DeWalt D25501 Instruction Manual

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DEWALT Industrial Tool Co., 701 Joppa Road, Towson, MD 21286
(MAR14) Part No. N392151 D25501, D25553, D25601, D25603, D25651, D25831, D25851
Copyright © 2010, 2014 DEWALT
The following are trademarks for one or more DEWALT power tools: the yellow and black color
scheme; the "D" shaped air intake grill; the array of pyramids on the handgrip; the kit box
configuration; and the array of lozenge-shaped humps on the surface of the tool.
Definitions: Safety Guidelines
The definitions below describe the level of severity for each signal word. Please read the
manual and pay attention to these symbols.
_DANGER: Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
_, WARNING: Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
,_ CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury.
NOTICE: indicates a practice not related to personal injury which, if not avoided, may
result in property damage.
IF YOU HAVE ANY
US TOLL FREE AT: 1-800-4-DEWALT (1-800-433-9258).
WARNING: To reduce the risk of injury, read the instruction manual.
QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL, CALL
General Power Tool Safety Warnings
_ ARNING! 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
1) WORK AREA SAFETY
a) Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b) 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.
c) Keep children and bystanders away while operating a power tool. Distractions can
cause you to lose control
2) ELECTRICAL SAFETY
a) 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 p/ugs and
matching outlets will reduce risk of electric shock.
b) 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.
c) Do not expose power tools to rain or wet conditions. Water entering a power tool will
increase the risk of electric shock.
d) 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.
e) 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.
0 If operating a power tool in a damp location is unavoidable, use a ground fault
circuff interrupter (GFCI) protected supply. Use of a GFC/ reduces the risk of electric
shock.
3) PERSONAL SAFETY
a) 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,
b) 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.
c) 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.
d) 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,
e) Do not overreach. Keep proper footing and balance at all times. This enables better
control of the power tool in unexpected situations.
0 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.
g) 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.
4} POWER TOOL USE AND CARE
a) 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.
b) 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.
c) Disconnect the plug from the power source andlor 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,
d) 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.
e) 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.
t) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting
edges are less likely to bind and are easier to control.
g) 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.
5) SERVICE
a) 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.
Additional Safety Instructions for Rotary Hammers
•
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,
•
Holdpower 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 other practical way to secure and support the workpiece to a stable
platform. Holding the work by hand or against your body is unstable and may lead to loss of
control
• Wear safety goggles or other eye protection. Hammering operations cause chips to
fly, Flying particles can cause permanent eye damage. Wear a dust mask or respirator for
applications that generate dust. Ear protection may be required for most applications.
• Keep a firm grip on the tool at all times. Do not attempt to operate this tool without
holding it with both hands. Operating this tool with one hand will result in loss of control.
Breaking through or encountering hard materials such as re-bar may be hazardous as well.
Tighten the side handle securely before use.
•
Do not operate this tool for long periods of time. Vibration caused by hammer action may
be harmful to your hands and arms. Use gloves to provide extra cushion and limit exposure by
taking frequent rest periods.
• Do not recondition bits yourself. Chisel reconditioning should be done by an authorized
specialist. Improperly reconditioned chisels could cause injury,
• Wear gloves when operating tool or changing bits. Accessible metal parts on the tool and
bits may get extremely hot during operation. Small bits of broken material may damage bare
hands.
• Never lay the tool down until the bit has come to a complete stop. Moving bits could
cause injury,
•
Do not strike jammed bits with a hammer to dislodge them. Fragments of metal or
material chips could dislodge and cause injury,
• Keep the power cord away from the rotating bit. Do not wrap the cord around any part
of your body. An electric cord wrapped around a spinning bit may cause personal injury and
loss of control
• Air vents often cover moving parts and should be avoided. Loose clothes, jewelry or long
hair can be caught in moving parts.
• An extension cord must have adequate wire size (AWG or American Wire Gauge) for
safety. The smaller the gauge number of the wire, the greater the capacity of the cable, that is
16 gauge has more capacity than 18 gauge. An undersized cord will cause a drop in line voltage
resulting in loss of power and overheating. When using more than one extension to make up
the total length, be sure each individual extension contains at least the minimum wire size. The
following table shows the correct size to use depending on cord length and nameplate ampere
rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the
cord.
Ampere Rating
More
Than
0
6
10
12
Not More
Than
6
10
12
16
Minimum Gauge for Cord Sets
Volts Total Length of Cord in Feet (meters)
120V 25 (7.6) 50 (15.2) 100 (30.5) 150 (45.7)
240V 50 (15.2) 100 (30.5) 200 (61.0) 300 (91.4)
AWG
18
18
16
14
16
16
16
12
16 14
14 12
14 12
Not Recommended
_ WARNING: ALWAYS use safety glasses. Everyday eyeglasses are NOT safety glasses. Also use
face or dust mask if cutting operation is dusty, ALWAYS WEAR CERTIFIED SAFETY EQUIPMENX
• ANSI Z87.1 eye protection (CAN/CSA Z94.3),
• ANSI $12.6 ($3.19) hearing protection,
• NIOSH/OSHA/MSHA respiratory protection.
_WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other
construction activities contains chemicals known to the State of California 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.
• Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling, and
other construction activities. Wear protective clothing and wash exposed areas with
soap and water. Allowing dust to get into your mouth, eyes, or lay on the skin may promote
absorption of harmful chemicals.
WARNING: Use of this tool can generate and/or disperse dust, which may cause serious and
permanent respiratory or other injury, Always use NIOSH/OSHA approved respiratory protection
appropriate for the dust exposure. Direct particles away from face and body,
_WARNING: Always wear proper personal hearing protection that conforms to ANSI
$12.6 ($3.19) during use. Under some conditions and duration of use, noise from this product
may contribute to hearing loss.
• The label on your tool may include the following symbols. The symbols and their definitions are
as follows
V..................... volts
Hz ................... hertz
min ................. minutes
- -- or DC ..... direct current
(_) ................... Class I Construction
....................... (grounded)
[] ................... Class II Construction
....................... (double insulated)
.../min ............ per minute
IPM ................. impacts per minute
SPM ............... strokes per minute
A ......................... amperes
W........................ watts
q_ or AC ............. alternating current
_-, or AC/DC ...... alternating or direct current
no ....................... no load speed
n ......................... rated speed
@ ....................... earthing terminal
,_1, ........................ safety alert symbol
BPM ................... beats per minute
RPM ................... revolutions per minute
sfpm ................... surface feet per minute
SAVE THESE INSTRUCTIONS FOR FUTURE USE
Motor
Be sure your power supply agrees with the nameplate marking. Voltage decrease of more than
10% will cause loss of power and overheating. DEWALT tools are factory tested; if this tool does
not operate, check power supply.
COMPONENTS (Fig. 1)
_, WARNING: Never modify the power tool or any part of it. Damage or personal injury could result.
A. Trigger switch (D25501, D25553, D25601, E. SHOCKS Active Vibration Control ® System
D25603, D25651) (D25651, D25601, D25603, D25831,
Toggle switch (D25831, D25851) D25851)
B. Lock-on slider (D25501, D25553, D25601, F. Mode selector
D25603, D25651) G. Electronic Speed and impact control dial
C. Side handle H. Clamp wheel
D. Main handle I. Rear side handle position
INTENDED USE
These heavy-duty rotary hammers have been designed for professional hammerdrilling, and
chipping at various work sites (i.e., construction sites). DO NOT use under wet conditions or in
presence of flammable liquids or gases.
These heavy-duty rotary hammers are professional power tools. DO NOT let children come into
contact with the tool. Supervision is required when inexperienced operators use this tool.
ASSEMBLY AND ADJUSTMENTS
_ WARNING: To reduce the risk of injury, turn unit off and disconnect it from power
source before installing and removing accessories, before adjusting or when making
repairs. An accidental start-up can cause injury,
Side Handle (Fig. 1)
D25501, D25553, D25601, D25603, D25851
_WARNING: To reduce the risk of personal injury, ALWAYS operate the tool with the side handle
properly installed and securely tightened. Failure to do so may result in the side handle slipping
during tool operation and subsequent loss of control Hold tool with both hands to maximize
control
The side handle clamps to the front barrel (collar) and may be rotated 360 ° to permit right or left-
hand use. For operating convenience, the side handle can be installed in front or rear positions.
TO MOUNT IN FRONT POSITION (FIG. 2)
1. Unscrew the side handle (C) and disassemble the side handle clamp (J).
2. Snap the steel ring (K) over the collar (L) behind the tool holder (M). Squeeze both ends of the
steel ring together. Mount the bushing (N) and insert the pin (O).
3. Slide the side handle clamp (J) onto the bushing (N) while keeping the pin (O) centered. Lightly
screw the clamp wheel (H) onto the busing (N)--do not tighten.
4. Screw the side handle (C) into the clamp knob (H) and tighten.
5. Rotate the side handle mounting assembly to the desired position. For hammerdrilling
horizontally with a heavy drill bit, place the side handle assembly at an angle of approximately
20 ° to the tool for optimum control.
6. Lock the side handle mounting assembly in place by securely tightening the clamp wheel (H)
so that the assembly will not rotate.
TO MOUNT IN REAR POSITION (FIG. 3}
1. Unscrew the side handle (C) and remove it from the side handle mounting assembly. Leave the
side handle mounting assembly in the front position.
2. Screw the side handle directly into one of the rear side handle positions (I)on either side of the
tool.
D25831, D25851 (FIG. 4}
1. Unscrew the D-shaped handle knob (R).