BOSCH GDR 120-LI Professional Cordless Impact Screwdriver Instruction Manual

BOSCH GDR 120-LI Professional Cordless Impact Screwdriver

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 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 ex- traction and collection facilities, ensure these are connected and properly used. The use  of dust collection can re- duce 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 ac cordance 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.

Battery tool use and care

• Recharge only with the charger specified by the manufacturer . A charger that is suitable for one type of battery pack may create a risk of fire when used with another battery pack.
• Use power tools only with specifically designated battery packs. The use  of any other battery packs may create a risk of injury and fire.
• When the 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 occurs, flush with water. If liquid contacts the eyes, additional seek medical help. Liquid ejected from the battery may cause irritation or burns.

Service

• Have your power tool serviced by a qualified repair per- son using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

Safety Warnings for Impact Wrenches

• Hold 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.
• 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.
• Do not open the battery. The danger of short-circuiting. Protect the battery against heat, e. g., against continuous intense sunlight, fire, water, and moisture.

The danger of explosion

• In case of damage and improper use of the battery, vapors may be emitted. Ventilate the area and seek medical help in case of complaints. The vapors can irritate the respiratory system.
• Use the battery only in conjunction with your Bosch product. This measure alone protects the battery against dangerous overload.
• The battery can be damaged by pointed objects such as nails or screwdrivers or by force applied externally. An internal short circuit can occur and the battery can burn, smoke, explode or overheat.

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 driving in and loosening screws and bolts as well as for tightening and loosening nuts within the respective range of dimensions. The light of this power tool is intended to illuminate the power tool’s direct area of working operation and is not suitable for household room illumination.

Product Features

The numbering of the product features refers to the illustration of the machine on the graphics page.

1. Tool holder
2. Locking sleeve
3. Gear selector
4. Fixture for carrying strap
5. Battery unlocking button
6. Battery pack
7. Rotational direction switch
8. On/Off switch
9. “PowerLight”
10. Handle (insulated gripping surface)
11. Double bit*
12. Universal bit holder*
13. Screwdriver bit*
14. Application tool (e. an impact socket)

Accessories shown or described are not part of the standard de- livery scope of the product. A complete overview of accessories can be found in our accessories program

Technical Data|
---|---
Cordless Impact Screwdriver|  | GDR 120-LI| GDS 120-LI
Article number|  | 3 601 JF0 0..| 3 601 JF0 1..
Rated voltage| V=| 12| 12
No-load speed

– Setting 1

| ****

min–1

| ****

0– 1300

| ****

0– 1300

– Setting 2| min–1| 0– 2600| 0– 2600
Impact rate

– Setting 1

| ****

min–1

| ****

0– 1900

| ****

0– 1900

– Setting 2| min–1| 0– 3200| 0– 3200
Maximum torque, hard screwdriving application according to ISO 5393| ****

Nm

| ****

100

| ****

105

• Limited performance at temperatures < 0 °C|  |  |  
  Cordless Impact Screwdriver|  | GDR 120-LI| GDS 120-LI
  ---|---|---|---
  Bolt size| mm| M4 – M12| M4– M12
  Max. screw dia.| mm| 8| 8
  Tool holder|  | ¼” hexagon socket| n 3/8″
  Weight according to EPTA-Procedure 01:2014| kg| 1.1| 1.1
  Permitted ambient temperature

– during charging

|

°C

|

0…+45

|

0…+45

– during operation* and during storage| °C| –20…+50| –20…+50
Recommended batteries|  | GBA 12V …| GBA 12V …
Recommended chargers|  | GAL 12.. CV| GAL 12.. CV

• Limited performance at temperatures < 0 °C|  |  |  

Noise/Vibration Information

Sound emission values were determined according to EN 60745-2-2. Typically the A-weighted noise levels of the product are 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 60745-2-2: Impact tightening of fasteners of the maximum capacity of the tool: ah =9.5 m/s2, K=1.5 m/s2. The vibration level 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.

Assembly

Removing the Battery

• Use only the battery chargers listed on the accessories page. Only these battery chargers are matched to the lith- ium-ion battery of your power tool.

Note: The battery supplied is partially charged. To ensure the full capacity of the battery, completely charge the battery in the battery 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 procedure does not damage the battery

The lithium-ion battery is protected against deep discharging by the “Electronic Cell Protection (ECP)”. When the battery is empty, the machine is switched off by means of a protective circuit: The inserted tool no longer rotates.

Do not continue to press the On/Off switch after the machine has been automatically switched off. The battery can be damaged. To remove the battery 6 press the unlocking buttons 5 and pull out the battery downwards. Do not exert any force.

Observe the notes for disposal

Changing the Tool

• Before any work on the machine itself (e. g. maintenance , tool change, etc.) as well as during transport and storage, remove the battery from the power tool. There is a danger of injury when unintentionally actuating the On/Off switch.
• Regularly clean the power tool’s air vents. The motor’s fan will draw the dust inside the housing and excessive ac- cumulation of powdered metal may cause electrical hazards.

GDR 120-LI: Inserting

Pull the locking sleeve 2 forward, push the insert tool to the stop into the tool holder 1 and release the locking sleeve 2 to lock the insert tool. Screwdriver bits 13 can be inserted using a universal bit holder with ball lock 12. Removing Pull the locking sleeve 2 forward and remove the insert tool.

GDS 120-LI:

• 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 the application. Slide the application tool 14 onto the square drive of the tool holder 1. With this system, there will be a slight amount of play around the application tool 14 after connecting securely to the tool holder 1 ; this has no influence on the function/safety.

Operation

Method of Operation

Tool holder 1 with the 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 thus load is put on the motor. In this instance, the impact mechanism converts the power of the motor 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 center position to protect the power tool against accidental starting. Insert the charged battery 6 from the front into the base of the power tool until the battery is securely locked. Reversing the rotational direction The rotational direction switch 7 is used to reverse the rotational direction of the machine. However, this is not possible with the On/Off switch 8 actuated.

Right rotation: For driving in screws and tightening nuts, press the rotational direction switch 7 through to the left stop.

Left Rotation: For loosening and unscrewing screws and nuts, press the rotational direction switch 7 through to the right stop.

Gear selection, mechanical Actuate the gear selector 3 only when the machine is at a standstill.
Two-speed ranges can be preselected with the gear selector 3.

• Gear I:
  Low-speed range; for a screwdriver or working with a large drilling diameter.

• Gear II:
  High-speed range; for working with small drilling diameter. If the gear selector 3 cannot be pushed through to the stop, lightly turn the drill chuck with a drill bit.

Switching On and Off
To start the machine, press the On/Off switch 8 and keep it pressed. The power light 9 lights up when the On/Off switch 8 is slightly or completely pressed and allows the work area to be illuminated when lighting conditions are insufficient. To switch off the machine, release the On/Off switch 8. To save energy, only switch the power tool on when using it.

Adjusting the Speed

The speed of the switched-on power tool can be variably adjusted, depending on how far the On/Off switch 8 is pressed. Light pressure on the On/Off switches 8 results in a low rotational speed. Further pressure on the switch results in an increase in speed. Temperature Dependent Overload Protection In normal conditions of use, the power tool cannot be overloaded. If the power tool is overloaded or not kept within the permitted battery temperature range, the power output is reduced or the power tool is switched off. The power tool will not run at full power output again until the permitted battery temperature has been reached.

Working Advice

• Apply the power tool to the screw/nut only when it 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. The maximum torque is achieved after an impact duration of 6–10 seconds. After this duration, the tightening torque is increased only minimally. The impact duration is to be determined for each required tightening torque. The actually achieved tightening torque is always to be checked with a torque wrench.

Screw Applications with Hard, Spring-loaded, or Soft Seat A test in which the achieved torques in an impact series are measured and transferred to a diagram will produce the curve of a torque characteristic. The height of the curve corresponds with the maximum reachable torque, and the steepness indicates the duration in which this is achieved.

A torque gradient 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 given for metal-to-metal screw applications with the use of After a relatively short impact duration, the maximum torque is reached (steep characteristic curve). Unnecessary long impact duration only causes damage to the machine.
• A spring-loaded seat is given for metal-to-metal screw applications, however with the use of spring washers, disc springs, studs or screws/nuts with a conical seat as well as when using
• A soft seat is given for screw applications, e. g., metal on wood or when using lead washers or fiber washers as back-

For a spring-loaded seat as well as for a soft seat, the maximum tightening torque is lower than for a hard seat. Also, a clearly longer impact duration is required.
Reference Values for Maximum Screw/Bolt Tightening Torques 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

Tips
Before screwing larger, longer screws into hard materials, it is advisable to predrill a pilot hole with the core diameter of the thread to approx. 2/3 of the screw length.

Note: Pay attention that no metal particles enter the power tool.
Recommendations for Optimal Handling of the Battery Protect the battery against moisture and water. Store the battery only within a temperature range between –20 °C and 50 °C. As an example, do not leave the battery in the car in summer. Occasionally clean the venting slots of the battery using a soft, clean, and dry brush. A significantly reduced working period after charging indicates that the battery is used and must be replaced. Observe the notes for disposal.

Maintenance and Service

Maintenance and Cleaning

• Before any work on the machine itself (e. g. maintenance , tool change, etc.) as well as during transport and storage, remove the battery from the power tool. There is a danger of injury when unintentionally actuating the On/Off switch.
• For safe and proper working, always keep the machine and ventilation slots clean.

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 al- so 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: [email protected]

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: [email protected]
• KZN – BSC Service Centre
• Unit E, Almar Centre 143 Crompton Street Pinetown
• Tel.: (031) 7012120
• Fax: (031) 7012446
• E-Mail: [email protected]
• Western Cape – BSC Service Centre Democracy Way, Prosperity Park Milnerton
• Tel.: (021) 5512577
• Fax: (021) 5513223
• E-Mail: [email protected]
• Bosch Headquarters Midrand, Gauteng Tel.: (011) 6519600
• Fax: (011) 6519880
• E-Mail: [email protected]

Transport

The contained lithium-ion batteries are subject to the Dangerous Goods Legislation requirements. The user can transport the batteries by road without further requirements. When being transported by third parties (e.g.: air transport or forwarding agency), special requirements on packaging and labeling must be observed. For the preparation of the item being shipped, consulting an expert for hazardous material is required. Dispatch batteries only when the housing is undamaged. Tape or mask off open contacts and pack up the battery in such a manner that it cannot move around in the packaging. Please also observe possibly more detailed national regulations.

Disposal

The machine, rechargeable batteries, accessories, and packaging should be sorted for environmentally-friendly recycling. Do not dispose of power tools and batteries/rechargeable batteries into household waste

Only EC countries
According to the European Guideline 2012/19/EU, power tools that are no longer usable, and according to the European Guideline 2006/66/EC, defective or used battery packs/batteries, must be collected separately and disposed of in an environmentally correct manner.

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