Bosch GBH 5-40 D Professional Rotary Hammer wirh SDS Max Instruction Manual

GBH 5-40 D Professional
Original instruction

Safety Notes

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 the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.
Work area safety

▶ Keep the work area clean and well-lit. Cluttered or dark areas invite accidents.
▶ Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Power tools create sparks that may ignite dust or fumes.
▶ Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.
Electrical safety
▶ 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 the risk of electric shock.
▶ 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.
▶ Do not expose power tools to rain or wet conditions.
Water entering a power tool will increase the risk of electric shock.

▶ 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, and moving parts. Damaged or entangled cords increase the risk of electric shock.
▶ When operating a power tool outdoors, use an extension cord suitable for outdoor use. The use of a cord suitable for outdoor use reduces the risk of electric shock.
▶ If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. The use of an RCD reduces the risk of electric shock.
Personal safety
▶ 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.
▶ Use personal protective equipment. Always wear eye protection. Protective equipment such as dust masks, non-skid safety shoes, hard hats, or hearing protection used for appropriate conditions will reduce personal injuries.
▶ Prevent unintentional starting. Ensure the switch is in the off-position before connecting to a power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.
▶ 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.
▶ Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
▶ Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts.
▶ If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. The use of dust collection can reduce dust-related hazards. Power tool use and care
▶ 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 at which it was designed.
▶ Do not use the power tool if the switch does not turn on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
▶ 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.
▶ 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.
▶ Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the power tool’s operation. If damaged,  have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
▶ Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
▶  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. Service
▶ 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.
Hammer Safety Warnings
▶ Wear ear protectors. Exposure to noise can cause hearing loss.
▶ Use auxiliary handle(s), if supplied with the tool. Loss of control can cause personal injury.
▶ Hold power tool by insulated gripping surfaces, when performing an operation where the cutting accessory may contact hidden wiring or its own cord. Cutting accessory contacting a “live” wire may make exposed metal parts of the power tool “live” and could give the operator an electric shock.
▶ Use suitable detectors to determine if utility lines are hidden in the work area or call the local utility company for assistance. Contact with electric lines can lead to fire and electric shock. Damaging a gas line can lead to an explosion. Penetrating a water line causes property damage or may cause an electric shock.
▶ When working with the machine, always hold it firmly with both hands and provide a secure stance. The power tool is guided more securely with both hands.
▶  Secure the workpiece. A workpiece clamped with clamping devices or in a vice is held more secure than by hand.
▶ Always wait until the machine has come to a complete stop before placing it down. The tool insert can jam and lead to loss of control over the power tool.
▶ Products sold in GB only: Your product is fitted with a BS 1363/A approved electric plug with an internal fuse (ASTA approved to BS 1362).
If the plug is not suitable for your socket outlets, it should be cut off and an appropriate plug fitted in its place by an authorized customer service agent. The replacement plug should have the same fuse rating as the original plug.
The severed plug must be disposed of to avoid a possible shock hazard and should never be inserted into the main socket elsewhere.
Products sold in AUS and NZ only: Use a residual current device (RCD) with a rated residual current of 30 mA or less.

Symbols

The following symbols can be important for the operation of your power tool. Please memorize the symbols and their meanings. The correct interpretation of the symbols helps you operate the power tool better and more safely.

Product Description and Specifications

Read all safety warnings and all instructions.
Failure to follow the warnings and instructions may result in electric shock, fire, and/or serious injury.
While reading the operating instructions, unfold the graphics page for the machine and leave it open.

Intended Use
The machine is intended for hammer drilling in concrete, brick, and stone as well as for chiseling.
Product Features
The numbering of the product features refers to the illustration of the machine on the graphics page.

1. Dust protection cap
2. Locking sleeve
3. Mode selector switch
4. On/Off switch
5. Handle (insulated gripping surface)
6. Thumbwheel for speed preselection/impact frequency preselection
7. Auxiliary handle (insulated gripping surface)

Accessories shown or described are not part of the standard delivery scope of the product. A complete overview of accessories can be found in our accessories program. 
Noise/Vibration Information
Sound emission values are determined according to EN 60745-2-6.
Typically the A-weighted noise levels of the product are:
Sound pressure level 93 dB(A); sound power level
104 dB(A). Uncertainty K=3 dB.
Wear hearing protection!
Vibration total values ah (triax vector sum) and uncertainty K determined according to EN 60745-2-6:
Hammer drilling into concrete: ah =14 m/s² , K=1.5 m/s²
Chiselling: ah =11.5 m/s² , K=1.5 m/s²
The vibration level given in this information sheet has been measured in accordance with a standardized test given in EN 60745 and may be used to compare one tool with another. It may be used for a preliminary assessment of exposure. The declared vibration emission level represents the main applications of the tool. However, if the tool is used for different applications, with different accessories or insertion tools, or is poorly maintained, the vibration emission may differ. This may significantly increase the exposure level over the total working period.
An estimation of the level of exposure to vibration should also take into account the times when the tool is switched off or when it is running but not actually doing the job. This may significantly reduce the exposure level over the total working period.
Identify additional safety measures to protect the operator from the effects of vibration such as: maintaining the tool and the accessories, keeping the hands warm, and organization of work patterns.

Technical Data

The values given are valid for a nominal voltage [U] of 230 V. For different voltages and models for specific countries, these values can vary.

Assembly

▶ Before any work on the machine itself, pull the mains plug.
Auxiliary Handle
▶ Operate your machine only with the auxiliary handle 7.
The auxiliary handle 7 can be set to any position for a secure and low-fatigue working posture.
– Turn the bottom part of the auxiliary handle 7 in a counterclockwise direction and swivel the auxiliary handle 7 to the desired position. Then retighten the bottom part of the auxiliary handle 7 by turning in a clockwise direction.

Changing the Tool
With the SDS-max tool holder, simpler and easier tool changing is possible without additional aids. The dust protection cap 1 largely prevents the entry of drilling dust into the tool holder during operation. When inserting the tool, take care that the dust protection cap 1 is not damaged.
▶ A damaged dust protection cap should be changed immediately. We recommend having this carried out by an after-sales service.
Inserting (see figure A)
– Clean and lightly grease the shank end of the tool.
– Push back the locking sleeve 2 and insert the tool in a twisting manner into the tool holder.
Release the locking sleeve 2 again in order to lock the tool.
–  Check the latching by pulling the tool.

Removing (see figure B)
– Push back the locking sleeve 2 and remove the tool.
Dust/Chip Extraction
Dust from materials such as lead-containing coatings, some wood types, minerals, and metal can be harmful to one’s health. Touching or breathing in the dust can cause allergic reactions and/or lead to respiratory infections in the user or bystanders. Certain dust, such as oak or beech dust, is considered carcinogenic, especially in connection with wood-treatment additives (chromate, wood preservative). Materials containing asbestos may only be worked by specialists.
– Provide for good ventilation of the working place.
– It is recommended to wear a P2 filter-class respirator.
Observe the relevant regulations in your country for the materials to be worked on.

Operation

Starting Operation
▶ Observe correct mains voltage! The voltage of the power source must agree with the voltage specified on the nameplate of the machine. Power tools marked with 230 V can also be operated with 220 V.
Setting the operating mode
The operating mode of the power tool is selected using the mode selector switch 3.
Note: Change the operating mode only when the machine is switched off! Otherwise, the machine can be damaged.
– Turn the mode selector switch 3 to the desired position.

Position for hammer drilling
When the drilling tool does not immediately rotate upon switching on, allow the machine to run slowly until the drilling tool rotates.Vario-Lock position for adjustment of the chiseling position

Position for chiseling

Switching On and Off
–To start the machine, press the On/Off switch 4 and keep it pressed.
–To switch off the machine, release the On/Off switch 4.
For low temperatures, the power tool reaches the full hammer/impact capacity only after a certain time. To save energy, only switch the power tool on when using it.
Setting the Speed/Impact Rate
The electronic control enables step-less speed and impact preselection in accordance with the material to be worked.
– Select the impact rate with the thumbwheel 6 according to the material.
The data in the following table are recommended values.

Overload Clutch
▶ If the tool insert becomes caught or jammed, the drive to the drill spindle is interrupted. Because of the forces that occur, always hold the power tool firmly with both hands and provide a secure stance.
▶ If the power tool jams, switch the machine off and loosen the tool insert. When switching the machine on with the drilling tool jammed, high reaction torques can occur. 
Changing the Chiselling Position (Vario-Lock)
The chisel can be locked in 12 positions. In this manner, the optimum working position can be set for each application.
– Insert the chisel into the tool holder.
– Turn the mode selector switch 3 to the position “VarioLock” (see “Setting the operating mode”, page 12).
– Turn the tool holder to the desired chiseling position.
– Turn the mode selector switch 3 to the position “Chiselling”. With this, the tool holder is locked.
▶ For chiseling, the mode selector switch 3 must always be set to the position “Chiselling”. 
Working Advice
▶ Before any work on the machine itself, pull the mains plug.

Sharpening Chisels
Good results are only achieved with sharp chisels; therefore, sharpen the chiseling tools in good time. This ensures a long service life of the tools and good working performance.

– Re-sharpening
Sharpen chiseling tools using grinding wheels (e. g. ceramic bonded corundum wheel) with a steady supply of water. Reference values are shown in the figure. Take care that no annealing coloration appears on the cutting edges; this impairs the hardness of the chiseling tools.
–For forging, heat the chisel to between 850 and 1050 °C (bright red to yellow).
–For hardening, heat the chisel to approx. 900 °C and quench in oil. Then anneal in an oven for approx. one hour at 320 °C (annealing color = light blue).

Maintenance and Service

Maintenance and Cleaning
▶ Before any work on the machine itself, pull the mains plug.
▶ For safe and proper working, always keep the machine and ventilation slots clean.
▶ A damaged dust protection cap should be changed immediately. We recommend having this carried out by an after-sales service.

If the replacement of the supply cord is necessary, this has to be done by Bosch or an authorized Bosch service agent in order to avoid a safety hazard.
Lubrication
The power tool is grease-lubricated. Replacement of the lubricating grease is required only during maintenance or repair through an authorized customer services agent for Bosch power tools. Here, it is essential that the specified Bosch lubricating grease is used.

After-sales Service and Application Service
Our after-sales service responds to your questions concerning maintenance and repair of your product as well as spare parts. Exploded views and information on spare parts can also be found under: www.bosch-pt.com Bosch’s application service team will gladly answer questions concerning our products and their accessories.
In all correspondence and spare parts orders, please always include the 10-digit article number given on the nameplate of the product.
Great Britain
Robert Bosch Ltd. (B.S.C.)
P.O. Box 98
Broadwater Park
North Orbital Road
Denham
Uxbridge
UB 9 5HJ

At www.bosch-pt.co.uk you can order spare parts or arrange the collection of a product in need of servicing or repair.
Tel. Service: (0344) 7360109
E-Mail:
Ireland
Origo Ltd.
Unit 23 Magna Drive
Magna Business Park
City West
Dublin 24
Tel. Service: (01) 4666700
Fax: (01) 4666888
Australia, New Zealand, and Pacific Islands
Robert Bosch Australia Pty. Ltd.
Power Tools
Locked Bag 66
Clayton South VIC 3169
Customer Contact Center
Inside Australia:
Phone: (01300) 307044
Fax: (01300) 307045
Inside New Zealand:
Phone: (0800) 543353
Fax: (0800) 428570
Outside AU and NZ:
Phone: +61 3 95415555
www.bosch.com.au
Republic of South Africa
Customer service
Hotline: (011) 6519600
Gauteng – BSC Service Centre
35 Roper Street, New Centre
Johannesburg
Tel.: (011) 4939375
Fax: (011) 4930126
E-Mail:
KZN – BSC Service Centre
Unit E, Almar Centre
143 Crompton Street
Pinetown
Tel.: (031) 7012120
Fax: (031) 7012446
E-Mail:
Western Cape – BSC Service Centre
Democracy Way, Prosperity Park
Milnerton
Tel.: (021) 5512577
Fax: (021) 5513223
E-Mail:
Bosch Headquarters
Midrand, Gauteng
Tel.: (011) 6519600
Fax: (011) 6519880
E-Mail:

Disposal
The machine, accessories, and packaging should be sorted for environmental-friendly recycling.
Do not dispose of power tools into household waste!
Only for EC countries:
According to the European Guideline 2012/19/EU for Waste Electrical and Electronic Equipment and its implementation into national rights, power tools that are no longer usable must be collected separately and disposed of in an environmentally correct manner.
Subject to change without notice.

Robert Bosch Power Tools GmbH
70538 Stuttgart
GERMANY
www.bosch-pt.com
1 609 92A 28B (2016.10) PS / 154