Instruction Manual for Generisch Carbon Brush Set KB-117-1120/411

1. Introduction

This instruction manual provides essential information for the proper installation and maintenance of the Generisch Carbon Brush Set, model KB-117-1120/411. These carbon brushes are designed as replacement parts for the Bosch GST 55 P pendulum jigsaw. Adhering to these instructions will help ensure optimal performance and longevity of your power tool.

2. Product Overview and Components

The Generisch Carbon Brush Set consists of two high-quality carbon brushes, engineered for durability and efficient operation. They feature a spring plate design with an automatic stop function, which helps prevent motor damage when the brushes are worn.

Included Components:

• 2 x Carbon Brushes (1 pair)

Figure 2.1: A pair of Generisch carbon brushes, each featuring a carbon block connected to a coiled spring and a metal cap.

3. Compatibility

This carbon brush set is specifically designed for the following Bosch pendulum jigsaw models:

• Bosch GST 55 P (Model numbers: 0 601 579 012, 0 601 579 077, 0 601 579 078)

It replaces original Bosch part numbers: 1 607 014 117, 1 617 014 146, 1 617 014 135.

4. Specifications

Refer to the table below for detailed specifications of the carbon brushes:

Figure 4.1: Dimensional diagram of the carbon brush, indicating a width (B) of 8.0 mm, a height (H) of 5.0 mm, and a length (L) of 15.0 mm.

5. Installation / Setup

Replacing carbon brushes typically involves accessing the motor housing of your power tool. Always ensure the tool is disconnected from the power supply before beginning any maintenance. Consult your Bosch GST 55 P jigsaw's original service manual for specific instructions on accessing and replacing its carbon brushes. The following are general steps:

1. Disconnect Power: Unplug the jigsaw from the electrical outlet to prevent accidental startup.
2. Locate Brush Holders: Identify the carbon brush access points on the motor housing. These are often secured by screws or caps.
3. Remove Old Brushes: Carefully remove the caps or screws and extract the old, worn carbon brushes. Note their orientation.
4. Clean Brush Holders: Use compressed air or a small brush to clean any carbon dust from the brush holders.
5. Insert New Brushes: Insert the new Generisch carbon brushes into the holders, ensuring they are oriented correctly and the springs are properly seated. The automatic stop feature will engage when the brush is sufficiently worn.
6. Secure Brushes: Replace the caps or screws to secure the new brushes in place.
7. Test Tool: Plug the jigsaw back into the power supply and perform a brief test run to ensure proper operation.

If you are unsure about any step, it is recommended to seek assistance from a qualified technician.

6. Operating Considerations

Once new carbon brushes are installed, the tool should operate as expected. During the initial use, a slight increase in sparking may be observed as the new brushes seat themselves against the commutator. This is normal and should subside after a short period of operation. If excessive sparking or unusual noises persist, discontinue use and inspect the installation.

7. Maintenance

Carbon brushes are wear-and-tear components and require periodic inspection and replacement. The automatic stop feature of these brushes is designed to protect the motor by stopping the tool when the brushes are critically worn. However, regular visual inspection is recommended:

• Inspect brushes for wear every 50-100 hours of operation, or if the tool exhibits reduced power or excessive sparking.
• Replace both carbon brushes simultaneously, even if only one appears significantly worn, to ensure balanced motor performance.
• Keep the motor's ventilation slots clear of dust and debris to prevent overheating.

8. Troubleshooting

If your Bosch GST 55 P jigsaw is not functioning correctly after carbon brush replacement, consider the following:

• Tool not starting:
  • Ensure the tool is properly plugged in.
  • Verify the new brushes are correctly seated and making contact with the commutator.
  • Check if the automatic stop feature has engaged prematurely due to incorrect installation or a faulty brush.
• Excessive sparking or unusual noise:
  • Confirm brushes are fully seated and springs are applying even pressure.
  • Inspect the commutator for damage or excessive dirt.
  • Ensure the correct brush size and type have been installed.
• Reduced power:
  • Check for proper brush contact and wear.
  • Ensure no other internal components are damaged.

For issues not resolved by these steps, consult a professional repair service.

9. Warranty and Support

Information regarding specific warranty terms for this Generisch carbon brush set is not provided in the product details. For any support inquiries or further assistance, please refer to the seller or the point of purchase.