment. 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.
   3. 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.
   4. Remove any adjusting key or wrench be-fore 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.
   5. Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
   6. Dress properly. Do not wear loose cloth-ing or jewellery. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts.
   7. 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.
4. Power tool use and care
   1. 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.
   2. 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.
   3. 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.
   4. 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.
   5. Maintain power tools. Check for mis-alignment 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.
   6. Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
   7. 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.
5. Service
   1. Have your power tool serviced by a qual-ified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

Safety Warnings for Sander

• Use the machine only for dry sanding. Penetration of water into the machine increases the risk of an electric shock.
• Pay attention that no persons are put at risk through sparking. Remove any combustible materials in the vicinity. Sparking occurs when sanding metal materials.
• Caution, fire hazard! Avoid overheating the object being sanded as well as the sander. Always empty the dust collector before taking breaks. In unfavourable conditions, e.g., when sparks emit from sanding metals, sanding debris in the dust bag, micro filter or paper sack (or in the filter sack or filter of the vacuum cleaner) can self-ignite. Particularly when mixed with remainders of varnish, polyurethane or other chemical materials and when the sanding debris is hot after long periods of working.
• When working with the machine, always hold it firmly with both hands and provide for a secure stance. The power tool is guided more secure with both hands.
• Secure the workpiece. A workpiece clamped with clamping devices or in a vice is held more secure than by hand.
• 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.
  Products sold in AUS and NZ only: Use a residual current device (RCD) with a rated residual current of 30 mA or less.

Functional Description

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

Intended Use

The machine is intended for dry sanding of wood, plastic, metal, filler as well as coated surfaces. Machines with electronic control are also suitable for polishing.

Product Features

The numbering of the product features refers to the illustration of the machine on the graphics page.

1. Thumbwheel for orbit frequency preselection
2. On/Off switch
3. Dust box, complete (Microfilter System)
4. Sanding plate
5. Auxiliary handle (insulated gripping surface)
6. Handle (insulated gripping surface)
7. Sanding sheet*
8. Alignment aid for sanding sheet*
9. Screws for sanding plate
10. Sanding-plate base
11. Extraction outlet
12. Filter element (Microfilter System)
13. Vacuum hose*
14. Wing nut
15. Screw for auxiliary handle

*Accessories shown or described are not part of the standard delivery scope of the product. A complete overview of accessories can be found in our accessories program.

Technical Data

Random Orbital Sander		PEX 400 AE
Article number		3 603 CA4...
Preselection of orbital stroke rate
Rated power input	W	350
No-load speed n0	min-1	2000–10600
No-load orbital stroke rate	min-1	4000–21200
Orbit diameter	mm	5
Sanding plate diameter	mm	125
Weight according to EPTA-Procedure 01/2003	kg	1.9
Protection class		/II

The values given are valid for a nominal voltage [U] of 230 V. For different voltages and models for specific countries, these values can vary.
Please observe the article number on the type plate of your machine. The trade names of the individual machines may vary.

Noise/Vibration Information

Measured sound values determined according to EN 60745.
Typically the A-weighted noise levels of the product are: Sound pressure level 80 dB(A); Sound power level 91 dB(A). Uncertainty K=3 dB.

Wear hearing protection!
Vibration total values (triax vector sum) determined according to EN 60745: Vibration emission value a_h = 8.0 m/s², Uncertainty K= 1.5 m/s².
The vibration emission level given in this information sheet has been measured in accordance with a standardised test given in EN 60745 and may be used to compare one tool with another. It may be used for a preliminary assessment of exposure.
The declared vibration emission level represents the main applications of the tool. However if the tool is used for different applications, with different accessories or poorly maintained, the vibration emission may differ. This may significantly increase the exposure level over the total working period.
An estimation of the level of exposure to vibration should also take into account the times when the tool is switched off or when it is running but not actually doing the job. This may significantly reduce the exposure level over the total working period.
Identify additional safety measures to protect the operator from the effects of vibration such as: maintain the tool and the accessories, keep the hands warm, organisation of work patterns.

Assembly

• Before any work on the machine itself, pull the mains plug.

Selecting the Sanding Sheet

Select a sanding sheet with the appropriate grain as required for the desired surface removal rate.
Bosch sanding sheets are suitable for paint, wood and metal.

Replacing the Sanding Sheet

To remove the sanding sheet 7, lift it from the side and pull it off of the sanding plate 4.
When attaching a new sanding sheet, remove any dust or debris from the sanding plate 4, e.g., with a brush.
The surface of the sanding plate 4 is fitted with Velcro backing for quick and easy fastening of sanding sheets with Velcro adhesion.
Press the sanding sheet 7 firmly against the bottom side of the sanding plate 4.
To ensure optimum dust extraction, pay attention that the punched holes in the sanding sheet match with the holes in the sanding plate.
The alignment aid 8 can be used for alignment of the sanding sheet 7 on the sanding plate 4. Place the sanding sheet with the Velcro facing upward on the alignment aid. Press the cams of the alignment aid into two holes of the sanding plate and roll off the sanding sheet from the alignment aid. Press the sanding sheet firmly against the sanding plate.

Selection of the Sanding Plate

Depending on the application, the machine can be equipped with sanding plates of different hardness:

• Sanding plate, medium (black): Suitable for all sanding work; universally usable.
• Sanding plate, soft (grey, accessory): Suitable for intermediate and fine sanding, incl. on convex surfaces.

Replacing the Sanding Plate

Note: Replace a damaged sanding plate 4 immediately.
Pull off the sanding sheet or the polishing accessory. Unscrew the four screws 9 completely and remove the sanding plate 4.
Clean the upper side of the new sanding plate 4. Apply a thin coat of synthetic grease to the outer ring hatched grey in the figure.
Attach the new sanding plate 4 and tighten the four screws again.
Note: A damaged sanding-plate base 10 may be changed only by an authorised after-sales service agent for Bosch power tools.

Dust/Chip Extraction

• Dusts from materials such as lead-containing coatings, some wood types, minerals and metal can be harmful to one's health. Touching or breathing-in the dusts can cause allergic reactions and/or lead to respiratory infections of the user or bystanders. Certain dusts, such as oak or beech dust, are considered as carcinogenic, especially in connection with wood-treatment additives (chromate, wood preservative). Materials containing asbestos may only be worked by specialists.
  • As far as possible, use a dust extraction system suitable for the material.
  • Provide for good ventilation of the work-ing place.
  • It is recommended to wear a P2 filter-class respirator.
    Observe the relevant regulations in your country for the materials to be worked.
• Prevent dust accumulation at the workplace. Dusts can easily ignite.
  Integrated Dust Extraction with Dust Box (see figures E–H)
  Attach the dust box 3 onto the extraction outlet 11 until it latches. The filling level of the dust box 3 can easily be checked through the transparent container. To empty the dust box 3, pull it off toward the bottom with a twisting motion. Before opening the dust box 3, it is recommended to loosen the dust from the filter element by gently striking it against a firm support (as shown in the figure).
  Hold the dust box 3 firmly, fold the filter element 12 upward and empty the dust box. Clean the thin plates of the filter element 12 with a soft brush.
  Note: To ensure optimum dust extraction, empty the dust box 3 in good time and clean the filter element 12 at regular intervals. When working vertical surfaces, hold the power tool in such a manner that the dust box 3 faces downward.
  
  
  
  

External Dust Extraction (see figure I)

Mount a vacuum hose 13 onto the extraction outlet 11. Connect the vacuum hose 13 with a vacuum cleaner. An overview for the connection of various vacuum cleaners can be found at the end of these instructions.
The vacuum cleaner must be suitable for the material being worked.
When vacuuming dry dust that is especially detrimental to health or carcinogenic, use a special vacuum cleaner.
When working vertical surfaces, hold the power tool in such a manner that the vacuum hose faces downward.

Auxiliary Handle

The auxiliary handle 5 enables convenient handling and optimal distribution of power, especially at high removal rates.
For sanding close to edges, the auxiliary handle can be removed. Unscrew wing nut 14 and pull screw 15 out of the housing. Now, pull off the auxiliary handle 5 toward the front.
To remount the auxiliary handle 5, slide it from the front onto the housing in such a manner that the studs of the handle engage into the recesses of the housing. Firmly tighten the auxiliary handle with the screw 15 and the wing nut 14.

Operation

Starting Operation

• Observe correct mains voltage! The voltage of the power source must agree with the voltage specified on the nameplate of the machine. Power tools marked with 230 V can also be operated with 220 V.

Switching On and Off
To start the machine, push the On/Off switch 2 forward so that the "1" is indicated on the switch.
To switch off the machine, push the On/Off switch 2 toward the rear so that the "0" is indicated on the switch.

Preselecting the Orbital Stroke Rate
With the thumbwheel for preselection of the orbital stroke rate 1, you can preselect the required orbital stroke rate, even during operation.
1–2 Low stroke rate
3–4 Medium stroke rate
5–6 High stroke rate
The required stroke rate depends on the material and the working conditions and can be determined through practical testing.
After longer periods of working at low stroke rate, allow the machine to cool down by running it for approx. 3 minutes at maximum stroke rate with no load.

Working Advice

• Before any work on the machine itself, pull the mains plug.
• Wait until the machine has come to a stand-still before placing it down.

Sanding Surfaces
Switch the machine on, place it with the complete sanding surface on the surface to be worked and move the machine with moderate pressure over the workpiece.
The removal capacity and the sanding pattern are mainly determined by the selection of the sanding sheet, the preselected orbital stroke rate and the applied pressure.
Only flawless sanding sheets achieve good sanding capacity and extend the service life of the machine.
Pay attention to apply uniform sanding pressure; this increases the working life of the sanding sheets.
Intensifiying the sanding pressure does not lead to an increase of the sanding capacity, but to increased wear of the machine and the sanding sheet.
A sanding sheet that has been used for metal should not be used for other materials.
Use only original Bosch sanding accessories.

Rough Sanding
Attach a sanding sheet with coarse grain.
Apply only light pressure to the machine so that it runs at a higher stroke rate and high material removal is achieved.

Fine Sanding
Attach a sanding sheet with fine grain.
By lightly varying the application pressure or changing the orbital stroke rate, the sanding plate stroke rate can be reduced whereby the orbital action is maintained.
With moderate pressure, move the machine in a circular pattern or alternately in lengthwise and crosswise directions over the workpiece. Do not tilt the machine to avoid sanding through the workpiece (e.g. when sanding veneer).
After finishing the working procedure, switch the power tool off.

Polishing
For the polishing of weathered paint or buffing out scratches (e.g., acrylic glass), the machine can be equipped with appropriate polishing accessories such as lamb's wool bonnet, polishing felt or sponge (accessories).
Select a low stroke rate (setting 1–2) for polishing in order to avoid excessive heating of the surface.
Apply the polish onto a somewhat smaller surface than you intend to polish. Work the polishing agent in with a suitable polishing tool applying it crosswise or with circular motion and moderate pressure.
Do not allow the polishing agent to dry out on the surface, otherwise the surface can become damaged. Do not subject the surface to be polished to direct sunlight.
Clean the polishing accessories regularly to ensure good polishing results. Wash out polishing accessories with a mild detergent and warm water; do not use paint thinner.

Application Table
The data in the following table are recommended values.
The most favourable combination for working is best determined by practical testing.

Maintenance and Cleaning

• Before any work on the machine itself, pull the mains plug.
• For safe and proper working, always keep the machine and ventilation slots clean.

If the replacement of the supply cord is necessary, this has to be done by Bosch or an authorized Bosch service agent in order to avoid a safety hazard.
If the machine should fail despite the care taken in manufacturing and testing procedures, repair should be carried out by an after-sales service centre for Bosch power tools.
In all correspondence and spare parts order, please always include the 10-digit article number given on the type plate of the machine.

After-sales Service and Customer Assistance

Our after-sales service responds to your questions concerning maintenance and repair of your product as well as spare parts. Exploded views and information on spare parts can also be found under:
www.bosch-pt.com
Our customer service representatives can answer your questions concerning possible applications and adjustment of products and accessories.

Great Britain
Robert Bosch Ltd. (B.S.C.)
P.O. Box 98
Broadwater Park
North Orbital Road
Denham
Uxbridge
UB 9 5HJ
Tel. Service: +44 (0844) 736 0109
Fax: +44 (0844) 736 0146
E-Mail: boschservicecentre@bosch.com

Ireland
Origo Ltd.
Unit 23 Magna Drive
Magna Business Park
City West
Dublin 24
Tel. Service: +353 (01) 4 66 67 00
Fax: +353 (01) 4 66 68 88

Australia, New Zealand and Pacific Islands
Robert Bosch Australia Pty. Ltd.
Power Tools
Locked Bag 66
Clayton South VIC 3169
Customer Contact Center Inside Australia:
Phone: +61 (01300) 307 044
Fax: +61 (01300) 307 045
Inside New Zealand:
Phone: +64 (0800) 543 353
Fax: +64 (0800) 428 570
Outside AU and NZ:
Phone: +61 (03) 9541 5555
www.bosch.com.au

Republic of South Africa
Customer service
Hotline: +27 (011) 6 51 96 00
Gauteng – BSC Service Centre
35 Roper Street, New Centre
Johannesburg
Tel.: +27 (011) 4 93 93 75
Fax: +27 (011) 4 93 01 26
E-Mail: bsctools@icon.co.za

KZN – BSC Service Centre
Unit E, Almar Centre
143 Crompton Street
Pinetown
Tel.: +27 (031) 7 01 21 20
Fax: +27 (031) 7 01 24 46
E-Mail: bsc.dur@za.bosch.com

Western Cape – BSC Service Centre
Democracy Way, Prosperity Park
Milnerton
Tel.: +27 (021) 5 51 25 77
Fax: +27 (021) 5 51 32 23
E-Mail: bsc@zsd.co.za

Bosch Headquarters
Midrand, Gauteng
Tel.: +27 (011) 6 51 96 00
Fax: +27 (011) 6 51 98 80
E-Mail: rbsa-hq.pts@za.bosch.com

People's Republic of China
China Mainland
Bosch Power Tools (China) Co., Ltd.
567, Bin Kang Road
Bin Jiang District 310052
Hangzhou, P.R.China
Service Hotline: 400 826 8484
Fax: +86 571 8777 4502
E-Mail: contact.ptcn@cn.bosch.com
www.bosch-pt.com.cn

HK and Macau Special Administrative Regions
Robert Bosch Hong Kong Co. Ltd.
21st Floor, 625 King's Road
North Point, Hong Kong
Customer Service Hotline: +852 (21) 02 02 35
Fax: +852 (25) 90 97 62
E-Mail: info@hk.bosch.com
www.bosch-pt.com.hk

Indonesia
PT. Multi Tehaka
Kawasan Industri Pulogadung
Jalan Rawa Gelam III No. 2
Jakarta 13930
Indonesia
Tel.: +62 (21) 46 83 25 22
Fax: +62 (21) 46 82 86 45/68 23
E-Mail: sales@multitehaka.co.id
www.multitehaka.co.id

Philippines
Robert Bosch, Inc.
28th Floor Fort Legend Towers,
3rd Avenue corner 31st Street,
Fort Bonifacio Global City,
1634 Taguig City, Philippines
Tel.: +63 (2) 870 3871
Fax: +63 (2) 870 3870
matheus.contiero@ph.bosch.com
www.bosch-pt.com.ph
Bosch Service Center:
9725-27 Kamagong Street
San Antonio Village
Makati City, Philippines
Tel.: +63 (2) 899 9091
Fax: +63 (2) 897 6432
rosalie.dagdagan@ph.bosch.com

Malaysia
Robert Bosch (S.E.A.) Pte. Ltd.
No. 8A, Jalan 13/6
G.P.O. Box 10818
46200 Petaling Jaya
Selangor, Malaysia
Tel.: +60 (3) 7966 3194
Fax: +60 (3) 7958 3838
cheehoe.on@my.bosch.com
Toll-Free: 1800 880 188
www.bosch-pt.com.my

Thailand
Robert Bosch Ltd.
Liberty Square Building
No. 287, 11 Floor
Silom Road, Bangrak
Bangkok 10500
Tel.: +66 (2) 6 31 18 79 – 18 88 (10 lines)
Fax: +66 (2) 2 38 47 83
Robert Bosch Ltd., P. O. Box 2054
Bangkok 10501, Thailand
Bosch Service – Training Centre
2869-2869/1 Soi Ban Kluay
Rama IV Road (near old Paknam Railway)
Prakanong District
10110 Bangkok
Thailand
Tel.: +66 (2) 6 71 78 00 – 4
Fax: +66 (2) 2 49 42 96
Fax: +66 (2) 2 49 52 99

Singapore
Robert Bosch (SEA) Pte. Ltd.
11 Bishan Street 21 Singapore 573943
Tel.: +65 6571 2772
Fax: +65 6350 5315
leongheng.leow@sg.bosch.com
Toll-Free: 1800 333 8333
www.bosch-pt.com.sg

Vietnam
Robert Bosch Vietnam Co. Ltd
10/F, 194 Golden Building
473 Dien Bien Phu Street
Ward 25, Binh Thanh District
84 Ho Chi Minh City
Vietnam
Tel.: +84 (8) 6258 3690 ext. 413
Fax: +84 (8) 6258 3692
hieu.lagia@vn.bosch.com
www.bosch-pt.com