Ozito bsr-800 User manual

Motor: 800W
Input: 230-240V ~ 50Hz
No load speed: 260/min
Belt Size: 457 x 76mm (18" x 3")
Weight: 3.1kgs
SPECIFICATIONS - MODEL NO. BSR-800
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1. Rear soft grip handle
2. On/Off switch
3. Adjustable front handle
4. Lock on switch
5. Belt tracking knob
6. Dust bag
7. Front roller
8. Belt tension release lever
9. Rear roller
10. Rear guide strip
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6
2
3
5
7
8
9
10
KNOW YOUR PRODUCT

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TABLE OF CONTENTS
SPECIFICATIONS………………………………………….
INTRODUCTION…………………………………………..
ELECRICAL SAFETY……………………………………….
GENERAL POWER TOOL SAFETY WARNINGS………..
BELT SANDER SAFETY WARNINGS……………………
PREPARATION & SETUP…………………………………..
OPERATION…………………………………………………
MAINTENANCE……………………………………………
SPARE PARTS………………………………………………
DESCRIPTION OF SYMBOLS…………………………….
CONTENTS…………………………………………………
WARRANTY…………………………………………………
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INTRODUCTION
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Congratulations on purchasing an Ozito Belt Sander.
We aim to provide quality tools at an affordable price.
We hope you will enjoy using this tool for many years.
Your Belt Sander BSR-800 has been designed for
sanding timber and is intended for DIY use only.
WARNING! When using mains-powered equipment, basic safety
precautions, including the following, should always be followed to
reduce risk of fire, electric shock, personal injury and material damage.
Read and understand the manual prior to operating this tool.
Save these instructions and other documents supplied with this tool for future reference.
The electric motor has been designed for 230V and 240V only. Always check that
the power supply corresponds to the voltage on the rating plate.
Note: The supply of 230V and 240V on Ozito tools are interchangeable for
Australia and New Zealand.
This tool is double insulated in accordance with AS/NZS60745-1;
therefore no earth wire is required.
If the supply cord is damaged, it must be replaced by a qualified electrician or a
power tool repairer in order to avoid a hazard.
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.
Note: Double insulation does not take the place of normal safety precautions when
operating this tool. The insulation system is for added protection against injury
resulting from a possible electrical insulation failure within the tool.
Using an Extension Lead
Always use an approved extension lead suitable for the power input of this tool.
Before use, inspect the extension lead for signs of damage, wear and ageing.
Replace the extension lead if damaged or defective. When using an extension lead
on a reel, always unwind the lead completely. Use of an extension lead not suitable
for the power input of the tool or which is damaged or defective may result in a
risk of fire and electric shock.
ELECTRICAL SAFETY
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GENERAL POWER TOOL SAFETY WARNINGS
Warning! Read all safety warnings and all instructions. Failure to follow the
warnings and instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
The term "power tool" in all of the warnings refers to your mains-operated
(corded) power tool or battery-operated (cordless) power tool.
1) Work area safety
a) Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b) 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.
c) Keep children and bystanders away while operating a power tool. Distractions
can cause you to lose control.
2) Electrical safety
a) 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.
b) 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.
c) Do not expose power tools to rain or wet conditions. Water entering a power
tool will increase the risk of electric shock.
d) 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.
e) 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.
f) 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.
3) Personal safety
a) 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.
b) 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.
c) 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 energising power tools
that have the switch on invites accidents.
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d) 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.
e) Do not overreach. Keep proper footing and balance at all times. This
enables better control of the power tool in unexpected situations.
f) Dress properly. Do not wear loose clothing or jewellery. Keep your hair,
clothing and gloves away from moving parts. Loose clothes, jewellery or
long hair can be caught in moving parts.
g) If devices are provided for the connection of dust extraction and collection
facilities, ensure these are connected and properly used. Use of these
devices can reduce dust-related hazards.
4) Power tool use and care
a) 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.
b) 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.
c) Disconnect the plug from the power source and/or the battery pack 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.
d) 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.
e) Maintain power tools. Check for misalignment or binding of moving parts,
breakage of parts and any other condition that may affect the power tools
operation. If damaged, have the power tool repaired before use. Many
accidents are caused by poorly maintained power tools.
f) Keep cutting tools sharp and clean. Properly maintained cutting tools with
sharp cutting edges are less likely to bind and are easier to control.
g) 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.
5) Service
a) Have your power tool serviced by a qualified repair person using only
identical replacement parts. This will ensure that the safety of the power tool
is maintained.
b) If the supply cord is damaged, it must be replaced by the manufacturer, its
service agent or similarly qualified persons in order to avoid a hazard.
GENERAL POWER TOOL SAFETY WARNINGS
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BELT SANDER SAFETY WARNINGS
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Hold power tool by insulated gripping surfaces, because the belt may contact its
own cord. Cutting a "live" wire may make exposed metal parts of the power tool
"live" and could give the operator an electric shock.
This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, unless
they have been given supervision or instruction concerning use of the appliance by a
person responsible for their safety.
Recommendations for the use of a residual current device with a rated residual
current of 30mA or less.
It is recommended that the extension lead is a maximum of 25m in length. Do Not
use multiple extension leads.
Unplug the sander before changing accessories. Accidental start-ups may occur if
the sander is plugged in while changing an accessory.
Disposing of dust. Be extremely careful of dust disposal, materials in fine particle form
may be explosive. Do not throw sanding dust on an open fire. Spontaneous
combustion, may in time, result from a mixture of oil or water with dust particles.
Always wear eye protection and a dust mask for dusty applications and when
sanding overhead. Sanding particles can be absorbed by your eyes and inhaled easily
and may cause health complications.
Use special precautions when sanding chemically pressure treated timber, paint
that may be lead based, or any other materials that may contain carcinogens. A
suitable breathing respirator and protective clothing must be worn by all persons
entering the work area. Work area should be sealed with plastic sheeting and persons
not protected should be kept out until work area is thoroughly cleaned.
Do not ‘wet sand’ with this sander. Liquids entering the motor housing are an
electrical shock hazard.
Keep fingers and clothing away from the belt. They could get cut or wedged
between the pulley, belt and motor housing.
Properly adjust tracking of belt to avoid it overhanging the housing.
A running belt overhanging its housing can cause severe lacerations.
Keep the cord to the side away from pulleys. The cord can be dragged into the
belt housing and become entangled with the pulleys.
WARNING! Some dust created by power sanding, sawing, grinding, drilling and
other construction activities contain chemicals known to cause cancer, birth
defects or other reproductive harm. Some examples of these chemicals are:
• Lead from lead-based paints
• Crystalline silica from bricks and cement and other masonry products
• Arsenic and chromium from chemically treated timber
Your risk from these exposures varies, depending on how often you do this type of
work. To reduce your exposure to these chemicals: work in a well ventilated area and
work with approved safety equipment, such as dust masks that are specially designed
to filter out microscopic particles.
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PREPARATION & SETUP
WARNING! Failure to unplug your belt sander could result in accidental
starting causing possible serious injury.
Attaching the Dust Bag to the Belt Sander
Attach the dust bag (6) to the belt sander by sliding the
plastic dust bag adaptor over the dust ejection port on
the left hand side of the belt sander beside the rear soft
grip handle (1) (Fig. 1).
To Adjust the Front Handle
The adjustable front handle (3) can be repositioned to
maximise your comfort whilst sanding.
1. Pull out the lever to disengage the front handle (3)
(Fig. 2).
2. Adjust the front handle to one of the three available positions.
3. Push the lever back into place to secure the
adjustable front handle (3) (Fig. 3).
Belt Selection
Selecting the correct belt for the job is an important step in achieving optimum
results. For initial smoothing of rough timber, use course or very course grit and
sand with the grain. On very uneven surfaces or hardwood , sand across the grain.
Be careful to avoid gouging. Next, switch to a medium grit belt and sand with the
grain. This will provide a relatively level and smooth finish. Insert a fine belt for final
finishing. Always sand with the grain to remove scratches left by coarser belts.
Keep the sander moving in long, light strokes during finishing operations. As a final
touch, experienced sanders will often insert a “used” fine belt to provide a smooth
surface before filling, sealing, brushing or spraying.
Note: It is recommended to test on a sample piece of timber prior to using on
your workpiece.
Fig. 2
Fig. 3
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Fig. 1

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PREPARATION & SETUP (cont.)
Removing Sanding Belts
1. Place the belt sander on its left side on a flat surface.
2. Pull out the belt tension release lever (9). Push it
towards the front of the sander until it locks into place.
The front roller retracts, releasing tension on the belt
(Fig. 4).
3. With the belt sander still on its left side, gently slide
the belt off the unit (Fig. 5). Use two hands easing both
sides simultaneously.
Installing Sanding Belts
When installing a belt, ensure you have the correct size for
your belt sander, and correct grit for your workpiece. Belts
have arrows marked on them to assist in fitting them to the
belt sander in the correct direction. Belts are also marked
with a grit rating (Fig. 6).
1. Place the belt sander on its left side on a flat surface.
2. With the belt tension release lever (8) locked, gently
place the belt over the front and rear rollers. The arrows
on the belt are to be aligned with the arrow marked on
the belt sander (Fig. 7).
CAUTION: The arrows on the belt must be aligned with the markings on the belt
sander. Incorrect fitment could cause the belt to break. Belts are not covered by
the warranty.
3. Once the belt is in place, return the belt tension release lever (8) to its
original position.
Fig. 4
Fig. 5
Fig. 6
Fig. 7

PREPARATION & SETUP (cont.)
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Tracking Adjustment
CAUTION: Ensure body parts, cords, workpieces and any loose items are clear of
the sanding belt before performing the tracking adjustment operation.
It is necessary to ensure the belt is tracking correctly, in
a straight line, to avoid the belt 'tracking off' the belt
sander's rollers.
1. Turn the sander upside down and hold it firmly with
one hand. Press the on/off switch (2) to start the
sander and observe the tracking of the sanding belt.
2. If the belt tracks outward, turn the belt tracking
knob (5) clockwise. If the belt tracks inward turn the
belt tracking knob (5) counter clockwise. (Fig. 8)
3. Adjust the belt until its outer edge is even with the
outer edge of the front and rear rollers. (Fig. 8)
Make sure the belt does not rub against the rear guide strip (10). Once the belt
stabilizes you can begin operation.
Note: Always check your belt after it has been in use as it may require
further adjustment.
Sanding Tips
Never force the sander. The weight of the sander supplies adequate pressure,
allowing the sandpaper to do the work. Applying additional pressure will slow the
motor, rapidly wear the sandpaper, and greatly reduce the sander speed. This will
slow the removal rate and produce an inferior quality surface.
Be sure to check your workpiece often. The sander is capable of removing material
rapidly, especially with coarse paper.
Do not sand on one spot for too long. The sander's rapid action may remove too
much material, creating an uneven surface.
Fig. 8
Rear Guide
Strip (10)

PREPARATION & SETUP (cont.)
Precautions to Take When Sanding Paint
CAUTION: A dust mask should be worn at all times.
Your belt sander will also help remove old paint, varnish or lacquer. However, if the
coating consists of several layers, remove as much as possible with a paint remover.
This will assist in removing the paint faster and not clogging up your belts and belt
sander. Use a hand scraper to remove the residue left by the paint removing solvent
and allow the surface to dry completely before sanding.
CAUTION: Follow all safety instructions provided by the manufacturer of the
paint remover.
Environmental Safety
• Paint should be removed in a manner which minimises the amount of dust generated.
• Areas where paint removal is occurring should be sealed with plastic sheeting.
• Sanding should be done in a manner which reduces the tracking of paint dust
outside the work area.
Cleaning and Disposal
•All surfaces of the work area should be vacuumed and thoroughly cleaned daily
for the duration of the sanding project. Vacuum filter bags should be
changed frequently.
•Plastic drop sheets should be gathered up and disposed of along with any dust
chips or other debris. They should be placed in sealed refuse receptacles and
disposed of through regular garbage pick-up.
• During clean-up, children and pregnant women should be kept away from the
immediate work area.
• All toys, washable furniture and utensils used by children should be washed
thoroughly before use.
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On/Off Switch
WARNING! Prior to connecting the tool to the power supply, ensure the
switch is not locked on. Always squeeze and release the on/off switch (2)
before connecting it to the power supply, this will ensure the lock on
switch (4) is not engaged.
1. To turn the tool on, depress the on/off switch (2)
(Fig. 9).
2. To turn the tool off release the on/off switch (2)
(Fig. 9).
Switch Lock On Button
The belt sander has been designed with a lock on switch (4) to reduce user fatigue
during longer periods of use.
1. To turn the sander on, depress the on/off switch (2), then depress the lock on
switch (4). Release the on/off switch (2) first, then release the lock on switch (4).
2. To unlock the switch and turn off the sander, simply depress and release the
on/off switch (2) (Fig. 9).
Note: It is recommended to disengage the lock on switch (4) prior to unplugging
the tool from the mains power. This will ensure the lock on switch (4) is not
engaged for the next use, avoiding accidental starting of the belt sander.
Timber Sanding
CAUTION: Prior to running the sander ensure you have a firm grip on the
rear handle and that the sanding belt is not in contact with the workpiece.
Apply firm even pressure when sanding. Excessive pressure can damage the
work piece and sander or cause the belt to "track off ".
1. Firmly grasp the sander in front of you and away from your body.
2. To commence sanding gently place the rear heel of
the belt sander (Fig. 10) on your workpiece. Ensure
that the sanding belt is not in contact with your
workpiece prior to starting the sander.
3. To start the sander depress the on/off switch (2).
Note: Refer to the procedure outlined above for
correct operation of the on/off switch (2) and lock on
switch (4).
4. Let the motor build up to maximum speed. Gradually lower it onto the
workpiece with a slight forward movement. This helps to prevent gouging.
5. The correct technique is a back and forth motion, with most of the sanding
done on the backwards, pulling movement. Don't apply a lot of pressure on
the unit. Allow the sander to do the work.
6. Upon completion of the sanding operation, remove the sander from the
workpiece. Turn off the sander by depressing and then releasing the on/off
switch (2).
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OPERATION
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Fig. 9
Fig. 10
Rear Heel

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MAINTENANCE
• Regularly empty the dust bag.
• Keep the ventilation slots of the sander clean at all times. If possible prevent
foreign matter from entering the vents.
• After each use, blow air through the sander housing to ensure it is free from all
dust particles that may build up.
CAUTION: Excessive build-up of dust particles may cause the sander to
overheat and fail.
•If the enclosure of the sander requires cleaning, use a soft, moist cloth only. Do
not use solvents.
CAUTION: Never immerse any part of the sander in liquid.
Carbon brushes will wear out after many uses, causing the sander to spark and/or
stop. The brushes are a wearing component of the sander and should be replaced
prior to the carbon wearing out completely. Take the sander to a suitably qualified
electrician or power tool repairer for replacement. Always replace both brushes at the
same time.
Note: Ozito Industries will not be responsible for any damage or injuries caused by
the repair of the tool by an unauthorised person or by mishandling of the tool.
IMPORTANT:
If the motor on your belt sander operates but the belt does not rotate, follow these
instructions. In most cases, it isn't necessary to return the product back to the store.
Check that the drive belt has not been damaged. If it is damaged or broken, replace
with the spare belt provided.
1. To remove and check the drive belt, remove the two
screws from the belt cover. (Fig. 11) If the belt is
damaged, worn or broken, replace with a new drive belt.
2. To remove drive belt, simply use a pair of scissors to cut
the drive belt.
Note: DO NOT pry the belt off the pulley as this may
damage the housing.
3. To fit the new drive belt, place it around the large belt
wheel. Align the ridges on the belt with the teeth on the
small gear wheel. Rotate the large belt wheel and push
the drive belt down onto the small gear wheel as it rotates.
The wheel can be difficult to rotate until the drive belt is
fed onto the small gear wheel. Keep rotating the wheel
and feed the drive belt onto the small gear wheel until it
sits flush with the edge of the wheels (Fig. 12).
4. Refit cover and tighten screws.
screws Fig. 11
Fig. 12

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SPARE PARTS
DESCRIPTION OF SYMBOLS
VVolts Hz Hertz
~Alternating current WWatts
/min Revolutions or
reciprocation per minute
Double insulated Regulator compliance mark
n o No load speed
Warning Read instruction manual
Limited spare parts are available subject to availability. Please contact your local
Bunnings Special Orders Desk to order the required spare parts.
Most common spare parts listed below
Spare Part Part No.
Front Wheel Assembly SPBSR800-16A
Brush Holder Cap (pair) SPBSR800-48A
Carbon Brushes (pair) SPBSR800-49
Drive Belt SPBSR800-56
Dust Bag SPBSR800-69

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AUSTRALIA (Head Office)
1-23 Letcon Drive, Bangholme Victoria, Australia, 3175
Telephone: [phone]
Facsimile: [phone]
Website: www.ozito.com.au
Email: [email protected]
1 x Belt Sander BSR-800
1 x Sanding Belt
1 x Dust Bag
1 x Instruction Manual
CARING FOR THE ENVIRONMENT
Power tools that are no longer usable should not be
disposed of with household waste but in an environmentally
friendly way. Please recycle where facilities exist. Check with
your local council authority for recycling advice.
Recycling packaging reduces the need for landfill and raw
materials. Reuse of recycled material decreases pollution in the
environment. Please recycle packaging where facilities exist.
Check with your local council authority for recycling advice.
CONTENTS
OZITO INDUSTRIES PTY LTD

3 YEAR REPLACEMENT WARRANTY
Your product is guaranteed for a period of 36 months from the original date of purchase
and is intended for DIY (Do It Yourself) use only. If a product is defective it will be replaced in
accordance with the terms of this warranty. Warranty excludes consumable parts, for example:
carbon brushes, dust bags, backing pads and sanding sheets.
WARNING
The following actions will result in the warranty being void.
Professional, Industrial or high frequency use.
If the tool has been operated on a supply voltage other than that specified on the tool.
If the tool shows signs of damage or defects caused by or resulting from abuse, accidents
or alterations.
Failure to perform maintenance as set out within the instruction manual.
If the tool is disassembled or tampered with in any way.
OZITO
Australia/New Zealand (Head Office)
1-23 Letcon Drive, Bangholme, Victoria, Australia 3175
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OW5
WARRANTY
YOUR WARRANTY FORM SHOULD BE RETAINED BY YOU AT ALL TIMES. IN ORDER
TO MAKE A CLAIM UNDER THIS WARRANTY YOU MUST RETURN THE PRODUCT TO
YOUR NEAREST BUNNINGS WAREHOUSE WITH YOUR BUNNINGS REGISTER RECEIPT.
PRIOR TO RETURNING YOUR PRODUCT FOR WARRANTY PLEASE TELEPHONE OUR
CUSTOMER SERVICE HELPLINE:
TO ENSURE A SPEEDY RESPONSE PLEASE HAVE THE MODEL NUMBER AND DATE OF
PURCHASE AVAILABLE. A CUSTOMER SERVICE REPRESENTATIVE WILL TAKE YOUR CALL
AND ANSWER ANY QUESTIONS YOU MAY HAVE RELATING TO THE WARRANTY POLICY
OR PROCEDURE.
The benefits provided under this warranty are in addition to other rights and remedies which
are available to you at law.
Our goods come with guarantees that cannot be excluded at law. You are entitled to a
replacement or refund for a major failure and for compensation for any other reasonably
foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if
the goods fail to be of acceptable quality and the failure does not amount to a major failure.
Generally you will be responsible for all costs associated with a claim under this warranty,
however, where you have suffered any additional direct loss as a result of a defective product
you may be able to claim such expenses by contacting our customer service helpline above.
` Australia 1800 069 486
New Zealand 0508 069 486