BOSCH RH540M Hammer Drill Instruction Manual

: June 3, 2024
: Bosch

BOSCH RH540M Hammer Drill

Safety Symbols

The definitions below describe the level of severity for each signal word. Please read the manual and pay attention to these symbols.

| This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
| DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
| WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
| CAUTION , used with the safety alert symbol, indicates a hazardous situation which, if not avoided, will result in minor or moderate injury.

General Power Tool Safety Warnings

Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious

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 Ground Fault Circuit Interrupter (GFCI) protected supply. Use of an GFCI 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 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 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. Use of dust collection can reduce disrelated 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 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 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.

Rotary Hammer Safety Rules

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 tools by insulated gripping surfaces, when performing an operation where the cutting tool 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 clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body leaves it unstable and may lead to loss of control.
Do not drill, fasten or break into existing walls or other blind areas where electrical wiring may exist. If this situation is unavoidable, disconnect all fuses or circuit breakers feeding this worksite.
Use a metal detector to determine if there are gas or water pipes hidden in the work area or call the local utility company for assistance before beginning the operation. Striking or cutting into a gas line will result in explosion. Water entering an electrical device may cause electrocution.
Always use the side handle for maximum control over torque reaction or kick- back.
Never attempt to operate this tool with one hand. The slip clutch engages if you firmly control the tool during a torque reaction or kickback.
Always wear safety goggles or eye protection when using this tool. Use a dust mask or respirator for applications that generate dust. Safety goggles or eye protection will help deflect fragments of the material that may be thrown toward your face and eyes. Dust generated or gases released from the material you are cutting (i.e. asbestos insulated pipes, radon) may cause respiratory difficulties.
Use thick cushioned gloves and limit the exposure time by taking frequent rest periods. Vibration caused by hammer-drill action may be harmful to your hands and arms.
Position the cord clear of rotating bit. Do not wrap the cord around your arm or wrist. If cord becomes entangled with the spinning bit it could entrap you causing serious personal injury.
Position yourself to avoid being caught between the tool or side handle and walls or posts. Should the bit become bound or jammed in the work, the reaction torque of the tool could crush your hand or leg.
Do not strike the bit with a handheld hammer or sledgehammer when attempting to dislodge a bound or jammed bit. Fragments of metal from the bit could dislodge and strike you or bystanders. Never place the tool down until the bit or accessory has come to a complete stop. Do not use dull or damaged bits and accessories. Dull or damaged bits have a greater tendency to bind in the workpiece.
When removing the bit from the tool avoid contact with skin and use proper protective gloves when grasping the bit or accessory. Accessories may be hot after prolonged use.
Do not run the tool while carrying it at your side. A spinning bit could become entangled with clothing and injury may result.

Additional Safety Warnings

GFCI and personal protection devices like electrician’s rubber gloves and footwear will further enhance your personal safety. Do not use AC only rated tools with a DC power supply. While the tool may appear to work, the electrical components of the AC rated tool are likely to fail and create a hazard to the operator.
Keep handles dry, clean and free from oil and grease. Slippery hands cannot safely control the power tool.
Develop a periodic maintenance schedule for your tool. When cleaning a tool be careful not to disassemble any portion of the tool since internal wires may be misplaced or pinched or safety guard return springs may be improperly mounted. Certain cleaning agents such as gasoline, carbon tetrachloride, ammonia, etc. may damage plastic parts.
Risk of injury to user. The power cord must only be serviced by a Bosch Factory Service Center or Authorized Bosch Service Station.

Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains 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, and
Arsenic and chromium from chemically treated lumber.

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 those dust masks that are specially designed to filter out microscopic particles.

Symbols

IMPORTANT : Some of the following symbols may be used on your tool. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to operate the tool better and safer.

Symbol	Designation / Explanation

V

| Volts (voltage)

A

| Amperes (current)

Hz

| Hertz (frequency, cycles per second)

W

| Watt (power)

kg

| Kilograms (weight)

min

| Minutes (time)

s

| Seconds (time)

⌀

| Diameter (size of drill bits, grinding wheels, etc.)

n0

| No load speed (rotational speed at no load)

n

| Rated speed (maximum attainable speed)
…/min| Revolutions or reciprocation per minute (revolutions, strokes, surface speed, orbits etc. per minute)

0

| Off position (zero speed, zero torque…)
| Selector settings (speed, torque or position settings. Higher number means greater speed)
| Infinitely variable selector with off (speed is increasing from 0 setting)
| Arrow (action in the direction of arrow)

∼

| Alternating current (type or a characteristic of current)

⎓

| Direct current (type or a characteristic of current)
| Alternating or direct current (type or a characteristic of current)
| Class II construction (designates double insulated construction tools)
| Earthing terminal (grounding terminal)
| Alerts user to read manual
| Alerts user to wear eye protection
| This symbol designates that this tool is listed by Underwriters Laboratories.
| This symbol designates that this tool is listed by Underwriters Laboratories, to United States and Canadian Standards.
| This symbol designates that this tool is listed by the Canadian Standards Association.
| This symbol designates that this tool is listed by the Canadian Standards Association, to United States and Canadian Standards.

| This symbol designates that this tool is listed by the Intertek Testing Services, to United States and Canadian Standards.
| This symbol designates that this tool complies to NOM Mexican Standards.

Functional Description and Specifications

Disconnect the plug from the power source before making any assembly, adjustments or changing accessories. Such preventive safety measures reduce the risk of starting the tool accidentally.

Model number RH540M RH540S
Shank style SDS Max Spline

Maximum Capacities:
Carbide tipped bits 1 9/16″ / 1 9/16″
Carbide tipped core bits 4″ / 4″

NOTE : For tool specifications refer to the nameplate on your tool.

Assembly

INSTALLING ACCESSORIES

Clean the insert shank end of the accessory to remove any debris, then lightly grease with a light oil or lubricant.
(Model RH540M only)
Pull and hold locking sleeve backward. Insert accessory into the tool holder through the dust shield, while twisting and pushing inward until it sets into place. Release locking sleeve to lock bit in place. Pull outward on the accessory to be certain it is locked into the tool holder ( Fig. 2 ).

(Model RH540S only)
Insert accessory into the tool holder, while twisting and pushing inward until it locks automatically into place (Fig. 3).
To install hex round chisels, align flat on chisel with alignment mark on tool holder, then push chisel into tool holder until it lock automatically into place. Pull outward on the accessory to be certain it is locked into the tool holder ( Fig. 3 ).

REMOVING ACCESSORIES

Accessories may be hot after use. Avoid contact with skin and use proper protective gloves or cloth to remove.
To remove an accessory, pull and hold locking sleeve backward and pull bit forward. All accessories should be wiped clean after removing.
NOTE : The high efficiency available from the rotary hammers can only be obtained if sharp and undamaged accessories are used. The “cost” to maintain sharp and undamaged accessories is more than offset by the “time saved” in operating the tool with sharp accessories.

AUXILIARY HANDLE
The tool must be supported with the auxiliary handle, which can be swiveled 360˚. To reposition and/or swivel the handle, loosen the hand grip, move the handle to the desired position along the barrel and securely retighten the hand grip ( Fig. 1 ).
Operating Instructions

TRIGGER “ON-OFF” SWITCH

To turn the tool “ON” squeeze the trigger switch. To turn the tool “OFF”, release the trigger switch, which is spring loaded and will return to the “OFF” position automatically. To increase switch life, do not turn switch on and off while tool is under load.

VARIABLE SPEED DIAL

Your tool is equipped with a variable speed dial. The speed and impact force can be adjusted by rotating the dial. Higher speeds and impact force work best for faster penetration when drilling or chiseling in hard masonry material. Slower speeds work best to reduce breakout when bits exit material being drilled or chiseling material such as plaster or tile (Fig. 1).
Regardless of the pressure applied on the trigger, the tool will not operate any faster than maximum speed setting selected.

SELECTOR LEVER

The selector lever allows the tool to be set for various applications as listed in the following chart, ( Fig. 4 ).
When using demolition or chipping bits such as bull points, chisels, spades, gouges, etc. the “Hammer Only” mode must be selected.

SELECTOR LEVER – “VARIO-LOCK”

The vario-lock can be set in any one of twelve positions (30˚ increments). Choose a position which is best suited for your operation. The Vario-Lock position is intended for use with chipping bits such as bull points, spades, gouges, etc.
Turn the selector lever, to the “vario-lock” setting. Next, rotate the locking sleeve, along with the accessory, to the desired position. Then turn the selector lever to the “hammer only” setting and slightly turn the locking sleeve to have it automatically lock into a definite position.

SLIP CLUTCH

The tool has a internal pre-set slip clutch. The output spindle will stop rotating if the accessory binds and overloads the tool.

“TOOL TIPS”

For the best penetration rates in concrete, run the tool with a steady pressure, but do not use excessive force as this will decrease the efficiency of the tool.
All hammers require a short period of time to warm up. Depending on the room temperature, this time may vary from approximately 15 seconds (90˚F) to 2 minutes (32˚F). A new hammer requires a break-in period before full performance is realized. This period may require up to 5 hours of operation.
A combination hammer is likely to be the most expensive portable tool at the construction job. The long wear and efficient operation of the BOSCH hammers will more than justify the cost for tools of this type. As earlier pointed out, sharp accessories as well as clean air vents are necessary for efficient operation. Establish and follow a set maintenance program.

Dust Extraction

For selection of dust collection systems and operating instructions, see the Operating / Safety Instructions for ‘Dust Extraction Attachments for Hammers and Hammer Drills’ included with your tool or with the dust extraction attachment

Maintenance

Service

Preventive maintenance performed by unauthorized personnel may result in misplacing of internal wires and components which could cause serious hazard. We recommend that all tool service be performed by a Bosch Factory Service Center or Authorized Bosch Service Station.

TOOL LUBRICATION

Your Bosch tool has been properly lubricated and is ready to use. It is recommended that tools with gears be lubricated with Bosch lubricant at every brush change.

CARBON BRUSHES

The brushes and commutator in your tool have been engineered for many hours of dependable service. To maintain peak efficiency of the motor, we recommend every two to six months the brushes be examined. Only genuine Bosch replacement brushes specially designed for your tool should be used.

BEARINGS

Every second brush change, the bearings should be replaced at Bosch Factory Service Center or Authorized Bosch Service Station. Bearings which become noisy (due to heavy load or very abrasive material cut ting) should be replaced at once to avoid overheating or motor failure.

REPLACEMENT OF CORD AND CARBON BRUSHES

Your tool is designed to provide a qualified service technician optimal access to replace the carbon brushes and the cord. This provides the service technician the ability to replace these components without the need of disassembling the entire tool housing.

Cleaning

To avoid accidents always dis connect the tool from the power supply before cleaning or performing any maintenance. The tool may be cleaned most effectively with compressed dry air. Always wear safety goggles when cleaning tools with compressed air.
Ventilation openings and switch levers must be kept clean and free of foreign matter. Do not at tempt to clean by inserting pointed objects through openings.

Certain cleaning agents and sol vents damage plastic parts. Some of these are: gasoline, carbon tetrachloride, chlorinated cleaning solvents, ammonia and house hold detergents that contain ammonia.

Extension Cords

If an extension cord is necessary, a cord with adequate size conductors that is capable of carrying the current necessary for your tool must be used. This will prevent excessive voltage drop, loss of power or overheating. Grounded tools must use 3-wire extension cords that have 3-prong plugs and receptacles.
NOTE : The smaller the gauge number, the higher the cord capacity.

RECOMMENDED SIZES OF EXTENSION CORDS 120 VOLT ALTERNATING CURRENT TOOLS

Tool’s Ampere Rating| Cord Size in A.W.G.| Wire Sizes in mm 2
---|---|---
Cord Length in Feet| Cord Length in Meters
25| 50| 100| 150| 15| 30| 60| 120
3-6| 18| 16| 16| 14| 0.75| 0.75| 1.5| 2.5
6-8| 18| 16| 14| 12| 0.75| 1.0| 2.5| 4.0
8-10| 18| 16| 14| 12| 0.75| 1.0| 2.5| 4.0
10-12| 16| 16| 14| 12| 1.0| 2.5| 4.0| –
12-16| 14| 12| –| –| –| –| –| –

Accessories

Auxiliary Handle (*= standard equipment)
Carrying case (**= optional accessories)

WARRANTY

LIMITED WARRANTY OF BOSCH PORTABLE AND BENCHTOP POWER TOOLS

Robert Bosch Tool Corporation (“Seller”) warrants to the original purchaser only, that all BOSCH portable and benchtop power tools will be free from defects in material or workmanship for a period of one year from date of purchase. SELLER’S SOLE OBLIGATION AND YOUR EXCLUSIVE REMEDY under this Limited Warranty and, to the extent permitted by law, any warranty or condition implied by law, shall be the repair or replacement of parts, without charge, which are defective in material or workmanship and which have not been misused, carelessly handled, or misreported by persons other than Seller or Authorized Service Station. To make a claim under this Limited Warranty, you must return the complete portable or benchtop power tool product, transportation prepaid, to any BOSCH Factory Service Center or Authorized Service Station. For Authorized BOSCH Power Tool Service Stations, please refer to your phone directory. THIS LIMITED WARRANTY DOES NOT APPLY TO ACCESSORY ITEMS SUCH AS CIRCULAR SAW BLADES, DRILL BITS, ROUTER BITS, JIGSAW BLADES, SANDING BELTS, GRINDING WHEELS AND OTHER RELATED ITEMS. ANY IMPLIED WARRANTIES SHALL BE LIMITED IN DURATION TO ONE YEAR FROM DATE OF PURCHASE. SOME STATES IN THE U.S., SOME CANADIAN PRO V – INCES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING BUT NOT LIMITED TO LIABILITY FOR LOSS OF PROFITS) ARISING FROM THE SALE OR USE OF THIS PRODUCT. SOME STATES IN THE U.S. AND SOME CANADIAN PROVINCES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU. THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE IN THE U.S., PROVINCE TO PROVINCE IN CANADA AND FROM COUNTRY TO COUNTRY. THIS LIMITED WARRANTY APPLIES ONLY TO PORTABLE AND BENCHTOP ELECTRIC TOOLS SOLD WITHIN THE UNITED STATES OF AMERICA, CANADA AND THE COMMONWEALTH OF PUERTO RICO. FOR WARRANTY COVERAGE WITHIN OTHER COUNTRIES, CONTACT YOUR LOCAL BOSCH DEALER OR IMPORTER.