DEWALT D25481 Heavy Duty Rotary Hammer Instructions

: October 27, 2023
: Dewalt

DEWALT D25481 Heavy Duty Rotary Hammer

Instruction

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You have chosen a DEWALT tool. Years of experience, thorough product development and innovation make DEWALT one of the most reliable partners for professional power tool users.

Technical Data

The vibration emission level given in this information sheet has been measured in accordance with a standardized test given in EN60745 and may be used to compare one tool with another. It may be used for a preliminary assessment of exposure.

WARNING: 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 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: maintain the tool and the accessories, keep the hands warm, organisation of work patterns.

EC-Declaration of Conformity

Machinery Directive

Heavy-Duty Rotary Hammer
D25481
DEWALT declares that these products described under Technical Data are in compliance with:
2006/42/EC, EN60745-1:2009+A11:2010, EN60745-2-6:2010. These products also comply with Directive 2014/30/EU and 2011/65/EU. For more information, please contact DEWALT at the following address or refer to the back of the manual.
The undersigned is responsible for compilation of the technical file and makes this declaration on behalf of DEWALT.
Markus Rompel
Director Engineering
DEWALT, Richard-Klinger-Straße 11,
D-65510, Idstein, Germany
06.02.2016

WARNING: To reduce the risk of injury, read the instruction manual.

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.
Denotes risk of electric shock.
Denotes risk of fire.

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.
3) 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 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 jewellery. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewellery 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.
Power tool use and care
- Do not force the power tool. Use the correct power 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.

Additional Safety Instructions for Rotary Hammers

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 tool by insulated gripping surfaces, when performing an operation where the cutting accessory 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. It is recommended that the side handle be used at all times. 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.
Slightly worn chisels can be rehappened by grinding.
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.

WARNING: We recommend the use of a residual current device with a residual current rating of 30mA or less.

Residual Risks
The following risks are inherent to the use of rotary hammers:

Injuries caused by touching the rotating parts or hot parts of the tool.

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 squeezing fingers when changing the accessory.
Health hazards caused by breathing dust developed when working in concrete and/or masonry.
Risk of personal injury due to flying particles.
Risk of burns due to accessories becoming hot during operation.
Risk of personal injury due to prolonged use.

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.
Your DEWALT tool is double insulated in accordance with EN60745; therefore no earth wire is required.
If the supply cord is damaged, it must be replaced by a specially prepared cord available through the DEWALT service organisation.

Mains Plug Replacement
(U.K. & Ireland Only)
If a new mains plug needs to be fitted:

Safely dispose of the old plug.
Connect the brown lead to the live terminal in the plug.
Connect the blue lead to the neutral terminal.

WARNING: No connection is to be made to the earth terminal.
Follow the fitting instructions supplied with good quality plugs. Recommended fuse: 13 A.

Using an Extension Cable

An extension cord should not be used unless absolutely necessary. Use an approved extension cable suitable for
the power input of your charger (see Technical Data). The minimum conductor size is 1.5 mm2; the maximum length is 30 m.
When using a cable reel, always unwind the cable completely.

Package Contents

The package contains:

1 Rotary Hammer
1 Side handle
1 Instruction manual

Markings on Tool
The following pictograms are shown on the tool:

Read instruction manual before use.
Wear ear protection.
Wear eye protection.

Date Code Position (Fig. A)

The date code 10 , which also includes the year of manufacture, is printed into the housing.
Example:
2017 XX XX
Year of Manufacture
Description (Fig. A)

WARNING: Never modify the power tool or any part of it. Damage or personal injury could result.

Trigger switch
Side handle
Front Barrel (Collar)
Mode selector dial
Mode selector release button
Main handle
Bit holder
Sleeve

Intended Use

Your rotary hammer has been designed for professional rotary drilling, chiseling and chipping applications.
DO NOT use under wet conditions or in the presence of flammable liquids or gases.
Your rotary hammer is a professional power tool.
DO NOT let children come into contact with the tool. Supervision is required when inexperienced operators use this tool.

Young children and the infirm. This appliance is not intended for use by young children or infirm persons without supervision.
This product is not intended for use by persons (including children) suffering from diminished physical, sensory or mental abilities; lack of experience, knowledge or skills unless they are supervised by a person responsible for their safety. Children should never be left alone with this product.

Active Vibration Control

For best vibration control, hold the tool as described in Proper Hand Position.
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.
The hammer only needs enough pressure to engage the active vibration control. Applying too much pressure will not make the tool drill or chip faster and active vibration control will not engage.

ASSEMBLY AND ADJUSTMENTS

WARNING: To reduce the risk of serious personal injury, turn tool off and disconnect tool from power source before making any adjustments or removing/installing attachments or accessories. Be sure the trigger switch is in the OFF position. An accidental start-up can cause injury.

Side Handle (Fig. A–B)

WARNING: To reduce the risk of personal injury, ALWAYS operate the tool with the side handle properly installed. 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 2 clamps to the front of the gear case and may be rotated 360˚ to permit right- or left-hand use.
Mounting the Straight Side Handle (Fig. B)

Widen the ring opening of the side handle 2 by rotating it anti-clockwise.
Place the assembly onto the tool by the putting the nose of the tool through the steel ring 9 and onto the collar 3 past the bit holder and sleeve.
Rotate the side handle assembly to the desired position. For hammer drilling horizontally with a heavy drill bit, place the side handle assembly at an angle of approximately 20° to the tool for optimum control.
Lock the side handle mounting assembly in place by securely tightening the handle 2 rotating it clockwise so that the assembly will not rotate.

Bit and Bit Holder

WARNING: Burn Hazard. ALWAYS wear gloves when 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.
WARNING: Do not attempt to tighten or loosen drill bits (or any other accessory) by gripping the front part of the chuck and turning the tool on. Damage to the chuck and personal injury may occur.

The rotary hammer can be fitted with various chisel bits depending on the desired application. Use sharp drill bits only.
Inserting and Removing SDS Bits (Fig. C)

Pull back the locking sleeve 8 and insert the bit shank. The bit shank must be clean.
Turn the bit slightly until the sleeve snaps back into position.
Ensure the bit is properly engaged.
NOTE: The bit needs to move several centimeters in and out of the bit holder 7 when properly engaged.

To remove the bit, pull back the locking sleeve and pull the bit out.

OPERATION

Instructions for Use

WARNING: Always observe the safety instructions and applicable regulations.
WARNING : To reduce the risk of serious personal injury, turn tool off and disconnect tool from power source before making any adjustments or removing/installing attachments or accessories. Be sure the trigger switch is in the OFF position. An accidental start-up can cause injury.

Proper Hand Position (Fig. D)

WARNING: To reduce the risk of serious personal injury, ALWAYS use proper hand position as shown.
WARNING: To reduce the risk of serious personal injury, ALWAYS hold securely in anticipation of a sudden reaction.
Proper hand position requires one hand on the mounted side handle, with the other hand on the main handle.

Overload Clutch
In case of jamming of a drill bit, the drive to the drill spindle is interrupted by the overload clutch. Due to the resulting forces, always hold the tool with both hands and take a firm stance. After the overload, release and depress the trigger to re-engage drive.

Mechanical Clutch
These tools are fitted with a mechanical clutch. The indication that the clutch has activated will be an audible ratcheting together with increased vibration.
WARNING: Drill may stall if overloaded causing a sudden twist. Always expect the stall. Grip the drill firmly to control the twisting action and avoid injury.

Operation Modes (Fig. E)

WARNING: Do not select the operating mode when the tool is running.
CAUTION: Never use in Rotary Drilling or Rotary Hammering mode with a chisel bit in the bit holder. Personal injury and damage to the the tool may result.

Your tool is equipped with a mode selector dial 4 to select the mode appropriate to desired operation.

To select an operating mode:

Depress the mode selector release button 5 .
Rotate the mode selector dial so that the arrow points to the symbol corresponding for the desired mode.

NOTE: The arrow on the mode selector dial 4 must be pointing at a mode symbol at all times. There are no operable positions in between. It may be necessary to briefly run the motor after having changed from ‘hammering only’ to ‘rotary’ modes in order to align the gears.
Performing an Application (Fig. A, E)

WARNING: Always wait until the motor has come to a complete standstill before changing the direction of rotation.

Choose and install the appropriate chuck, adapter, and/or bit onto to the tool. Refer to Bit and Bit Holder.
Using the mode selector dial 4 , select the mode appropriate to desired application. Refer to
Operation Modes.
Adjust the side handle 2 as necessary.
Place the bit/chisel on the desired location.
Depress the trigger switch 1 .
To stop the hammer, release the switch.

Recommendations for Tool Operation

When drilling, always apply pressure in a straight line with the bit, but do not push hard enough to stall the motor or deflect the bit. A smooth even flow of material indicates the proper drilling rate.
Your hammer can be used for dry diamond drilling into masonry up to 100 mm. For diamond drilling above this diameter in masonry and regular large diameter diamond drilling in masonry and concrete, we advise the use of a dedicated diamond core drill. Follow the core bit or manufacturer’s recommendations for using the accessory.

NOTE: Always use core bits with integral Centre drill systems and ensure the RPM (speed) of the hammer does not exceed the maximum rated RPM of the diamond core.

Insert the Centre drill into its holder in the center of the core bit.
Remove and unplug the machine.
Remove the Centre drill from its holder.
Plug the machine in and insert the core bit into the workpiece.
WARNING:
Do not use this tool to mix or pump easily combustible or explosive fluids (benzine, alcohol, etc.).
Do not mix or stir inflammable liquids labelled accordingly.

MAINTENANCE

Your DEWALT power tool has been designed to operate over a long period of time with a minimum of maintenance. Continuous satisfactory operation depends upon proper tool care and regular cleaning.

WARNING: To reduce the risk of serious personal injury, turn tool off and disconnect tool from power source before making any adjustments or removing/installing attachments or accessories. Be sure the trigger switch is in the OFF position. An accidental start-up can cause injury.

Lubrication
Your power tool requires no additional lubrication.

Cleaning

WARNING: Blow dirt and dust out of the main housing with dry air as often as dirt is seen collecting in and around the air vents. Wear approved eye protection and approved dust mask when performing this procedure.
WARNING: Never use solvents or other harsh chemicals for cleaning the non-metallic parts of the tool. These chemicals may weaken the 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.

Optional 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. Various types of SDS-Max bits and chisels are available as
an option. Accessories and attachments used must be regularly lubricated around the SDS-Max fitment. Consult your dealer for further information on the appropriate accessories.

Protecting the Environment
Separate collection. Products and batteries marked with this symbol must not be disposed of with normal household waste.
Products and batteries contain materials that can be recovered or recycled reducing the demand for raw materials. Please recycle electrical products and batteries according to local provisions. Further information is available at www.2helpU.com.