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Robert Bosch GmbH 2005 Geschäftsbereich Elektrowerkzeuge Power Tools and their Application Sales Consulting Training PT/SCT 1500 Questions and Answers Postfach 10 0156 D-70745 Leinfelden-Echterdingen English issue · 1stedition www.pt-knowledge.com www.ewbs.de www.bosch-pt.de www.powertool-portal.com n ISBN 3-87125-879-2 o Order-No. 71368 i t 1stedition a c i l p p A r i e h t d n a s l o Power Tool o Training Club T r e w o P 1500 Questions and Answers Power Tools and their Application Chlorine Publisher’s notes Published by © Holger H. Schweizer ROBERT BOSCH GmbH 2005 Power Tool Division Sales Consulting Training EW/SCT P.O.B. 10 01 56 D-70745 Leinfelden-Echterdingen http://www.bosch-pt.de http://www.ewbc.de Editor-in-chief Holger H. Schweizer The contents of this publication have been co-ordinated with in-house technical departments, reflect the latest technical knowledge at the time of printing and refer to general application. Special conditions can apply to special application areas. The handling of the equipment men- tioned in this publication is subject to the applicable rules, operating instructions and safety regulations. No claims for liability can be derived from the contents of this publication. Some text passages contain protected trademarks. They are not specifically highlighted. Reprinting, copying and translation, also of excerpts, require our prior written authorisation and the mentioning of the list of sources. Subject to changes. Your helpful remarks and suggestions are welcome at all times. Copy deadline January 2005 1st edition, January 2005 1 609 901 X007 EW/SCT – TLEX1500-1.0 – 04/05 En All rights reserved © Dr.-Ing. Paul Christiani Technical institute for vocational and advanced professional training GmbH & Co. KG Hermann-Hesse-Weg 2 D-78464 Konstanz www.christiani.de ISBN 3-87125-879-2 Printed by Senner-Druck GmbH & Co. KG, BOSCH-Nr.: 1609901X007 Carl-Benz-Straße 1, D-72622 Nürtingen Printed in Germany. Christiani-Order-No. 71368 Imprimé en Allemagne Preface The anthology “1500 Questions and An- source in the power tool sector, was swers” on the subject of power tools added as a supplement. and their applicationis a compilation of the hitherto published series of brochures More information on power tools and their called “Pocket Encyclopaedia” each con- application is also available on the follow- taining 75 questions and answers on var- ing websites: ious power tool-related topics and the ap- http://www.bosch–pt.de plication of power tools. http://www.powertool-portal.com The first volume of the series of book- http://www.ewbc.de lets “75 Questions and Answers” was http://www.ewbs.de published in 1995. Its purpose was to teach sales specialists of power tools, With the publication of this anthology we and all other interested tradesmen and wish all those who are professionally or DIY hobbyists, the necessary basic privately involved with power tools a lot knowledge on the subject of cordless of success! technology in easily comprehensible form. Encouraged by the success of the Holger H. Schweizer booklet, we continued the series with fur- ther topics. After the series had reached a total number of over 200000 copies published in several languages, we decided to combine the 20 topics which had ap- peared up to now in this anthology as 1500 Questions and Answers on the Subject of Power Tools and their Appli- cation in handy pocket book format. Tar- get groups for this pocket book are trainees and sales specialists in the hard- ware business, but also professional tradesmen and DIY hobbyists interested in increasing their knowledge on the utilisation of power tools and their accessories. More information on power tools, their utilisation and the correct selection of suitable accessories are the key to – better working quality – fast work progress – safe tool operation In addition to the usual questions and answers, this pocket book also contains ref- erence charts and selection diagrams with “logical ways” leading to the right power tool and accessories. For this second edition all subject areas were carefully revised and updated to represent the latest technical develop- ments. Due to the rapid development of the market segment “cordless power tools” the corresponding subject areas were completely redesigned. Information on “lithium-ion-batteries”, the new energy Contents Practical Safety for Power Tools 6 Power Tool Technology 30 Electronic Control of Power Tools 62 Drilling 84 Screwdriving 118 Fastening technology 142 Sanding and grinding 166 Surface Treatment 194 Sawing 208 Battery technology 230 Cordless Power Tools 244 Routing 264 Planing 280 Diamond-tipped application tools 296 Stoneworking 318 Shears and Nibblers 342 Joining and Spray painting 356 Measuring technologies 374 Electronic Control of Power Tools 392 Pneumatic tools 414 Index 438 6 Power Tools and their Application Practical Safety Preface 7 for Power Tools Basic principles 7 Product safety 7 – electrical safety 8 – mechanical safety 9 – safety communication 10 Practical safety 10 – active safety measures 10 – workplace safety 11 – tool-related safety measures 11 – drilling 12 – impact drilling 13 – hammer drilling 13 – chiselling 14 – screwdriving 14 – sawing 15 – routing 16 – electric hand-held planer 18 – sanding, grinding 18 – abrasive cutting 21 – rotary brushing 22 – shearing, nibbling 23 – electronic measuring tools 24 – cordless power tools 24 Passive safety measures 25 7 Practical Safety for Power Tools Preface Basic principles In general, power tools are very safe. 1. What is the definition of safety? However, as is the case with all technical Safety is defined as the protection of the appliances, improper handling can pro- user and other persons against dangers duce risks. Like a motorcar which is very to their health, life and property. safe if it is properly driven. However, if it is used for a purpose for which it was not 2. Who is responsible for safety? intended or driven in a dangerous way, ei- The manufacturer of a technical appliance ther wilfully or carelessly, an automobile has to make sure that the appliance pro- can become a source of danger for one- duced by him conforms to safety require- self or others. ments valid at the time of manufacture. The purpose of this booklet is to dis- The user is responsible for his opera- cuss the topic of safety in relation to tion of the appliance in work areas and hand-held power tools in an easily under- with the working methods recommended standable manner. As you read through by the manufacturer and for his adher- this booklet you will learn that on-the-job ence to valid safety regulations and provi- safety has a lot to do with common sense. sions for the prevention of accidents. This is proven by the fact that the majori- ty of problems are caused by application 3. What is the manufacturer’s errors, and here mainly through careless- contribution to safety? ness. Many regulations and recommen- In addition to fulfilling the prescribed safe- dations form the basis of safety instruc- ty regulations, the manufacturer tries to tions. Many of these are binding achieve the highest possible safety stan- instructions defined as obligatory regula- dardin accordance with the latest techni- tions by governing bodies and authorities. cal know-how. Regional differences often exist, and ma- jor differences can be expected from one 4. What can users contribute to country to another. For this reason we their safety? cannot describe all regulations in detail Users should adhere to the application within the context of this booklet. In the range recommended by the manufactur- interest of your own personal safety we er and to operate the tool in accordance recommend therefore that you obtain the with the supplied operating instructions. relevant information from the regulating The user is also obliged to observe the authorities in charge of your field of acti- manufacturer's safety instructions. In ad- vity. As a matter of principle, the safety dition, he should take passive safety pre- measures and precautions described in cautions appropriate to the intended this booklet do not release the user from working task (e.g. wear safety goggles). his obligation to observe the safety measures recommended in operating and safety instructions and any applicable Product safety legally binding safety regulations. 5. What is the definition of product safety? The term product safety relates to functional safety in a technical sense and means that the product does not endan- ger users, other persons or their property if used as directed. 6. Which government regulations apply to product safety? The government and the employer’s liability insurance associationshave de- 8 Power Tools and their Application termined product safety standardsof a binding nature. The contents of these reg- IP degrees of protection (symbols) ulations are defined in publications of the respective government departments and IP 05 (protection against dust) regulating authorities. IP 06 Electrical safety (dust-proof protection) IP 31 7. What is the definition of (protection against electrical safety? dripping water) Electrical safety is defined as the protec- IP 33 tion of the users of electrical equipment (protection against rain against the hazards of electric shock. water) 8. Which degrees of protectionand IP 54 (protection against earthing contact classes are splashing water) there? Depending on their construction and line- IP 55 up, electric systems and appliances must (protection against be protected by features which prevent water jets) risks arising from the contact with active (live) parts and the ingress of foreign bod- IP 67 ies and water. The resulting degrees of (water-tight) protection are described in DIN 40 050. The additional labelling of appliances in IP 68 earthing contact (protection) classes I, II, (proof against water ...bar and III is implemented in accordance with under pressure) DIN VDE 0720. Required are for EWL-INT003/P – protection classI = protective conductor – protection class II = total insulation 9. What is protective earthing? – protection class III = protective low Protective earthing means that all metal voltage parts which the user can touch are con- nected to the protective conductor (zero conductor, earth connection) of the pow- Earthing contact classes (symbols) er network. In case of damage the current will take the way along the protective conductor, instead of travelling through the protection class I user, and trigger the fuse protection of the (earthing terminal) power line. Precondition (and disadvan- tage) of this type of protection is that the protective conductor is suitably dimen- sioned (sufficient diameter), securely con- protection class II nected and tested as directed. This is es- (total insulation) pecially true for repair work. 10. What is total insulation? p(prorotetecctitoivne clolaws sv oIIlItage NT002/P Tpthoaetra tsbl aionsfsi cua nlsa ataifoepntpy l imainnescauenla sat irotehn,a ,i tni n tahsdueld aeittleieodcn t irntioc- of 50V max.) WL-I side the housing from all other touchable E metal parts. This always includes the drive shaft in power tools. In case there is 9 Practical Safety for Power Tools a defect of the basic safety insulation, the This prevents electricity from reaching the insulation damage will stay limited to in- operator through the handle or other tool ternal electric components and will not parts if the application tool comes into penetrate to the outside. The connection contact with live wires or other conductive of a protective conductor is no longer objects. In this fashion risks through in- needed in this case. advertent contact with conductive parts (i.e. drilling into live wires concealed under plasterwork) are avoided. Total insulation 5 12. What is protective low voltage? 4 Protective low voltages are defined as al- 3 ternating voltages of up to 50 volt and di- rect voltages of up to 120 volt. 2 1 Mechanical safety 13. What is the definition of mechanical safety? Mechanical safety is an essential feature of power tools which are often operated under extreme working conditions. 1 armature (motor) shaft Power tools must remain mechanically 234 ctwooitnmadlm iinnugstsualtaotrion SIH 03/P s1a4f.e eHvoewn uisn dmeer chheaanviyc-adlu stya fsettryain. 5 iron core TLX- Amonrega olitsheedr ?factors, mechanical safety is primarily determined by the following 11. What is full insulation? design features: Full insulation means that all external – housing design parts of the power tool are made of elec- – choice of materials trically insulating materials. – dimensioning – clamping fixtures – safety features Among the various construction features Electric safety of a tool listed above, the mechanical Full insulation safety features are directly visible to the user. All other features serve mainly to en- sure the functional safety of the tool. 15. What is the main precondition of mechanical safety? Safety featureshave to be so designed that they provide maximum protection for the user while not obstructing the job at hand more than is unavoidable, and, if they are adjustable, that the adjustment P SI001/ cinagn a buex icliaarrryi etdo oolsu.t easily and without us- E Tarhee pgrroiptepcintegd a argeaai,n tshte e hxoteursnianlg e alencdt rtihceit ym.otor EWL- 10 Power Tools and their Application Safety communication Practical safety 16. What is the definition of safety 18. What is the definition of practical communication? safety? Safety-relevant information must be com- Practical safety is defined as the obser- municated from the manufacturer to the vance of all safety-relevant factors during user. The classic ways to do this are: the practical handling of power tools. – operating instructions – safety instructions 19. Who is responsible for safety – service instructions during practical power tool – hotline application? – training Responsible for his personal safety during These communication methods do not re- practical power tool applications is only place each-other, they rather complement the user himself. each-other. 20. Which measures form the basis Operating instructions: Operating in- of practical safety? structions are the best-known way to con- The most important safety precautions vey information from the manufacturer to are: the user. The contents of operating instruc- – observation of all government regulations are subject to a standardised structions ture and – if issued by brand name manu- – observation of the operating rules facturers – without mistakes and clearly specified or recommended by the man- formulated in the language of the user. ufacturer – observance of the manufacturer’s safe- Safety instructions:Special safety in- ty instructions structions come with the operating in- – application of common sense structions whenever this is required. They deserve special attention. Active safety measures Service instructions: The purpose of maintenance (tool service) is to maintain the tool properties during the total service 21. What is the definition of active life of the tool. The service instructions in- safety measures? clude recommendations for the intervals Active safety measures are all those ac- between regular maintenance operations tions which the user contributes by ap- such as the replacement of lubricants. propriate handling of application tools, power tools, workpieces and auxiliaries in Hotline:Serious power tool manufactur- order to safely carry out the working task ers offer competent and low-cost cus- at hand. tomer telephone services (“hotlines”) and e-mail links through which the user can 22. Which are the most important receive detailed and individual informa- active safety measures? tion on all questions concerning applica- The most important active safety mea- tion and safety. sures are: – the selection of a suitable application 17. Why is safety communicationso tool important? – the selection of a suitable power tool Since the manufacturer not only relates – machine operation in accordance with technical data and operating instructions the manufacturer’s recommendations to the user through it, but also important and possible statutory requirements information on suitable application tools. – the selection of a suitable working tech- In addition, operating limits and measures nique for the job at hand for the prevention of accidents are also – the creation of a safe working environ- available. ment