Table Of ContentRobert 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
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ISBN 3-87125-879-2
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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 techni-
cal departments, reflect the latest techni-
cal knowledge at the time of printing and
refer to general application. Special con-
ditions 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 lia-
bility can be derived from the contents of
this publication.
Some text passages contain protected
trademarks. They are not specifically
highlighted.
Reprinting, copying and translation, al-
so 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 pub-
lished 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 utili-
sation of power tools and their acces-
sories.
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 an-
swers, 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 ar-
eas 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 mea-
sures 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 func-
tional 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 con-
ductor, 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 regula-
tions are subject to a standardised struc- tions
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
