BOSCH GTR55-85 9 In Drywall Sander Kit Instruction Manual

BOSCH GTR55-85 9 In Drywall Sander Kit 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

Work Area Safety
a. Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b. Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
c. Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

Electrical Safety
a. 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 electricshock.
b. 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.
c. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
d. Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock.
e. When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
f. 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
a. Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.
b. 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.
c. Prevent unintentional starting. Ensure the switch is in the off- position before connecting to power source and / or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.
d. Remove any adjusting key or wrench 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.
e. Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
f. 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.
h. 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
a. Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.
b. Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
c. Disconnect the plug from the power source and/or remove the battery pack from the power tool before making any adjustments, changing accessories, o storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.
d. Store idle power tools out of the reach of 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.
e. 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.
f. Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
g. Use the power tool, accessories and tool 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.
h. 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
a. Have your power tool serviced by a qualified repair person using only identical replacement parts.

Safety Rules for Random Orbital Sanders

a. Hold power tool by insulated gripping surfaces, when performing an operation where the sanding disk may contact its own cord. Sanding disk contacting a “live” wire may make exposed metal parts of the power tool “live” and could give the operator an electric shock.
b. Unplug the sander before changing accessories. Accidental start-ups may occur if sander is plugged in while changing an accessory.
c. 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.
d. 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.
e. Use special precautions when sanding chemically pressure treated lumber, paint that may be lead based, or any other materials that may contain carcinogens. A suitable breathing respirator and protective clothing must be worn by all persons entering the work area. Work area should be sealed by plastic sheeting and persons not protected should be kept out until work area is thoroughly cleaned.
f. Do not wet sand with this sander. Liquids entering the motor housing is an electrical shock hazard.
g. Do not use PSA pad on random orbit sanders whose speed exceeds 12,000/min. Exceeding the maximum operating speed of pad may cause pad to rupture or fly apart during use striking user or bystanders.
h. 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.
i. Be aware of the location and setting of the Switch “Lock-ON” Button. If the switch is locked “ON”, be ready for emergency situations to switch it “OFF”, by first pulling the trigger then immediately releasing it without pressing the “Lock-ON” button.
j. Clamp or secure workpiece when sanding. Clamping the workpiece prevents it from being ejected from under the sander and leaves both hands to control the tool.
k. Keep the cord away from the spinning pad and sandpaper. The cord can become entangled with the pad.

Additional Safety Warnings

Do not hold the vacuum hose against any body parts during operation. Static electricity build-up in the hose during operation may result in static shock. GFCI and personal protection devices like electrician’s rubber gloves and footwear will further enhance your personal safety. Do not use AC only rated tools with a DC power supply. While the tool may appear to work, the electrical components of the AC rated tool are likely to fail and create a hazard to the operator.

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

Use this tool only as intended. Unintended use may result in personal injury and property damage. The power tool is intended for dry sanding dry wall that has had drywall plaster applied to close seams and blemishes, ceilings and walls in indoor and outdoor areas, and for removing coats of paint, adhesive residues and loose plaster. This power tool is not suitable for bench-mounted use. It must not be clamped into a vice or fastened to a workbench.

Specifications

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)
0| Off position (zero speed, zero torque…)
1, 2, 3, … I, II, III,| 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)
| 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)

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	Designation/Explanation

Alerts user to read manual.
| Alerts user to wear eye protection.
| Alerts user to wear hearing protection.
| Alerts user to wear respiratory protection.
| This symbol designates that this tool is listed by the Canadian Standards Association, to United States and Canadian Standards.

Getting to Know Your Drywall Sander

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

1. Suction Power Thumbwheel
2. Speed Preselection Thumbwheel
3. On/Off Slide Switch
4. Handle (Insulated Gripping Surface)
5. Vacuum Hose
6. Vacuum Outlet
7. Handle Section
8. Safety Hook
9. Clamping Lever
10. Extension Tube
11. Sanding Head
12. Brush Segment Locking Mechanism
13. Suction Power Adjusting Lever
14. Sanding Sheet
15. Intermediate Pad
16. Screw for Sanding Pad
17. Sanding Pad
18. Brush Segment
19. Connection Hose
20. Sanding Pad Holder

Assembly

Changing the Sanding Sheet

To remove the Sanding Sheet 14, lift it from the side and pull it off the Intermediate Pad 15. Remove any dirt or debris from Intermediate Pad 15 with a brush before attaching a new sanding sheet. Use hook and loop style sanding sheets to properly secure to Intermediate Pad 15, press the Sanding Sheet 14 firmly onto the underside of the Intermediate Pad 15. To ensure optimum dust extraction, make sure that the punched holes in the Sanding Sheet 14 are aligned with the punched holes in the Intermediate Pad 15 and the drilled holes in the Sanding Pad 17.
Note: An Intermediate Pad 15 is not required when working with the medium-hard sanding pad; the Sanding Sheet 14 is attached directly to the Sanding Pad 17. In all other cases, the change is performed as described here.

Selection of the Sanding Pad

Soft Sanding Pad Set (GTR801)

• For universal use on flat and curved surfaces.
• The set consists of a soft sanding pad and an intermediate pad. The sanding pad may only be used with an intermediate pad.

Medium/Hard Sanding Pad (GTR802)

• High material removal rate, ideal for hard plaster and removing old wall paints
• For use on flat surfaces
• Optimal suction support makes work easier when using a dust extractor.

Changing the Intermediate Pad (GTR800)

An Intermediate Pad 15 must always be used when working with the soft sanding pad (included with the drywall sander). To remove the Intermediate Pad 15 lift it from the side and pull it off the Sanding Pad 17. Remove dirt and dust from the Sanding Pad 17, e.g. with a paintbrush, before attaching a new intermediate pad. The surface of the Sanding Pad 17 is fitted with a hook- andloop fastening, allowing intermediate pads to be secured quickly and easily. Press the Intermediate Pad 15 firmly against the underside of the Sanding Pad 17. To ensure optimum dust extraction, make sure that the punched holes in the Intermediate Pad 15 are aligned with the drilled holes in the Sanding Pad 17.

Changing the Sanding Pad

Caution Observe for and replace damaged sanding pad immediately. Using a damaged sanding pad could cause a hazard.

Pull off the Sanding Sheet 14 and the Intermediate Pad 15. While grabbing the Sanding Pad 17, turn the screw 16 counter-clockwise to loosen completely and remove it. Attach the new Sanding Pad 17 and retighten the screw by turning it clockwise.
Note: For proper fit, the keyed hub on the sanding pad must align with the keyed flange on the Sanding Head Output Shaft 21.

Inserting and Removing Extension Tubes (Fig. 4)
Use the Extension Tubes 10 when necessary. The effort required to perform the sanding operation is reduced when working without the extension tube.
Note: A maximum of two extension tubes may be inserted. Undoing the

Connection between Sanding Head/Handle Section/Extension Tube (Fig. 1, Fig. 4)

1. Open the Clamping Lever 9 .A
2. Open the Safety Hook 8 .B
3. Pull the previously connected parts apart .C

Fastening the Connection between Sanding Head/Handle Section/Extension Tube (Fig. 1, Fig. 5)

1. Slide the Sanding Head 11, Handle Section 7, and/or Extension Tubes 10 into each other depending on the required connection .A
2. Close the Safety Hook 8 .B
3. Push the Clamping Lever 9 until it is at a right angle to the Sanding Head 11, Handle Section 7, or Extension Tube 10 .C
4. To avoid loosening during operation, firmly tighten the Eccentric Screw 22 clockwise .D
5. Close the Clamping Lever 9 by pressing it back in place .E

Attaching the Vacuum Hose (Fig. 1)
Attach the Vacuum Hose 5 to the Vacuum Outlet 6 on the Handle Section 7. Connect the Vacuum Hose 5 to a vacuum (sold separately). The vacuum must be suitable for the material being sanded. When working on vertical surfaces, hold the drywall sander with the Vacuum Hose 5 facing downwards

Installing/Removing the Hose/Cable Clip (Fig. 6)

Place the Hose/Cable Clip 23 over the Vacuum Hose 5 . Insert the power cable into the cable groove of the Hose/ Cable Clip 23 . To remove the Hose/Cable Clip 23, pull it off the Vacuum Hose 5 and remove the power cable from the Hose/Cable Clip 23.

Dry Wall Sander 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. Power tools marked with 120V can and should be operated with 120V.

Preselecting the Speed
You can preselect the required speed using the Speed Preselection Thumbwheel 2, even during operation. The higher numbers indicate a high speed, while the smaller ones represent a low speed. The Constant Electronic keeps the speed at no load and under load virtually consistent, producing uniform performance. The electronic soft start limits the torque when the power tool is switched on and increases the service life of the motor.

Applications
See the table “Applications” below for application information. Do not put the power tool down on its side. This could permanently warp the sanding pad.

On/Off Slide Switch (Fig. 1)
Hold the tool with both hands while turning on or off the tool. Torque from the motor can cause the tool to twist. To turn the tool “ON,” slide the On/Off Slide Switch 3 forward so that “I” appears on the switch. To turn the tool “OFF,” slide the On/Off Slide Switch 3 backwards so that “0” appears on the switch.

Applications

joint compound/ plaster hardness| wall or ceiling| internal/external air flow setting| suction power| speed setting| sanding sheet grit
| | | | |
very soft/soft| wall or ceiling| 1| 6| 2–4| from P180
medium hardness| wall| 1| 6| 4–6| from P120
ceiling| 3| 1–5(optimum: 3)
extremely hard| wall or ceiling| 1 on uneven surfaces| 6| 4–6| from P100
3 on even surfaces| 1–3

Dry Wall Sander Operation

Sanding Surfaces
Caution Always wait until the power tool has come to a complete stop before placing it down. The spinning accessory may grab a surface and cause you to lose control of the power tool. Switch the power tool on, place the entire sanding surface against the surface of the workpiece and apply moderate pressure as you move the sander over the workpiece. The material removal rate and sanding result are primarily determined by the choice of sanding sheet, the preselected speed setting and the contact pressure. Only new or unused sanding sheets achieve good sanding performance and make the power tool last longer. Be sure to apply consistent contact pressure in order to increase the lifetime of the sanding sheets. 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 sheet. Do not use a sanding sheet for other materials after it has been used to work on metal.

Sanding Close to Edges (Fig. 7, Fig. 8)


Taking out the removable Brush Segment 18 helps reduce the lateral distance between the edges/corners and the sanding pad.

• Press and hold the Locking Mechanism 12 for the Brush Segment 18.
• Swivel the Brush Segment 18 forwards and remove it.
• To insert, hook the Brush Segment 18 onto the opposite side of the Locking Mechanism 12, and swivel it towards the Sanding Head 11 until it clicks into place.

Adjusting Suction Power (Fig. 1)
You can adjust the suction power to achieve your preferred balance between sanding speed and suction power. This is only possible when the Suction Power Adjusting Lever 13 is set to position 3. (See the table “Adjusting the Internal/External Airflow” below.)

Adjust the suction power with the Thumbwheel 1:

• 1−5: Low to high suction power, suitable for sanding ceilings
• 6: Highest suction power, suitable for sanding walls
  Start with a low suction power (position 1) and increase slowly, until there is a noticeable contact pressure. High suction power allows low-fatigue sanding of ceilings and walls. An excessively high suction power can cause the power tool to vibrate, which can make handling more difficult

Changing the Connection Hose (Fig. 9)
Removing the Connection Hose

To remove the Connection Hose 19, loosen the screw on the Hose Clamp 24 with a screwdriver and lift the Hose Clamp 24 off with the Connection Hose 19. Remove the Hose Clamp 24. Pull out the Inner Housing 25 of the Hose Mount 26 at the other end of the Connection Hose 19. Hold the Inner Housing 25 in place and unscrew the Connection Hose 19

Inserting a New Connection Hose
To insert a new Connection Hose 19, hold the Inner Housing 25 in place and screw in the new Connection Hose 19 all the way. Fit the hose Hose Clamp 24 on the other side of the Connection Hose 19. Position the screw head so that you can tighten the Hose Clamp 24 effortlessly on the Sanding Head 11 with a screwdriver with a torque of around 17.7 Lbf-in (2 Nm).

Adjusting the Internal/External Airflow

switch position| type of airflow| use
| 1 – External airflow| Ideal for sanding walls at high sanding speeds without vacuum suction.
| 2 – Mixed external and internal airflow| Medium sanding performance with low vacuum suction.
| 3 – Mixed external and internal airflow| Ideal for sanding ceilings at low sanding speeds but with high vacuum suction.

Troubleshooting

dust extraction, if necessary.
The joint compound material and/or substrates are hard.| Reduce the suction power or switch to external dust extraction, if necessary.
Reduce the speed.
The removal rate of the material being sanded is too high.| The drywall sander’s speed is too high.| Reduce the speed.
The suction effect on the drywall sander is too strong.| Reduce the suction effect or switch to external dust extraction.
The joint compound material has a high proportion of compound or is very soft.| Switch on the external dust extraction, set the suction power thumbwheel to setting 6 and, in extreme cases, reduce the speed.
The grit of the abrasive is too coarse.| Use a sanding sheet with a finer grit.
The surface quality is not optimal.| The grit of the abrasive is too coarse.| Use a sanding sheet with a finer grit.
The drying times for the joint compound material have not been observed.| Refer to the technical information sheets and manufacturer’s recom- mendations.
The suction effect is too strong.| Reduce the suction power.
The joint compound material has a high proportion of filler or is very soft.| Use a sanding sheet with a finer grit.
The drywall sander’s head scratches the drywall while operating (scoring).| Position the power tool before switch- ing it on.
Work on the surface and always work with the removable brush segment.
There are sanding marks on the surface.| The hard sanding pad has been posi- tioned at an angle on the surface.| Use a soft sanding pad with an interme- diate pad.
In the case of very soft joint compound material, the sanding pad is too hard or the grit of the abrasive is too coarse.| Use a soft sanding pad with an interme- diate pad.
Choose a finer abrasive grit.
Problem| Cause| Corrective Action
---|---|---
The suction effect is insufficient.| The suction power on the dust extrac- tor is too low.| Increase the suction power on the dust extractor.
The drywall sander’s speed is too high.| Reduce the speed.
The internal dust extraction on the drywall sander is too low.| Reduce the suction power or switch to external dust extraction.
The joint compound material has a high proportion of compound or is very soft.| Switch on the external dust extraction, set the suction power thumbwheel to setting 6 and, in extreme cases, reduce the speed.
The main filter on the dust extractor is blocked/jammed.| Clean the filter element regularly: Option 1: Set the suction power regu- lation to the maximum suction power. Seal the nozzle, extraction hose or in- take port on the dust extractor with the palm of your hand for 10 seconds until the automatic cleaning starts. Option 2: Clean the filter element me- chanically (extraction). Option 3: Check the filter element for damage and blockages. Insert a new filter element regularly.
A fleece dust bag is being used.| Use a waste disposal dust bag.
The extraction hose is blocked or twisted.| Remove the blockage or untwist the hose.
The dust extractor’s dust container is full.| Empty the dust extractor’s dust container.

Maintenance

Warning To avoid accidents always disconnect the tool from the power supply before cleaning or performing any maintenance.

Service

Warning NO USER SERVICEABLE PARTS INSIDE. Preventive maintenance performed by unauthorized per sonnel may result in misplacing of internal wires and components which could cause serious hazard.

Warning All tool service, including the replacement of the power cord, must be performed by a Bosch Factory Service or Authorized Bosch Service Station. This will ensure that the safety of the power tool is maintained.

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

Warning 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 and 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.

Extension Cords

Warning If an extension cord is necessary, a cord with adequate size conductors that is capable of carrying the current necessary for your tool must be used. This will prevent excessive voltage drop, loss of power or overheating. Grounded tools must use

Recommended Sizes of Extension Cords 120 Volt Alternating Current Tools

Tool’s Ampere Rating| Cord Length in Feet| Cord Length in Meters
---|---|---
25| 50| 100| 150| 15| 30| 60| 120
Cord Size in A.W.G.| Wire Sizes in mm 2
3-6| 18| 16| 16| 14| 0.75| .75| 1.5| 2.5
6-8| 18| 16| 14| 12| 0.75| 1.0| 2.5| 4.0
8-10| 18| 16| 14| 12| 0.75| 1.0| 2.5| 4.0
10-12| 16| 16| 14| 12| 1.0| 2.5| 4.0| —
12-16| 14| 12| —| —| —| —| —| —

Accessories and Attachments

Warning 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

•    Microfilter dust canister•    Sanding disc•    5 mm Pad Wrench•    VAC024 Vacuum hose adaptor•    GTR801 backing pad soft + intermediate pad•    GTR024 extension pole| •    Additional types of sanding discs•    Vacuum hoses• GTR802 backing pad medium•    GTR800 intermediate pad

References

• Bosch Power Tools | Boschtools

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