Generisch Carbon Brushes for Bosch POF 500 EA Router - Instruction Manual

1. Product Overview

These Generisch carbon brushes are designed as high-quality replacement parts for various Bosch POF 500 EA router models. They are engineered for maximum performance, offering extra durability, minimal sparking, and reduced wear for long-lasting operation. These motor carbons provide a reliable alternative to original parts, ensuring your power tools operate efficiently.

Image 1.1: A pair of Generisch carbon brushes, featuring their rectangular carbon blocks, flexible wire leads, and brass spade terminals, ready for installation.

2. Package Contents

Each package contains the following items:

• 2 x Carbon Brushes (1 pair)

3. Compatibility

These carbon brushes are compatible with the following Bosch router models and replace part number 2 604 320 912:

• Bosch POF 500 EA 0 603 261 703
• Bosch POF 500 EA 0 603 261 732
• Bosch POF 500 EA 0 603 261 737
• Bosch POF 500 EA 0 603 261 742
• Bosch POF 500 EA 0 603 261 748
• Bosch POF 500 EA 0 603 261 750

Replaces original item number: 2 604 320 912

4. Specifications

5. Installation Instructions

Replacing carbon brushes is a common maintenance task for power tools. Always prioritize safety and consult your tool's original manual for specific disassembly instructions if available. If you are unsure, seek professional assistance.

1. Safety First: Disconnect the power tool from the main power supply before beginning any maintenance or installation.
2. Locate Brush Holders: Identify the carbon brush access points on your Bosch POF 500 EA router. These are typically small caps or covers on the motor housing.
3. Remove Old Brushes: Carefully unscrew or unclip the brush holder caps. Gently pull out the old carbon brushes. Note their orientation for correct installation of the new brushes.
4. Inspect Commutator: While the brushes are out, inspect the commutator (the copper segments on the motor's armature). It should be clean and smooth. If it's excessively grooved or dirty, professional servicing may be required.
5. Install New Brushes: Insert the new Generisch carbon brushes into the brush holders, ensuring they are oriented correctly. The wire lead and terminal should connect properly. The automatic shut-off feature means the brush will stop contact when worn down, protecting the motor.
6. Secure Brush Holders: Replace and secure the brush holder caps. Ensure they are tightened sufficiently but do not overtighten.
7. Test Operation: Reconnect the power tool to the power supply. Run the tool briefly at a low speed to allow the new brushes to seat properly. Initial sparking is normal and should reduce quickly.

6. Maintenance

To ensure optimal performance and longevity of your carbon brushes and power tool:

• Regular Inspection: Periodically check the carbon brushes for wear. Replace them when they are significantly worn down, typically when they are about one-third of their original length.
• Cleanliness: Keep the motor's ventilation slots clear of dust and debris to prevent overheating, which can accelerate brush wear.
• Proper Usage: Avoid continuously overloading the tool, as this can cause excessive heat and sparking, leading to premature brush wear.

7. Troubleshooting

If your power tool experiences issues after carbon brush replacement, consider the following:

• Tool Not Starting: Ensure the brushes are correctly seated and making proper contact. Check all electrical connections.
• Excessive Sparking: While some initial sparking is normal, persistent heavy sparking may indicate improperly seated brushes, a dirty or damaged commutator, or incorrect brush type. Re-check installation or consult a professional.
• Reduced Power/Intermittent Operation: This could be due to worn brushes (if not new), poor contact, or other internal motor issues.

8. Warranty and Support

For specific warranty information regarding these Generisch carbon brushes, please refer to the purchase documentation or contact the seller directly. If you have further questions or require assistance, the seller is available to provide support and advice.