BOSCH 5-40D GBH Professional Power Tools Instruction Manual

: June 2, 2024
: Bosch

Table of Contents

BOSCH 5-40D GBH Professional Power Tools
Safety instructions
Symbols
Product Description and Specifications
Technical Data
Maintenance and Service
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BOSCH 5-40D GBH Professional Power Tools

BOSCH 5-40D-GBH-Professional-Power-Tools-PRODUCT

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 (cordless) 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 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 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 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. 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 injuries.
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 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 and clothing 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. Use of dust collection can reduce 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 injury 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 designed.
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 remove 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 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 main-tained 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.
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.

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 ac-cessory 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 explosion. Penetrating a water line causes property damage or may cause an electric shock.
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.
Secure the workpiece. A workpiece clamped with clamping devices or in a vice is held more secure than by hand.

Products sold in GB only

Your product is fitted with an BS 1363/A approved electric plug with 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 a mains socket elsewhere.

Hold the power tool firmly with both hands and make sure you have a stable footing. The power tool can be more securely guided with both hands.

Symbols

The following symbols may be important for the operation of your power tool. Please take note of these symbols and their meaning. Correctly interpreting the symbols will help you to operate the power tool more effectively and safely.

Symbols and their meaning

To change the application tool, pull back the locking sleeve.

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 power tool is intended for hammer drilling in concrete, masonry and stone, as well as for chiseling work.

Product Features
The numbering of the product features refers to the diagram of the power tool on the graphics page.

Dust protection cap
Locking sleeve
Mode selector switch
On/off switch
Handle (insulated gripping surface)
Speed/impact rate preselection thumbwheel
Auxiliary handle (insulated gripping surface)

$BOSCH 5-40D-GBH-Professional-Power-Tools-PRODUCT $2$$

Technical Data

$BOSCH 5-40D-GBH-Professional-Power-Tools-PRODUCT $6$$ The specifications apply to a rated voltage [U] of 230 V. These specifications may vary at different voltages and in country-specific models.

Noise/Vibration Information
Noise emission values determined according to EN 60745-2-6.
Typically, the A-weighted noise level of the power tool is: 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 these instructions has been measured in accordance with a standardized measuring procedure and may be used to compare power tools. It can also be used for a preliminary estimation of exposure to vibration.
The stated vibration level applies to the main applications of the power tool. However, if the power tool is used for different applications, with different application tools or poorly maintained, the vibration level may differ. This can signific-antly increase the exposure to vibration over the total working period.

To estimate the exposure to vibration 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 can significantly reduce the exposure to vibration 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 the hands warm, and organising workflows correctly.

Assembly

Pull the plug out of the socket before carrying out any work on the power tool.

Auxiliary handle

Do not operate your power tool without the auxiliary handle (7).

Swivelling the Auxiliary Handle
You can swivel the auxiliary handle (7) to any angle for a safe work posture that minimizes fatigue.
Turn the lower gripping end of the auxiliary handle (7) anticlockwise and swivel the auxiliary handle (7) into the required position. Then turn the lower gripping end of the auxiliary handle (7) clockwise to retighten it. Make sure that the retaining strap of the auxiliary handle slots into the corresponding groove of the housing.

Changing the Tool
The dust protection cap (1) largely prevents the penetration of drilling dust into the tool holder during operation. When inserting the tool, make sure that the dust protection cap (1) does not become damaged.

Replace a damaged dust protection cap immediately.
It is recommended that you have use an after-sales service for this.

Changing the Tool (SDS max)

Inserting the Application Tool (see figure A)
With the SDS-max tool holder, you can change the application tool simply and easily without additional aids.

$BOSCH 5-40D-GBH-Professional-Power-Tools-PRODUCT $3$$

Clean and lightly grease the shank of the application tool.
Push the locking sleeve (2) back and insert the application tool by turning it into the tool holder. Release the locking sleeve (2) to lock the application tool.
Check that it is locked by pulling on the tool.

Removing the application tool (see figure B) $BOSCH 5-40D-GBH- Professional-Power-Tools-PRODUCT $4$$

Push the locking sleeve (2) back and remove the application 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 of 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.

Avoid dust accumulation at the workplace. Dust can easily ignite.

Operation

Products that are only sold in AUS and NZ: Use a residual current device (RCD) with a nominal residual current of 30 mA or less.

Start-up

Pay attention to the mains voltage. The voltage of the power source must match the voltage specified on the rating plate of the power tool. 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).

To change the operating mode, turn the mode selector switch (3) to the required position.

Note: Only change the operating mode when the power tool is switched off. Otherwise, the power tool may become damaged.

Position for hammer drilling
If the application tool does not start rotating straight away, run the power tool slowly until the application tool starts rotating.
Vario-Lock position for changing the chiseling position
Position for chiselling

Switching On/Off

To start the power tool, press the on/off switch (4) and keep it pressed.
To switch off, release the on/off switch (4).
For low temperatures, the power tool reaches the full hammer/impact capacity only after a certain time.

Adjusting the Speed/Impact Rate
The electronic control enables continuous speed and impact rate preselection for material-specific adjustments.

Select the impact rate with the thumbwheel (6) according to the material.
The information in the table below describes the recommended values.

$BOSCH 5-40D-GBH-Professional-Power-Tools-PRODUCT $8$$

Changing the chiseling position (Vario-Lock)
You can lock the chisel in 12 different positions, allowing you to select the optimum working position for each task.

Insert the chisel into the tool holder.
Turn the mode selector switch (3) to the “drilling” position.
Turn the application tool to the required chisel position.
Turn the mode selector switch (3) to the “chiseling” position. With this, the tool holder is locked.

Practical Advice

If the application tool jams or snags, the power transmission to the drill spindle will be interrupted. Always hold the power tool firmly with both hands to withstand the forces this may create and adopt a position with stable footing.
Switch the power tool off immediately and remove the application tool if the power tool becomes blocked. Switching on when the drilling tool is blocked may cause high torque reactions.

Sharpening Chisels
Only sharp chiselling tools will produce good results, there-fore sharpen your chiselling tools in good time before use. This will ensure a long service life for the tools and good work results.

Re-sharpening
Grind chiselling tools against sanding discs, e.g. aluminium oxide, under a steady stream of water. Make sure that the cutting edges show no annealing colours; this will impair the hardness of the chiselling tools.
To forge a chisel, heat it to 850–1050 °C (pale red to yellow).

To harden a chisel, heat it to approx. 900 °C and quench in oil. Then, leave it in an oven for approx. one hour at 320 °C (annealing colour: pale blue).

Maintenance and Service

Maintenance and Cleaning

Pull the plug out of the socket before carrying out any work on the power tool.
To ensure safe and efficient operation, always keep the power tool and the ventilation slots clean.

In order to avoid safety hazards, if the power supply cord needs to be replaced, this must be done by Bosch or by an after-sales service centre that is authorised to repair Bosch power tools.

Replace a damaged dust protection cap immediately. It is recommended that you have use an after-sales service for this.

Lubrication
The power tool is lubricated with grease and is ready for immediate use.
The lubricating grease should only be changed during maintenance or commissioning carried out by an after-sales ser-vice centre authorised to work with Bosch power tools. It is crucial that only lubricating grease provided by Bosch is used.

After-Sales Service and Application Service
Our after-sales service responds to your questions concerning the 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

Disposal
The power tool, accessories and packaging should be re-cycled in an environmentally friendly manner.

Do not dispose of power tools along with household waste.

Only for EU countries:
According to the European Directive 2012/19/EU on Waste Electrical and Electronic Equipment and its implementation into national law, power tools that are no longer usable must be collected separately and disposed of in an environmentally friendly manner.

$BOSCH 5-40D-GBH-Professional-Power-Tools-PRODUCT $1$$

EU Declaration of Conformity
Rotary Hammer 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: *