INSTRUCTION MANUAL D25901-XE, D25941-XE DEMOLITION HAMMERS FIG. 1 C D25901 E D A B D25941 E D A B F 1. WORK AREA a. Keep work area clean and well lit. Cluttered and 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 plugs 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. 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 safety equipment. Always wear eye protection. Safety equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries. c. Avoid accidental starting. Ensure the switch is in the off position before plugging in. Carrying power tools with your finger on the switch or plugging in power tools that have the switch on invites accidents. 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. CAUTION: Used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL, CALL US AT: 1800 654 155 (Aust) or 09 259 1111 (NZ). SAFETY INSTRUCTIONS FOR POWER TOOLS When using power tools, always observe the safety regulations applicable in your country to reduce the risk of fire, electric shock and personal injury. Read the following safety instructions before attempting to operate this product. Keep these instructions in a safe place. General Safety Rules WARNING! Read all instructions. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury. The term “power tool” in all of the warnings listed below refers to your mains operated (corded) power tool or battery operated (cordless) power tool. SAVE THESE INSTRUCTIONS 1 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. f. Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewellery 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 these devices 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 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 tools operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools. f. 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 and in the manner intended for the particular type of power tool, 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. Electrical Safety The electric motor has been designed for one voltage only. Always check that the power supply corresponds to the voltage on the rating plate. 240 V AC means your tool will operate on alternating current. As little as 10% lower voltage can cause loss of power and can result in overheating. All DEWALT tools are factory tested; if this tool does not operate, check the power supply. Your DEWALT tool is double insulated, therefore no earth wire is required. • Young children and the infirm. This appliance is not intended for use by young children or infirm persons without supervision. Young children should be supervised to ensure that they do not play with this appliance. • Replacement of the supply cord. If the supply cord is damaged, it must be replaced by the manufacturer or an authorised DEWALT Service Centre in order to avoid a hazard. Extension Cords CAUTION: Use only extension cords that are approved by the country’s Electrical Authority. Before using extension cords, inspect them for loose or exposed wires, damaged insulation and defective fittings. Replace the cord if necessary. MINIMUM GAUGE FOR CORD SETS For Cable length (m): 7.5 15 25 30 45 60 Use Cable with minimum rating (Amperes) Tool Amperes 0 - 3.4 7.5 7.5 7.5 7.5 7.5 7.5 3.5 - 5.0 7.5 7.5 7.5 7.5 10 15 5.1 - 7.0 10 10 10 10 15 15 7.1 - 12.0 15 15 15 15 20 20 12.1 - 20.0 20 20 20 20 25 – 2 Safety Warnings for Impact demolition hammers • lead from lead-based paints, • crystalline silica from bricks and cement and other masonry products, and • arsenic and chromium from chemically-treated lumber (CCA). 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 disburse 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 S12.6 (S3.19) 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 A ...............amperes Hz .................. hertz W ..............watts min ................ minutes ...........alternating current ........... direct current ...........alternating or direct current no ..............no load speed ................. Class I Construction ...................... (grounded) .............earthing terminal ................. Class II Construction .............safety alert symbol ...................... (double insulated) BPM ..........beats per minute …/min ........... per minute RPM ..........revolutions per minute • Wear ear protectors. Exposure to noise can cause hearing loss. • Use auxiliary handles 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. Contacting a “live” wire may make exposed metal parts of the tool “live” and shock the operator. • Be certain that the material being drilled does not conceal electric or gas service and that their locations have been verified with the utility companies. • 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. • Ensure the chisel is secured in place before operating the tool. • In cold-weather conditions or when the tool has not been used for a longer period of time, let the tool run with no load for several minutes before use. • When working above ground level ensure the area below is clear. • Do not touch the chisel or the parts close to the chisel immediately after operation, as they may be extremely hot and cause burns to the skin. • Always direct the power cable to the rear, away from the chisel. • Do not operate this tool for long periods of time. Vibration caused by tool action may be harmful to your hands and arms. Use gloves to provide extra cushion and limit exposure by taking frequent rest periods. 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 EQUIPMENT: • ANSI Z87.1 eye protection (CAN/CSA Z94.3), • ANSI S12.6 (S3.19) 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 cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are: SAVE THESE INSTRUCTIONS FOR FUTURE USE 3 COMPONENTS (FIG. 1) Active Vibration Control WARNING: Never modify the power tool or any part of it. Damage or personal injury could result. A. On/off switch B. Rear handle C. Electronic impact energy control dial (D25901 only) D. Chisel position index collar E. Tool holder/sleeve F. Side handle INTENDED USE The D25901 and D25941 heavy-duty demolition hammers are designed for professional demolition, chipping and chasing applications in concrete, brick, stone and other masonry materials. DO NOT use under wet conditions or in presence of flammable liquids or gases. These heavy-duty demolition hammers are professional power tools. DO NOT let children come into contact with the tool. Supervision is required when inexperienced operators use this tool. D25901, D25941 The active vibration control neutralizes rebound vibration from the hammer mechanism. Lowering hand and arm vibration, it allows more comfortable use for longer periods of time and extends the life of the unit. Electronic Impact Energy Control Dial D25901 ONLY (FIG. 1) The electronic impact energy control dial (C) offers optimal tool control for precise chiselling with minimal break-out when chiselling soft or brittle materials. It also allows the use of smaller accessories without risk of breakage. ASSEMBLY AND ADJUSTMENT WARNING: Prior to assembly and adjustment always unplug the tool. WARNING: Always wear gloves when changing accessories. The exposed metal parts on the tool and accessory may become extremely hot during operation. WARNING: Since accessories, other than those offered by DEWALT, have not been tested with this product, use of such accessories with this tool could be hazardous. To reduce the risk of injury, only DEWALT, recommended accessories should be used with this product. CAUTION: To reduce dust contamination in the tool, keep dust and debris away from the bit and the beat piece. Residual Risks • In spite of the application of the relevant safety regulations and the implementation of safety devices, certain residual risks cannot be avoided. These are: – Impairment of hearing. – Risk of dust inhalation. – Risk of personal injury due to prolonged use. – Risk of burns due to accessories becoming hot during operation. Inserting and Removing SDS-max® Accessories CAUTION: To reduce the risk of tool damage, only use SDS max shank accessories with the D25901. D25901 (FIG. 2, 3) This machine uses SDS-max® chisels (refer to the inset in Figure 3 for a cross-section of a chisel shank). 1. Clean and grease the chisel shank. CAUTION: Do not apply lubricant to the machine. Soft Start Feature D25901, D25941 The soft start feature allows the impact rate to build up more slowly, thus preventing the chisel or point from “bouncing” around on the masonry when starting up. 4 FIG. 2 FIG. 3 D25941 FIG. 5 FIG. 4 D25901 H 19 mm D25901 D25941 E E G 2. Insert the chisel shank into the tool holder/sleeve (E). Press and turn the chisel slightly until the sleeve snaps into position. 3. Pull on the chisel to check if it is properly locked. The hammering function requires the chisel to be able to move axially several centimeters when locked in the tool holder. 4. To remove a chisel, pull back the tool holder/sleeve (E) and pull the chisel out of the tool holder. 4. To remove a chisel, pull back the tool holder/sleeve (E) and pull the chisel out of the tool holder. Indexing the Chisel Position (Fig. 6) The chisel can be indexed and locked into 12 different positions. 1. Insert the chisel as described above. 2. Rotate the chisel position collar (D) in the direction of the arrow until the chisel is in the desired position. Inserting and Removing 19 mm Hex Accessories CAUTION: To reduce the risk of tool damage, only use 19 mm (3/4") hex shank accessories with the D25941. D25941 (FIG. 4, 5) This machine uses chisels with a 19 mm hex shank (refer to the inset in Figure 5 for a cross-section of a chisel shank). 1. Clean and grease the chisel shank. CAUTION: Do not apply lubricant to the machine. 2. Pull back the tool holder/sleeve (E), align the groove (G) with the yellow marker (H) and insert the chisel shank into the tool holder. Release the locking sleeve. 3. Pull on the chisel to check if it is properly locked. The hammering function requires the chisel to be able to move axially several centimetres when locked in the tool holder. FIG. 6 D 5 Setting the Electronic Impact Energy Control Dial 4. Slide and rotate the side handle to the desired position. 5. Lock the side handle in place by tightening the clamp knob (J). D25901 (FIG. 1) Turn the dial (C) to the desired level. The higher the number, the greater the impact energy. With dial settings from 1 (low) to 7 (full power) the tool is extremely versatile and adaptable for many different applications. The required setting is a matter of experience, for example: • when chiselling soft, brittle materials or when minimum break-out is required, set the dial to 1 or 2 (low); • when breaking harder materials, set the dial to 7 (full power). Instructions for Use WARNING: Always observe the safety instructions and applicable regulations. WARNING: Be aware of the location of pipework and wiring. WARNING: Apply a pressure of approx. 20–30 kg. (44–66 lbs.) to the tool. Excessive force does not speed up chiselling but decreases tool performance and may shorten tool life. Switching On and Off (Fig. 1) Fitting and Adjusting the Side Handle (Fig. 7) To turn the tool on, set the on/off switch (A) to position 1. To turn the tool off, set the on/off switch (A) to position 0. The side handle (F) can be mounted on the front of the machine to suit both right- and left-hand users. WARNING: Always operate the machine with the side handle properly mounted. 1. Unscrew the side handle clamp knob (J). 2. Slide the side handle assembly onto the machine locating the steel ring (I) in the mounting area (X). The correct position of the side handle is between head and middle of the tube. 3. Adjust the side handle (F) to the desired angle. Demolition, Chasing and Channelling (Fig. 1) WARNING: Ensure that the cutting edge does not show discoloration caused by too much pressure. This may impair the hardness of the accessory. Various types of chisels are available as an option. 1. Select the appropriate chisel. Clean and grease its shank. 2. Insert the chisel and check whether it is properly locked. 3. Set the desired impact energy level. 4. Fit and adjust the side handle (F) and make sure it is firmly tightened. 5. Hold the tool at both handles (B, F) and switch on. The tool now runs in continuous operation. 6. Always switch off the tool when work is finished and before unplugging. FIG. 7 F MAINTENANCE WARNING: To reduce the risk of serious personal injury, turn tool off and disconnect battery pack before making any adjustments or removing/installing attachments or accessories. Lubrication Your power tool requires no additional lubrication. I J 6 Cleaning For warranty repair information, call (AUS) 1800 654 155 or (NZ) 09 259 1111. This warranty does not apply to • Accessories • Damage caused where repairs have been made or attempted by others. • Damage due to misuse, neglect, wear and tear, alteration or modification. This warranty gives you specific legal rights and you may have other rights under the provisions of the Consumer Guarantee Act 1993 (New Zealand only), Trade Practices Act 1974 and State Legislation (Australia only). In addition to the warranty, DEWALT tools are covered by our: FREE ONE YEAR SERVICE CONTRACT DEWALT will also maintain the tool for free at any time during the first year of purchase. This includes labour, parts and lubrication required to restore the product to sound mechanical and/or electrical condition. Normal wear parts are not covered in this service. Carbon brushes worn more then 50% will be replaced. NOTE: Three Year Warranty is not applicable to items deemed as consumables. Radial arm saws are covered by a one (1) year warranty only. DEWALT Reserves the right to review its warranty policy prior to launch of any new business development products. 30 DAY NO SATISFACTION GUARANTEE If you are dissatisfied with any DEWALT power tool, laser or nailer, for any reason, simply return it to the point of purchase with your sales receipt within 30 days for a replacement unit or a full refund. FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are missing, call (AUS) 1800 654 155 or (NZ) 09 259 1111 for a free replacement. WARNING: Blow dirt and dust out of all air vents with clean, dry air at least once a week. To minimize the risk of eye injury, always wear ANSI Z87.1 approved eye protection when performing this. WARNING: Never use solvents or other harsh chemicals for cleaning the non-metallic parts of the tool. These chemicals may weaken the plastic materials used in these parts. Use a cloth dampened only with water and mild soap. Never let any liquid get inside the tool; never immerse any part of the tool into a liquid. Repairs To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including brush inspection and replacement) should be performed by certified service centers or other qualified service organizations, always using identical replacement parts. ACCESSORIES WARNING: Since accessories, other than those offered by DEWALT, have not been tested with this product, use of such accessories with this tool could be hazardous. To reduce the risk of injury, only DEWALT, recommended accessories should be used with this product. Recommended accessories for use with your tool are available at extra cost from your local service center. If you need any assistance in locating any accessory, please contact DEWALT Industrial Tool Co., 20 Fletcher Road, Mooroolbark, VIC 3138 Australia or call 1800 654 155 or (NZ) 09 259 1111. Guarantee Applicable to hand held Power Tools, Lasers and Nailers. Three Year Limited Warranty DEWALT will repair, without charge, any defects due to faulty materials or workmanship for three years from the date of purchase. Please return the complete unit, transportation prepaid, to any DEWALT Service Centre, or any authorised service station. 7 8 9 DEWALT Industrial Tool Co., 20 Fletcher Road, Mooroolbark, VIC 3138 Australia (03 8720 5100) • 5 Te Apunga Place, Mt Wellington, New Zealand (09 259 1111) (FEB08) Part No. 1006463-04 D25901-XE, D25941-XE Copyright © 2008 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.