BOSCH GSS18V-40 18V Brushless Sheet Orbital Finishing Sander Instruction Manual

BOSCH GSS18V-40 18V Brushless Sheet Orbital Finishing Sander Instruction Manual

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 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 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 Ground Fault Circuit Interrupter (GFCI) protected supply.
  Use of an GFCI 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 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.
  This enables better control of the power tool in unexpected situations.

• Dress properly. Do not wear loose clothing or jewelry. Keep your hair and clothing away from moving parts.
  Loose clothes, jewelry 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.

Battery tool use and care

• Recharge only with the charger specified by the manufacturer.
  A charger that is suitable for one type of battery pack may create a risk of fire when used with another battery pack.

• Use power tools only with specifically designated battery packs.
  Use of any other battery packs may create a risk of injury and fire.

• When battery pack is not in use, keep it away from other metal objects like paper clips, coins, keys, nails, screws, or other small metal objects that can make a connection from one terminal to another.
  Shorting the battery terminals together may cause burns or a fire.

• Under abusive conditions, liquid may be ejected from the battery, avoid contact.
  If contact accidentally occurs, flush with water.
  If liquid contacts eyes, additionally seek medical help.
  Liquid ejected from the battery may cause irritation or burns.

• Do not use a battery pack or tool that is damaged or modified.
  Damaged or modified batteries may exhibit unpredictable behavior resulting in fire, explosion or risk of injury.

• Do not expose a battery pack or tool to fire or excessive temperature.
  Exposure to fire or temperature above 265 °F may cause explosion.

• Follow all charging instructions and do not charge the battery pack or tool outside the temperature range specified in the instructions.
  Charging improperly or at temperatures outside the specified range may damage the battery and increase the risk of fire.

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.

• Never service damaged battery packs.
  Service of battery packs should only be performed by the manufacturer or authorized service providers.

Safety Symbols
The definitions below describe the level of severity for each signal word.
Please read the manual and pay attention to these symbols.

| This is the safety alert symbol. It is used to alert you to  potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
| DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
| WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
| CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Safety Rules for Orbital Sanders

• Use clamps or another practical way to secure and support the workpiece to a stable platform.
  Holding the work by your hand or against the body leaves it unstable and may lead to loss of control.

• Remove battery before changing accessories. Accidental start-ups may occur if battery is installed while changing an accessory.

• If your tool is equipped with a dust bag, empty it frequently and after completion of sanding.
  Be extremely careful of dust disposal, materials in fine particle form may be explosive.
  Do not throw sanding dust on an open fire.
  Spontaneous combustion may, in time, result from mixture of oil or water with dust particles.

• Always wear eye protection and a dust mask for dusty applications and when sanding overhead.
  Sanding particles can be absorbed by your eyes and inhaled easily and may cause health complications.

• Do not wet sand with this sander. Liquids entering the motor housing is an electrical shock hazard.

• Do not use sandpaper intended for larger sanding pads.
  Larger sandpaper will extend beyond the sanding pad causing snagging, tearing of the paper or kick-back.
  Extra paper extending beyond the sanding pad can also cause serious lacerations.

Additional Safety Warnings

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

Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to cause cancer, birth defects or other reproductive harm.
Some examples of these chemicals are:

• Lead from lead-based paints,
• Crystalline silica from bricks and cement and other masonry products, and
• Arsenic and chromium from chemically treated lumber.

Your risk from these exposures varies, depending on how often you do this type of work.
To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

Intended Use
The power tool is intended for dry sanding of wood, plastic, filler and coated surfaces.

SAVE THESE INSTRUCTIONS

Specifications

(-20…+50°C)
Recommended ambient temperature during charging| +32…+95°F (0…+35°C)
Weight| 2.4 lbs.

Battery Packs / Chargers:
Please refer to the battery/charger list, included with your tool.
NOTE: For tool specifications refer to the nameplate on your tool.

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.

speed, orbits etc. per minute)
| Off position (zero speed, zero torque…)
| Selector settings (speed, torque or position settings. Higher number means greater speed)
| Infinitely variable selector with off (speed is increasing from 0 setting)
| Arrow (action in the direction of arrow)
| Type or a characteristic of current
| Type or a characteristic of current
| Type or a characteristic of current
| Designates Double Insulated Construction tools
| Grounding terminal
| Alerts user to warning messages
Symbol| Designation/Explanation
---|---
| Alerts user to read manual.
| Alerts user to wear eye protection.
| Alerts user to wear respiratory protection.
| Alerts user to wear hearing protection.
| Alerts user to wear eye, respiratory, and hearing protection.
| 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.
| Designates Li-ion battery recycling program.

Getting to Know Your Product page heading

Cordless Orbit Sander

1. On/Off Button Switch
2. Dust Bag Assembly
3. Battery Pack Release Button
4. Battery Pack
5. Variable Speed Dial
6. Battery Charge Indicator Button
7. Battery Charge Indicator
8. Pivoting Feet
9. Base Mounting Recess
10.  Quarter (1/4) Sheet Base Plate
11. Quarter (1/4) Sheet Backing Pad
12. Base Plate Screws (x4)
13. Rectangular (1/3) Sheet Base Plate
14. Rectangular (1/3) Sheet Backing Pad
15. Detail Sheet Base Plate
16. Detail Sheet Backing Pad
17. Gripping Surface (Insulated)

Assembly

Disconnect battery pack from tool before making any assembly, adjustments or changing accessories.
Such preventive safety measures reduce the risk of starting the tool accidentally.

Backing Pad/Base Plate Installation
This orbital sander is equipped with three different base plate and backing pad configurations and in general are used as follows:

1/4 Sheet Base Plate and Backing Pad
All purpose general plate and pad configuration used for finishing details.

1/3 Sheet Base Plate and Backing Pad
All purpose plate and pad configuration for more difficult to reach areas where a 1/4 Sheet Base Plate and Backing Pad will not fit.

Detail Sheet Base Plate and Backing Pad
Designed for hard-to-reach corners and crevices where 1/4 Sheet or 1/3 Sheet Base Plate and Backing Pad will not fit.

Changing Orbital Sander Base Plate and Backing Pad
To change the backing pad, unscrew the four Base Plate Screws 12 completely and remove the backing pad (Fig. 1).
Pull the base plate away from the four Pivoting Feet 8 and place the replacement base plate on the four pivoting feet.
Push the Pivoting Feet 8 into the four Base Mounting Recesses 9.
Align the backing pad to base plate and secure both base plate and backing pad in place with the Base Plate Screws 12.

Installing Accessories
(Fig. 2, 3, 4, 5)
Remove dirt and dust from the sanding plate e.g., with a brush, before attaching a new sanding sheet.

For 1/3 and Detail Sheets with a hook-and-loop Backing

If the sanding plate is fitted with a hook-and loop fastening, sanding sheets with a hook and loop fastening backing can be secured quickly and easily.
Tap the hook-and-loop fastening of the sanding plate before fitting the Sanding Sheet 18 to facilitate maximum adhesion.
Position the Sanding Sheet 18 so that is it flush with one side of the sanding plate, then place the Sanding Sheet on the sanding plate and press on firmly.
To remove the Sanding Sheet 18, take hold of it by a corner and pull it away from the sanding plate.

For 1/4 Sheet with a hook-and loop Backing
Unlock both Sanding Sheet Clamp 20 levers and swivel them downwards (Fig. 2).
Insert the Sanding Sheet 18 under the Rear Clamping Bracket 21. Ensure that the Sanding Sheet 18 is not too short to be correctly clamped under both Sanding Sheet Clamps 20 and the Rear Clamping Bracket 21.
Swivel the Sanding Sheet Clamp 20 lever back into starting position, lock it there, and repeat for the other Sanding Sheet Clamp lever **(Fig. 3).

**

Place the Sanding Sheet 18 taut around the ¼ Sheet Backing Pad 11. Clamp the front part of the Sanding Sheet 18 under the Front Clamping Bracket 19.
Ensure that the Sanding Sheet 18 is not too short and that it is correctly clamped.
Swivel the Sanding Sheet Clamp 20 lever back into the starting position, lock it there, and repeat for the other Sanding Sheet Clamp lever (Fig. 4).
To remove the Sanding Sheet 18, unlock both Sanding Sheet Clamp 20 levers and pull the Sanding Sheet out of its holder.

Punch Plate
After the Sanding Sheet 18 has been installed, it will be necessary to punch holes into the sheet using the Punch Plate 26 provided with your sander.
Align sander backing pad with Punch Plate 26 and push down on the sander until Punch Plate pierces the sheet.
Then remove Punch Plate 26 from sander (Fig. 5).
To ensure optimum dust extraction, pay attention that the punched holes in the Sanding Sheet 18 match with the holes in the backing pad.

Dust Collection

Dust Bag Assembly
(Fig. 6, 7)

Your tool is equipped with a dust bag: empty it frequently, after completion of sanding, and before storing the sander.
Be extremely careful of dust disposal, materials in fine particle form may be explosive.
Do not throw sanding dust on an open fire.
Combustion from mixture of varnishes, lacquers, polyurethane, oil or water with dust particles can occur if there is a static discharge, spark introduced in the box, or excessive heat.
The integral dust extraction system collects sanding dust in the Dust Bag 23 supplied with your sander.
For maximum efficiency, the Dust Bag 23 should be emptied frequently during operation.

Removing and Installing Dust Bag Assembly
To remove Dust Bag Assembly 2: twist the Dust Bag 23 left or right and simply pull away from the tool.
To install Dust Bag Assembly 2: align Dust Port 22 with hole in Dust Bag Assembly 2 and push onto tool until it locks into place (Fig. 5).

Cleaning and Emptying the Dust Bag Assembly
Before opening the Dust Bag 23, it is recommended to loosen dust from the Dust Bag 23 by gently tapping it against a solid surface.
To empty Dust Bag 23: hold Dust Bag 23 and maintain a firm grip.
Unscrew the Dust Bag 23 from the Dust Bag Adapter 24 and pull them apart (Fig. 6).
Then, shake out the Dust Bag 23 over a suitable waste bin (Fig. 7).
Knock excess dust out of the Dust Bag 23, or remove dust with your fingers or a soft brush.
You may notice that all the dust may not come out of the Dust Bag 23.
This will not affect sanding performance but will reduce dust collection efficiency.
NOTE: Do not wash the Dust Bag 23 with soap and water.
Dust may become more firmly lodged in the pores, which will reduce dust collection.

Attaching a Vacuum Cleaner
(Fig. 8)
Dust collection can also be achieved by attaching the tool to a vacuum cleaner / dust extractor, hose and adapter, if necessary (all sold separately).

1. Attach the hose to the vacuum cleaner / dust extractor.
2. Attach the hose to the tool’s Dust Port 22 in one of the following ways (Fig. 8):
   • Bosch VH-series hoses – The VX120 hose adapter is required (included with VHseries hoses).
   • Other 35mm and 22mm hoses, such as the Bosch VAC-series hoses – Connect hose directly to the tool.
   • Common 1-1/4” or 1-1/2” hoses – The Bosch VAC002 or VAC024 adapter is required.

Operation

On/Off Button
TO TURN THE TOOL “ON” depress the On/Off Button Switch 1.
TO TURN THE TOOL “OFF”: depress the On/Off Button Switch 1.
See “Start of Sanding” on page 15.

Variable Speed Dial
Your sander is also equipped with a Variable Speed Dial 5 (Fig. 1).
The sander’s speed can be preset from zero to maximum nameplate speed by rotating the Variable Speed Dial 5 in the housing.
The Variable Speed Dial 5 may be set on or between any of six positions (1=low through 6=high).
The following table may be used as a general guide for abrasive and backing pad selection, but the best results will be obtained by sanding a test sample of the workpiece first.

| Range of applications| Application| Grit Size| Speed setting
---|---|---|---|---
1/3 Sheet Base Plate and Backing Pad|

• Sanding surfaces and corner spaces
• Sanding in windows and doors
• Sanding paint and varnish
• Sanding wood
• Sanding solid wood edges and veneer edges

| Coarse sanding| 40–180| 4-6
Fine sanding| 220-400| 1-3
1/4 Sheet Base Plate and Backing Pad|

• Sanding surfaces and corner spaces
• Sanding in windows and doors
• Sanding paint and varnish
• Sanding wood

| Coarse sanding| 40–180| 4-6
Fine sanding| 220-400| 1-3
Detail Sheet Base Plate and Backing Pad|

• Sanding slats
• Removal from surfaces with angles, corners and edges
• Sanding paint and varnish
• Sanding wood

| Coarse sanding| 40–180| 4-6
Fine sanding| 220-400| 1-3

Using the Orbit Sander
Your sander was designed to sand in small or confined areas.
Its small size and light weight makes it ideal for overhead work.
You may grip the tool from the Gripping Surface 7 with either the battery behind your hand or in front of you hand.

Selecting Sanding Sheets
Open-coat aluminum oxide sanding sheets are recommended for most wood or metal sanding applications, as this synthetic material cuts quickly and wears well. Some applications, such as plastics, glass, or stone require silicon carbide sheets, which have a very sharp cutting edge.
For best results, use Bosch sanding and polishing accessories, which are of superior quality and are carefully selected to produce
professional quality results with your sander.

Start of Sanding
With the workpiece firmly secured, first place the sander’s pad on the work surface, then switch the tool on.
DO NOT start the tool and bring it up to speed before applying to the work.
DO NOT apply excessive pressure when switching the tool on (or at any other time).
Either method will likely create swirl marks.
Applying excessive pressure upon start-up will also shorten the life of the switch.

Sanding Action
In general, higher speeds will give the best results. If faster removal is desired, DO NOT APPLY PRESSURE ON THE TOOL; use a coarser grade of abrasive.
Move the sander in long sweeping strokes, parallel to the grain using some lateral motion to overlap the strokes by as much as 75%.
The random orbit action allows cross-grain sanding, but be careful not to tilt the sander near edges, or undesirable rounding may result.

Sanding Sequence
If the surface is rough, begin with coarser grits and then complete the surfacing with medium and fine abrasives.
Because the orbit action is so effective, it is often possible to begin sanding with a medium grit sheet and go directly to fine finishing.
To avoid uneven results, do not skip more than one grit size when going from coarser to finer, and do not sand in one area for too long.

Removal of Sander
To help prevent swirl marks when the job is completed, gently lift the tool from the work surface, then switch the tool off.
Operating in this manner will also prolong the switch life.

Maintenance

To avoid accidents, always disconnect the battery pack from tool before servicing or cleaning.

Service
NO USER SERVICEABLE PARTS INSIDE.
Preventive 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.

Batteries
Be alert for battery packs that are nearing their end of life.
If you notice decreased tool performance or significantly shorter running time between charges then it is time to replace the battery pack.
Failure to do so can cause the tool to operate improperly or damage the charger.

Tool Lubrication
Your Bosch tool has been properly lubricated and is ready for use.

Motors
The motor in your tool has been engineered for many hours of dependable service.
To maintain peak efficiency of the motor, we recommend it be examined every six months.
Only a genuine Bosch replacement motor specially designed for your tool should be used.

Cleaning
Certain cleaning agents and solvents damage plastic parts.
Some of these are: gasoline, carbon tetrachloride, chlorinated cleaning solvents, ammonia and household detergents that contain ammonia.
Ventilation openings and switch levers must be kept clean and free of foreign matter.
Do not attempt to clean by inserting pointed objects through opening.

Accessory Storage & Maintenance
Store accessories in a cool dry place and avoid freezing.
Before use check accessory for cracks and fractures, do not use if damage is suspected.

Accessories

Do not use attachments/accessories other than those specified by Bosch.
Use of attachments/accessories not specified for use with the tool described in this manual may result in damage to tool, property damage, and or personal injury.

• 1/3 Sheet Base Plate and Backing Pad 3.2” x 5.1”
• 1/4 Sheet Base Plate and Backing Pad 3.9” x 4.9”
• Detail Sheet Base Plate and Backing Pad 3.9 x 5.9”
• Dust Bag Assembly
• Sand Paper
• Hole Punch

|

• Additional Types of Sanding Sheets
• Vacuum Hoses
• Vacuum Hose Adapters

Warranty

LIMITED WARRANTY OF BOSCH PORTABLE AND BENCHTOP POWER TOOLS

Robert Bosch Tool Corporation (“Seller”) warrants to the original purchaser only, that all BOSCH portable and benchtop power tools will be free from defects in material or workmanship for a period of one year from date of purchase.
Seller’s sole obligation and your exclusive remedy under this Limited Warranty and, to the extent permitted by law, any warranty or condition implied by law, shall be the repair or replacement of parts, without charge, which are defective in material or workmanship and which have not been misused, carelessly handled, or misreported by persons other than Seller or Authorized Service Station.
To make a claim under this Limited Warranty, you must return the complete portable or benchtop power tool product, transportation prepaid, to any BOSCH Factory Service Center or Authorized Service Station.
For Authorized BOSCH Power Tool Service Stations, please refer to your phone directory.
This Limited Warranty does not apply to accessory ITEMS SUCH AS CIRCULAR SAW BLADES, DRILL BITS, ROUTER BITS, JIGSAW BLADES, SANDING BELTS, GRINDING WHEELS AND OTHER RELATED ITEMS.
ANY IMPLIED WARRANTIES SHALL BE LIMITED IN DURATION TO ONE YEAR FROM DATE OF PURCHASE. SOME STATES IN THE U.S., SOME CANADIAN PROVINCES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING BUT NOT LIMITED TO LIABILITY FOR LOSS OF PROFITS) ARISING FROM THE SALE OR USE OF THIS PRODUCT. SOME STATES IN THE U.S. AND SOME CANADIAN PROVINCES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.
THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE IN THE U.S., PROVINCE TO PROVINCE IN CANADA AND FROM COUNTRY TO COUNTRY.
THIS LIMITED WARRANTY APPLIES ONLY TO PORTABLE AND BENCHTOP ELECTRIC TOOLS SOLD WITHIN THE UNITED STATES OF AMERICA, CANADA AND THE COMMONWEALTH OF PUERTO RICO. FOR WARRANTY COVERAGE WITHIN OTHER COUNTRIES, CONTACT YOUR LOCAL BOSCH DEALER OR IMPORTER.

CUSTOMER SUPPORT

Call Toll Free for Consumer Information & Service Locations
1-877-BOSCH99
(1-877-267-2499)
www.boschtools.com

References

• Bosch Power Tools | Boschtools

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