BOSCH PEX 400 AE Expert Random Orbit Sander Instruction Manual

: June 3, 2024
: Bosch

BOSCH PEX 400 AE Expert Random Orbit Sander

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Safety instructions

General Power Tool Safety Warnings

WARNING – 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.
Keep all safety instructions and information 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 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 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

Always charge the batteries only in chargers recommended by the manufacturer.
Chargers designed for a specific type of battery may pose a fire hazard when used together with other battery types.
Use only the batteries provided for this purpose in the power tools. Using other
batteries may cause injuries and pose a fire hazard.
When not in use, keep batteries away from paper clips, coins, nails, screws or other small metal objects that could bridge the contacts.
Short circuits between battery contacts can cause burns or fires.
Fluid may escape if batteries are used inappropriately. Avoid all contact with this fluid. In the event of accidental skin contact, rinse the affected area thoroughly. If the fluid enters your eyes, seek immediate medical assistance. Escaping battery fluid can cause skin irritation or burns.
Do not use damaged or modified batteries. Damaged or modified batteries may behave unpredictably and lead to fire, explosion or risk of injury.
Do not expose the battery pack to fire or excessive temperatures. Fire or temperatures above 130 °C can cause an explosion.
Follow all instructions on charging and never charge the battery or the cordless tool outside the temperature range indicated in the operating instructions. Incorrect charging or charging outside the permitted temperature range may destroy the battery and increase the risk of fire.

Service

Have your power tool serviced by a qualified technician using only original replacement parts. This will ensure that the safety of the power tool is maintained.
Never service damaged batteries. Any servicing of batteries should only be carried out by the manufacturer or authorized customer service points.

Safety Warnings for Sander

Only use the power tool for dry sanding. Water entering a power tool will increase the risk of electric shock.
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.
Warning: Danger of fire! Avoid overheating the work-piece 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.
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.
Always wait until the power tool has come to a complete stop before placing it down.
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 au-thorised 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.

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 sanding of wood, plastic, metal, filler and varnished surfaces.
Power tools with electronic control are also suitable for polishing.

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

Orbital stroke rate preselection thumbwheel
On/off switch
Complete dust box (Microfilter system)
Sanding pad
Auxiliary handle (insulated gripping surface)
Handle (insulated gripping surface)
Sanding sheet A)
Alignment aid for sanding sheet A)
Screws for sanding pad
Sanding pad holder
Extraction outlet
Filter element (Microfilter system)
Extraction hose
Wing nut
Screw for auxiliary handle

Accessories shown or described are not included with the product as standard. You can find the complete selection of accessories in our accessories range.

Technical Data

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The specifications apply to a rated voltage [U] of 230 V. These specifications may vary at different voltages and in country-specific mod-els.

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 83 dB(A); sound power level 94 dB(A). Uncertainty K = 3 dB.

Wear hearing protection!
Vibration total values ah (triax vector sum) and uncertainty K determined according to EN 62841-2-4: ah = 8.0 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 standardized measuring procedure and may be used to com-pare 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 ap-plication tools 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 application tools, 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.

Choosing the Sanding Sheet

Select a sanding sheet with a grit suitable for how much material you want to remove. Bosch sanding sheets are suitable for paint, wood and metal. BOSCH-
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Changing the sanding sheet (see figures A–B)
To remove the sanding sheet (7), lift it from the side and pull it from the sanding pad (4).
Remove dirt and dust from the sanding pad (4), e.g. with a paintbrush, before attaching a new sanding sheet.
The surface of the sanding pad (4) is fitted with a hook-and-loop fastening, allowing sanding sheets with a hook-and-loop backing to be secured quickly and easily.
Press the sanding sheet (7) firmly onto the underside of the sanding pad (4).
To ensure optimum dust extraction, make sure that the punched holes in the sanding sheet (7) are aligned with the drilled holes in the sanding pad (4).
You can use the alignment aid (8) to precisely align the sanding sheet (7) on the sanding pad (4). Place the sanding sheet onto the alignment aid with the hook-and-loop fastening facing upwards. Press the cams of the alignment aid into the two holes in the sanding pad and unroll the sanding sheet from the alignment aid. Firmly press the sanding sheet into place.

Selecting a Sanding Pad
The power tool can be fitted with sanding pads of various harnesses, depending on the application:

Medium sanding pad (black): Suitable for all sanding work, universal application.
Soft sanding pad (grey, accessory): Suitable for intermediate and fine sanding even on curved surfaces.

Changing the Sanding Pad (see figures C–D)
Note: Replace damaged sanding pads (4) immediately.
Remove the sanding sheet or polishing tool. Unscrew the four screws completely (9) and remove the sanding pad (4).
Clean the top of the new sanding pad (4). Lubricate the outer ring (shaded in grey in the figure) with a thin layer of synthetic grease.
Attach the new sanding pad (4) and retighten the four screws.
Note: Damaged sanding pads must only be replaced by an after-sales service centre authorized to work with Bosch power tools.

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 E–H)
Place the dust box (3) onto the extraction outlet (11) until it clicks into place.
You can easily check the filling level of the dust box (3) through the transparent container.
To empty the dust box (3), rotate and pull it downwards. Before opening the dust box (3), knock the dust box against a firm surface as shown in the figure to loosen the dust from the filter element.
Holding the dust box (3) firmly, flap 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: In order to ensure optimum dust extraction, empty the dust box (3) in good time and clean the filter element (12) regularly.
When working on vertical surfaces, hold the power tool with the dust box (3) facing downwards. BOSCH-PEX-400-AE-Expert-Random-Orbit-
Sander-05

External dust extraction (see figure I)
Fit a dust extraction hose (13) onto the extraction outlet (11).
Connect the dust extraction hose (13) 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.
When working on vertical surfaces, hold the power tool with the dust extraction hose facing downwards. BOSCH-PEX-400-AE-Expert-Random-Orbit-
Sander-06

Auxiliary Handle (see figure J)
The auxiliary handle (5) enables comfortable handling and optimum power distribution, with a high sanding removal rate in particular.

You can remove the auxiliary handle in order to sand close to edges. Unscrew and remove the wing nut (14) and pull the screw (15) out of the housing. Then pull the auxiliary handle (5) off towards you.
To reinstall the auxiliary handle (5), push it onto the housing from the front such that the ridges on the auxiliary handle engage in the recesses on the housing. Firmly fix the auxili-ary handle in place using the screw (15) and the wing nut (14).

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/Off

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

To switch on the power tool, slide the on/off switch (2) for-ward so that “1” appears on the switch.
To switch off the power tool, slide the on/off switch (2) backward so that “0” appears on the switch.

Preselecting the orbital stroke rate
You can even preselect the orbital stroke rate during operation using the necessary orbital stroke rate preselection thumbwheel (1).

1–2 Low orbital stroke rate
3–4 Medium orbital stroke rate
5–6 High orbital stroke rate

The required orbital stroke rate is dependent on the material and the work conditions and can be determined using prac-tical tests.
After working at a low orbital stoke rate for an extended period, you should operate the power tool at the maximum orbital stroke rate for approximately three minutes without load to cool it down.

Working Advice

Pull the plug out of the socket before carrying out any work on the power tool.
Always wait until the power tool has come to a complete stop before placing it down.
This power tool is not suitable for bench-mounted use. It must not be clamped into a vice or fastened to a work-bench, for example.

Sanding Surfaces
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 orbital stroke rate level and the contact pressure.
Only immaculate sanding sheets achieve good sanding per-formance and make the power tool last longer.
Be sure to apply consistent contact pressure in order to in-crease 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.
Use only original Bosch-sanding accessories.

Rough Sanding
Attach a coarse grit sanding sheet.
Apply only light pressure to the power tool so that it runs at a higher orbital stroke rate and a higher material removal rate is achieved.

Fine Sanding
Attach a fine grit sanding sheet.
You can reduce the sanding plate orbital stroke rate by lightly varying the contact pressure or changing the orbital stroke rate level; the random orbit motion will be retained. Move the power tool with moderate pressure flat on the workpiece in a circular motion or alternately along and across it. Do not tilt the power tool in order to avoid sanding through the workpiece, e.g. veneers.
Switch the power tool off after completing operation.

Polishing
For polishing weathered lacquers and redressing scratches (e.g. acrylic glass), the power tool can be fitted with an ap-propriate polishing tool, e.g. lambs wool bonnet, polishing felt or polishing sponge (accessory).
Select a low orbital stroke rate (level 1–2) when polishing in order to avoid heating up the surface excessively.
Apply the polish to an area slightly smaller than the area which you intend to polish. Using the appropriate polishing tool, work in the polish with either linear or circular move-ments and with moderate pressure.
Do not allow the polish to dry out on the surface; this may damage the surface. Do not expose the surface which you in-tend to polish to direct sunlight.
Clean the polishing tool regularly to ensure good polishing results. Wash the polishing tools with mild detergent and warm water; do not use thinning agents.

Application Table
The figures in the table below are recommended values. The best method for determining the best combination while sanding or polishing is practical experimentation.

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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 authorized to repair Bosch power tools.

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 accessor-ies.
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

Ireland
Origo Ltd.
Unit 23 Magna Drive
Magna Business Park
City West
Dublin 24
Tel. Service: (01) 4666700
Fax: (01) 4666888

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: (01300) 307044
Fax: (01300) 307045
Inside New Zealand:
Phone: (0800) 543353
Fax: (0800) 428570
Outside AU and NZ:
Phone: +61 3 95415555
www.bosch-pt.com.au
www.bosch-pt.co.nz

Republic of South Africa
Customer service
Hotline: (011) 6519600

Gauteng – BSC Service Centre
35 Roper Street, New Centre
Johannesburg
Tel.: (011) 4939375
Fax: (011) 4930126
E-Mail: bsctools@icon.co.za

KZN – BSC Service Centre
Unit E, Almar Centre
143 Crompton Street
Pinetown
Tel.: (031) 7012120
Fax: (031) 7012446
E-Mail: bsc.dur@za.bosch.com

Western Cape – BSC Service Centre
Democracy Way, Prosperity Park
Milnerton
Tel.: (021) 5512577
Fax: (021) 5513223
E-Mail: bsc@zsd.co.za

Bosch Headquarters
Midrand, Gauteng
Tel.: (011) 6519600
Fax: (011) 6519880
E-Mail: rbsa-hq.pts@za.bosch.com

Disposal
The power tool, accessories and packaging should be re-cycled in an environmentally friendly manner.
Do not dispose of power tools along with household waste.

Only for EU countries:
According to the European Directive 2012/19/EU on Waste Electrical and Electronic Equipment and its implementation into national law, power tools that are no longer usable must be collected separately and disposed of in an environment-ally friendly manner.