BOSCH GDR 120-LI Cordless Impact Driver Instruction Manual

: June 12, 2024
: Bosch

Table of Contents

BOSCH GDR 120-LI Cordless Impact Driver
Product Information
Product Usage Instructions
Safety Instructions
Product Description and Specifications
Technical data
Assembly
Operation
Maintenance and Service
After-Sales Service and Application Service
Transport
Disposal
EU Declaration of Conformity
References
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BOSCH GDR 120-LI Cordless Impact Driver

Product Information

Product Name: GDR 120-LI
Manufacturer: Robert Bosch Power Tools GmbH
Country: Germany
Website: www.bosch-pt.com
Model Number: 1 609 92A 7TL
Date of Manual: 04.08.2022

Product Description: The GDR 120-LI is a cordless impact driver manufactured by Bosch Power Tools. It is designed for professional use and provides high torque for various fastening applications.

Technical Specifications:

Nominal Voltage: 12V
Max. Torque: Refer to ISO 5393 standard
No-load Speed: Adjustable between min-1 and max min-1
Tool Holder: 3/8 inch
Weight: 1.1 kg (including battery)
Recommended Ambient Temperature for Charging: 0°C to +35°C
Recommended Ambient Temperature for Operation and Storage: 0°C to +35°C
Recommended Batteries: GBA 12V series

Product Usage Instructions

Safety Precautions:

Read all safety instructions provided in the manual before using the tool.
The term “Power Tool” refers to both corded and cordless tools mentioned in the safety instructions.

Workplace Safety:

If using the power tool in a damp environment is unavoidable, use a residual current device (RCD) to reduce the risk of electric shock.

Personal Safety:

Always use the power tool according to the instructions provided to ensure personal safety.

Product Handling and Usage:

Avoid short-circuiting between the battery contacts as it may result in burns or fire.
Only have your power tool repaired by qualified professionals using original spare parts to maintain its safety.

Assembly, Charging, and Operation:

Refer to the provided manual for instructions on assembly, charging, and operation of the GDR 120-LI.
Ensure proper battery installation and charging using compatible chargers (e.g., GAL 12 or GAX 18).
Follow the tool change procedures mentioned in the manual for both GDR 120-LI and GDS 120-LI models.
Familiarize yourself with the tool’s functions and operating procedures before use.

Work Recommendations:

Refer to the provided manual for specific work recommendations and guidelines.
The GDR 120-LI is suitable for fastening applications with various strength classes of screws. Refer to the table in the manual for specific torque values.

Maintenance and Service:

Regularly maintain and clean your power tool according to the instructions provided in the manual.
If you have any questions regarding repairs, maintenance, or spare parts, contact the customer service or visit the manufacturer’s website for further assistance.

Safety Instructions

General Power Tool Safety Warnings

WARNING Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below 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 (cord-less) power tool.

Work area safety

Keep 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 which may ignite the 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 risk of electric shock.
Avoid body contact with earthed or grounded sur-faces, 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 or 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. Use of a cord suit-able for outdoor use reduces the risk of electric shock.
If operating a power tool in a damp location is un-avoidable, use a residual current device (RCD) protected supply. 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 a dust mask, non-skid safety shoes, hard hat or hearing protection used for appropriate conditions will reduce personal in-juries.
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.
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 in-jury.
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 jewellery. Keep your hair and clothing away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts.
If devices are provided for the connection of dust ex-traction and collection facilities, ensure these are connected and properly used. Use of dust collection can re-duce dust-related hazards.
Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe in-jury within a fraction of a second.

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 for which it was de-signed.
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.
Disconnect the plug from the power source and/or re-move the battery pack, if detachable, 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 and accessories. Check for mis-alignment 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 ac-count the working conditions and the work to be per-formed. Use of the power tool for operations different from those intended could result in a hazardous situation.
Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

Battery tool use and care

Recharge only with the charger specified by the manufacturer. A charger that is suitable for one type of bat-tery pack may create a risk of fire when used with another battery pack.
Use power tools only with specifically designated bat-tery packs. Use of any other battery packs may create a risk of injury and fire.
When battery pack is not in use, keep it away from other metal objects, like paper clips, coins, keys, nails, screws or other small metal objects, that can make a connection from one terminal to another. Shorting the battery terminals together may cause burns or a fire.
Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact accidentally oc-curs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the bat-tery may cause irritation or burns.
Do not use a battery pack or tool that is damaged or modified. Damaged or modified batteries may exhibit unpredictable behaviour resulting in fire, explosion or risk of injury.
Do not expose a battery pack or tool to fire or excess-ive temperature. Exposure to fire or temperature above 130°C may cause explosion.
Follow all charging instructions and do not charge the battery pack or tool outside the temperature range specified in the instructions. Charging improperly or at temperatures outside the specified range may damage the battery and increase the risk of fire.

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.
Never service damaged battery packs. Service of bat-tery packs should only be performed by the manufacturer or authorized service providers.

Safety Warnings for Impact Wrenches

Hold the power tool by insulated gripping surfaces, when performing an operation where the fastener may contact hidden wiring. Fasteners 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 there are hid-den supply lines or contact the local utility company for assistance. Contact with electric cables can cause fire and electric shock. Damaging gas lines can lead to ex-plosion. Breaking water pipes causes property damage.
Hold the power tool securely. When tightening and loosening screws be prepared for temporarily high torque reactions.
Secure the workpiece. A workpiece clamped with clamping devices or in a vice is held more secure than by hand.
Always wait until the power tool has come to a complete stop before placing it down. The application tool can jam and cause you to lose control of the power tool.
In case of damage and improper use of the battery, vapours may be emitted. The battery can set alight or explode. Ensure the area is well ventilated and seek medical attention should you experience any adverse effects. The vapours may irritate the respiratory system.
Do not open the battery. There is a risk of short-circuiting.
The battery can be damaged by pointed objects such as nails or screwdrivers or by force applied externally. An internal short circuit may occur, causing the battery to burn, smoke, explode or overheat.
Only use the battery with products from the manufacturer. This is the only way in which you can protect the battery against dangerous overload.
Protect the battery against heat, e.g. against continuous intense sunlight, fire, dirt, water and moisture. There is a risk of explosion and short-circuiting.

Product Description and Specifications

Read all the safety and general instructions.

Failure to observe the safety and general instructions may result in electric shock, fire and/or serious injury.

Please observe the illustrations at the beginning of this operating manual.

Intended Use
The machine is intended for driving in and loosening screws and bolts as well as for tightening and loosening nuts within the respective range of dimension.

Product features
The numbering of the product features refers to the diagram of the power tool on the graphics page. BOSCH-GDR-120-LI-Cordless-Impact-Driver-
fig1

Tool holder
Locking sleeve
Gear selector switch
Carrying strap lug
Battery release button
Battery
Rotational direction switch
On/off switch
“PowerLight” lamp
Handle (insulated gripping surface)
Double bita)
Universal bit holdera)
Screwdriver bita)
Application tool (e.g. impact socket)a)
a) Accessories shown or described are not included with the product as standard. You can find the complete selection of accessories in our accessories range.

Technical data

BOSCH-GDR-120-LI-Cordless-Impact-Driver-fig6

A) measured at 20–25 °C with battery .
B) Limited performance at temperatures < 0 °C

Noise/vibration information
Noise emission values determined according to
EN 62841-2-2.
Typically, the A-weighted noise level of the power tool is: Sound pressure level 92 dB(A); sound power level
103 dB(A). Uncertainty K = 3 dB.
Wear hearing protection!
Vibration total values ah (triax vector sum) and uncertainty K determined according to EN 62841-2-2:
Impact tightening of fasteners of the maximum capacity of the tool: ah = 9.5 m/s2, K = 1.5 m/s2
The vibration level and noise emission value given in these instructions have been measured in accordance with a standardised measuring procedure and may be used to com-pare power tools. They may also be used for a preliminary estimation of vibration and noise emissions.
The stated vibration level and noise emission value represent the main applications of the power tool. However, if the power tool is used for other applications, with different ap-plication tools or is poorly maintained, the vibration level and noise emission value may differ. This may significantly increase the vibration and noise emissions over the total working period.
To estimate vibration and noise emissions accurately, the times when the tool is switched off or when it is running but not actually being used should also be taken into account. This may significantly reduce vibration and noise emissions over the total working period.
Implement additional safety measures to protect the operator from the effects of vibration, such as servicing the power tool and application tools, keeping their hands warm, and organising workflows correctly.

Assembly

Remove the battery from the power tool before carry-ing out work on the power tool (e.g. maintenance, changing tool, etc.). The battery should also be re- moved for transport and storage. There is risk of injury from unintentionally pressing the on/off switch.

Battery Charging

Use only the chargers listed in the technical data. Only these chargers are matched to the lithium-ion battery of your power tool.

Note: The battery is supplied partially charged. To ensure full battery capacity, fully charge the battery in the charger before using your power tool for the first time.
The lithium-ion battery can be charged at any time without reducing its service life. Interrupting the charging process does not damage the battery.
The lithium-ion battery is protected against deep discharge by the “Electronic Cell Protection (ECP)”. When the battery is discharged, the power tool is switched off by means of a protective circuit: The application tool no longer rotates.

Do not continue to press the On/Off switch after the power tool has automatically switched off. The battery can be damaged.

Removing the battery (see figure A) To remove the battery (6), press the release button (5) and pull the battery downwards out of the power tool. Do not use force to do this.

Changing the Tool

Remove the battery from the power tool before carrying out work on the power tool (e.g. maintenance, changing tool, etc.). The battery should also be removed for transport and storage. There is risk of injury from unintentionally pressing the on/off switch.

GDR 120-LI:
Inserting the application tool (see figure B) Pull the locking sleeve (2) forward, guide the application tool (1) into the tool holder up to the stop and release the locking sleeve (2) to lock the application tool.
Screwdriver bits (13) can be inserted using a universal bit holder with ball catch (12).
Removing
Pull the locking sleeve (2) forward and remove the application tool.

GDS 120-LI: (see figure C)

When working with an application tool, pay attention that the application tool is connected securely to the tool holder. When the application tool is not securely connected with the tool holder, it can come off during ap-plication.

Slide the application tool (14) onto the square drive of the tool holder (1).
Due to the way the system operates, the application tool (14) will move around slightly in the tool holder(1); this has no influence on the function/safety.

Operation

Method of Operation
The tool holder (1) (with the application tool) is driven by an electric motor via a gear and impact mechanism.
The working procedure is divided into two phases: Screwing in and tightening (impact mechanism in action). The impact mechanism is activated as soon as the screwed connection runs tight and load is therefore put on the motor. The impact mechanism then converts the power of the mo-tor to steady rotary impacts. When loosening screws or nuts, the process is reversed.

Starting Operation

Inserting the Battery
Set the rotational direction switch (7) to the middle position to avoid unintentionally switching it on. Insert the charged battery (6) into the handle until you feel it engage and it is flush with the handle.
Set the rotational direction (see figure D)
The rotational direction switch (7) is used to change the rotational direction of the power tool. However, this is not possible while the on/off switch (8) is being pressed.
Right rotation: To drive in screws and tighten nuts, press the rotational direction switch (7) through to the left stop. Left Rotation: To loosen and unscrew screws and nuts, press the rotational direction switch (7) through to the right stop.

Mechanical gear selection
Only operate the gear selector (3) when the power tool is not in use.

You can preselect two speed ranges with the gear selector (3).
Gear I:
Low speed range; for screwdriving or working with a large drilling diameter.
Gear II:
High speed range; for working with a small drilling diameter. If the gear selector (3) cannot be swivelled all the way to the stop, turn the drive spindle slightly with the drill.

Switching on/off
To start the power tool, press and hold the on/off switch
(8).
The lamp (9) lights up when the on/off switch (8) is lightly or fully pressed, meaning that the work area is illuminated in poor lighting conditions.
To switch off the power tool, release the on/off switch (8).

Adjusting the speed
You can adjust the speed of the power tool when it is on by pressing in the on/off switch (8) to varying extents.
A light pressure on the on/off switch (8) results in a low rotational speed. Increased pressure on the switch causes an in-crease in speed.
Temperature-dependent overload protection
In normal conditions of use, the power tool cannot be over-loaded. If the power tool is overloaded or the permitted battery temperature is exceeded, the electronics of the power tool will switch off until the temperature returns to within the optimum operating temperature range.

Practical advice

Only apply the power tool to the screw/nut when the tool is switched off. Rotating tool inserts can slip off.

The torque depends on the impact duration. The maximum achieved torque results from the sum of all individual torques achieved through impact. Maximum torque is achieved after an impact duration of 6–10 seconds. After this duration, the tightening torque is increased only minim-ally.
The impact duration is to be determined for each required tightening torque. The tightening torque actually achieved should always be checked with a torque wrench.
Screw applications with hard, spring-loaded or soft seats When the achieved torques in an impact series are measured during a test and transferred into a diagram, the result is the curve of a torque characteristic. The height of the curve cor-responds to the maximum achievable torque, and the steep-ness indicates the duration in which this is achieved.
A torque characteristic depends on the following factors:

Strength properties of the screws/nuts
Type of backing (washer, disc spring, seal)
Strength properties of the material being screwed/bolted together
Lubrication conditions at the screw/bolt connection The following application cases result accordingly:
A hard seat is a metal-to-metal screw application which uses washers. After a relatively short impact duration, the maximum torque is achieved (steep characteristic curve). An unnecessarily long impact duration only causes dam-age to the machine.
A spring-loaded seat is also a metal-to-metal screw ap-plication but uses spring washers, disc springs, studs or screws/nuts with conical seats. It is also called a spring-loaded seat when extensions are used.
A soft seat is a screw application of e.g. metal on wood or a screw application that uses lead washers or fibre washers as backing.

For a spring-loaded seat, as well as for a soft seat, the max-imum tightening torque is lower than for a hard seat. A much longer impact duration is also required.

Guide values for maximum screw tightening torques
Figures given in Nm; calculated from the tensional cross-section; utilization of the yield point: 90% (with friction coefficient µtotal = 0.12). As a control measure, always check the tightening torque with a torque wrench.

BOSCH-GDR-120-LI-Cordless-Impact-Driver-fig8

Tips
Before screwing larger, longer screws into hard materials, it is advisable to pre-drill a pilot hole with the core diameter of the thread to approx. 2/3 of the screw length.
Note: Ensure that no metal particles enter the power tool.
Recommendations for optimal handling of the battery Protect the battery against moisture and water.
Only store the battery only within a temperature range of -20 to 50 °C. Do not leave the battery in your car in the summer, for example.
Occasionally clean the ventilation slots on the battery using a soft brush that is clean and dry.
A significantly reduced operating time after charging indicates that the battery has deteriorated and must be replaced. Follow the instructions on correct disposal.

Maintenance and Service

Maintenance and Cleaning

Clean the air vents on your power tool regularly. The motor’s fan will draw the dust inside the housing and excessive accumulation of powdered metal may cause electrical hazards.
Remove the battery from the power tool before carry-ing out work on the power tool (e.g. maintenance, changing tool, etc.). The battery should also be re-moved for transport and storage. There is risk of injury from unintentionally pressing the on/off switch.
To ensure safe and efficient operation, always keep the power tool and the ventilation slots clean.

After-Sales Service and Application Service

Our after-sales service responds to your questions concern-ing maintenance and repair of your product as well as spare parts. You can find explosion drawings and information on spare parts at: www.bosch-pt.com
The Bosch product use advice team will be happy to help you with any questions about 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: boschservicecentre@bosch.com
You can find further service addresses at: www.bosch- pt.com/serviceaddresses

Transport

The recommended lithium-ion batteries are subject to legis-lation on the transport of dangerous goods. The user can transport the batteries by road without further require-ments.

When shipping by third parties (e.g.: by air transport or for-warding agency), special requirements on packaging and la-belling must be observed. For preparation of the item being shipped, consulting an expert for hazardous material is re-quired.
Dispatch battery packs only when the housing is undam-aged. Tape or mask off open contacts and pack up the bat-tery in such a manner that it cannot move around in the packaging. Please also observe the possibility of more de-tailed national regulations.

Disposal

Power tools, rechargeable batteries, accessor-ies and packaging should be sorted for environ-mental-friendly recycling.
Do not dispose of power tools and batteries/re-chargeable batteries into household waste!

Only for EU countries:
According to the Directive 2012/19/EU on waste electrical and electronic equipment and its transposition into national law, power tools that are no longer usable, and, according to the Directive 2006/66/EC, defective or drained batteries must be collected separately and disposed of in an environ- mentally correct manner.
If disposed incorrectly, waste electrical and electronic equipment may have harmful effects on the environment and human health, due to the potential presence of hazardous substances.
Only for United Kingdom:
According to The Waste Electrical and Electronic Equipment Regulations 2013 (SI 2013/3113) (as amended) and the Waste Batteries and Accumulators Regulations 2009
(SI 2009/890) (as amended), products that are no longer usable must be collected separately and disposed of in an environmentally friendly manner.
Battery packs/batteries:
Li-ion:
Please observe the notes in the section on transport (see
“Transport”, page 16).

EU Declaration of Conformity

Cordless Impact Wrench
Article number
We declare under our sole responsibility that the stated products comply with all applicable provisions of the directives and regulations listed below and are in conformity with the following standards.
Technical file at: * BOSCH-GDR-120-LI-Cordless-Impact-Driver-
fig10