Milwaukee SDS MAX Rotary Hammers and Demolition Hammers Operator's Manual

Models: 5426-21, 5446-21

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

Electrical Safety

Personal Safety

Power Tool Use and Care

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.

Specific Safety Rules for Rotary Hammer

Specifications

Cat. No.5426-215446-21
Volts120 AC120 AC
Amps1414
No Load BPM2200 / 28402200 / 2840
Shank typeSDS MaxSDS Max
No Load RPM350 / 450N/A
Carbide Tipped Percussion Bit (concrete)1-3/4"N/A
Percussion Core Bit (concrete/brick)4-1/2" / 6"N/A

Functional Description

The rotary hammer has the following parts:

Symbology

Extension Cords

Grounded tools require a three-wire extension cord. Double insulated tools can use either a two or three-wire extension cord. As the distance from the supply outlet increases, you must use a heavier gauge extension cord. Using extension cords with inadequately sized wire causes a serious drop in voltage, resulting in loss of power and possible tool damage. Refer to the table shown to determine the required minimum wire size.

The smaller the gauge number of the wire, the greater the capacity of the cord. For example, a 14 gauge cord can carry a higher current than a 16 gauge cord. When using more than one extension cord to make up the total length, be sure each cord contains at least the minimum wire size required. If you are using one extension cord for more than one tool, add the nameplate amperes and use the sum to determine the required minimum wire size.

Guidelines for Using Extension Cords

Recommended Minimum Wire Gauge For Extension Cords*
Nameplate AmpsExtension Cord Length
25'50'75'100'150'
0 - 2.01818181816
2.1 - 3.41818181614
3.5 - 5.01818161412
5.1 - 7.01816141212
7.1 - 12.016141210--
12.1 - 16.0141210----
16.1 - 20.01210------

* Based on limiting the line voltage drop to five volts at 150% of the rated amperes.

READ AND SAVE ALL INSTRUCTIONS FOR FUTURE USE.

Grounding

WARNING: Improperly connecting the grounding wire can result in the risk of electric shock. Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded. Do not modify the plug provided with the tool. Never remove the grounding prong from the plug. Do not use the tool if the cord or plug is damaged. If damaged, have it repaired by a MILWAUKEE service facility before use. If the plug will not fit the outlet, have a proper outlet installed by a qualified electrician.

Grounded Tools (Three-Prong Plugs)

Tools marked "Grounding Required" have a three-wire cord and three-prong grounding plug. The plug must be connected to a properly grounded outlet (See Figure A). If the tool should electrically malfunction or break down, grounding provides a low-resistance path to carry electricity away from the user, reducing the risk of electric shock.

The grounding prong in the plug is connected through the green wire inside the cord to the grounding system in the tool. The green wire in the cord must be the only wire connected to the tool's grounding system and must never be attached to an electrically "live" terminal.

Your tool must be plugged into an appropriate outlet, properly installed and grounded in accordance with all codes and ordinances. The plug and outlet should look like those in Figure A.

Double Insulated Tools (Two-Prong Plugs)

Tools marked "Double Insulated" do not require grounding. They have a special double insulation system which satisfies OSHA requirements and complies with the applicable standards of Underwriters Laboratories, Inc., the Canadian Standard Association and the National Electrical Code. Double Insulated tools may be used in either of the 120 volt outlets shown in Figures B and C.

Assembly

WARNING: To reduce the risk of injury, always unplug tool before changing or removing accessories. Only use accessories specifically recommended for this tool. Others may be hazardous.

To reduce the risk of injury, always use a side handle when using this tool. Always brace or hold securely.

Adjusting the Side Handle Position

  1. Loosen the side handle by unscrewing the side handle grip (5426-21) or ball (5446-21) until the side handle rotates freely.
  2. Rotate the side handle to the desired position.
  3. Tighten the side handle grip or ball securely.

Moving the Side Handle (Cat. No. 5426-21)

  1. Remove the side handle by unscrewing the side handle grip until it comes free.
  2. Screw the side handle into the alternate location.
  3. Tighten the side handle grip securely.

Setting the Depth Gauge

  1. Press in the clamp lever.
  2. Slide the depth gauge rod backward or forward until it is set for the desired depth. NOTE: The drilling depth is the distance between the tip of the bit and the tip of the depth gauge rod.
  3. Release the clamp lever.

WARNING: To reduce the risk of injury, do not grasp the bit while the chuck is rotating or while the bit is falling from the chuck.

Installing Drill Bits and Chisels

Be sure that the shank of the bit is clean. Dirt particles may cause the bit to line up improperly. Do not use bits larger than the maximum recommended capacity of the drill because gear damage or motor overloading may result. For best performance, be sure that the bit is properly sharpened and the shank is lightly greased before use.

SDS Drive System

NOTE: Only use accessories with SDS Max shanks.

  1. Unplug the tool.
  2. Lightly grease the bit or chisel shank.
  3. Insert the bit or chisel into the nose of the tool.
  4. Rotate bit slowly until it aligns with the locking mechanism.
  5. Push bit into tool until it locks.
  6. Check that the bit is locked properly; it should be possible to pull the bit back and forth slightly (about 1/4").
  7. To remove bits and chisels, pull bit holder toward the rear of tool and remove bit. NOTE: Use caution when handling hot bits and chisels.

Operation

WARNING: To reduce the risk of injury, always unplug tool before attaching or removing accessories or making adjustments. Use only specifically recommended accessories. Others may be hazardous.

Electronic Feedback Control Circuit

These hammers have an Electronic Feedback Control Circuit (EFCC) which helps improve the operation and life of the tool. It allows the tool to maintain constant speed and torque between no-load and load conditions.

Soft Start

The Soft-Start feature reduces the amount of torque reaction at startup to the tool and the user. This feature gradually increases the motor speed up from zero to the top no-load speed.

WARNING: To reduce the risk of injury, when using chisels or other hammering-only accessories, the action selector must be set to the "hammering only" position.

Selecting Mode

  1. For hammering with rotation, turn the selector lever to display the hammer and twist drill symbols. (Not available on Cat. No. 5446-21)
  2. For hammering only, turn the selector lever to display the hammer symbol. (See "Selecting Hammering Speed")
  3. To freely rotate the bit to the desired angle for chiseling only, turn the selector lever to display the 0 symbol.

Selecting Hammering Speed

  1. To increase the Hammering speed (2840 blows per second), move the hammer speed control selector to the large hammer. Use the high hammer speed for harder materials, such as concrete.
  2. To decrease the Hammering speed (2200 blows per second), move the hammer speed control selector to the small hammer. Use the low hammer speed for softer materials, such as brick.

Starting and Stopping

  1. Insert the accessory.
  2. Select the mode and hammering speed.
  3. Position the tool on the workpiece.
  4. Grasp both handles firmly (trigger handle and either the spade handle or straight handle).
  5. To start the tool, grasp the handles firmly and pull the trigger. Always hold the tool securely using two handles and maintain control.
  6. Use only enough pressure to hold the tool in place, engage the hammering mechanism, and prevent the tip of the chisel from wandering. This tool has been designed to achieve top performance with only moderate pressure. Let the tool do the work. NOTE: To engage the hammering mechanism, maintain pressure on the bit/chisel. When pressure is released, hammering stops.
  7. To stop the tool, release the trigger. Make sure the tool comes to a complete stop before laying the tool down.

Chiseling

When chiseling or chipping, hold the tool at an angle to the work area. For best performance, work from a corner or close the edge of the work and break off a small area at a time.

Drilling

When drilling deep holes, the speed may begin to drop off. Pull the bit partially out of the hole while the tool is running to help clear dust.

NOTE: Do not use water to settle the dust since it will clog the bit flutes and tend to make the bit bind in the hole.

If a bit binds:

If the bit should bind, a built-in, nonadjustable slip clutch prevents the bit from turning when the tool is held or braced securely. If this occurs:

  1. Turn off and unplug the tool.
  2. Free the bit from the workpiece.
  3. Clear debris from the hole.
  4. Begin drilling again.

If a hammer iron gets stuck:

  1. Unplug the tool.
  2. Pull out bit lock and rotate it 180°.
  3. Pull the tool off of the stuck accessory.
  4. Remove the accessory from the workpiece.

Locking Trigger (Cat. No. 5446-21 only)

  1. To lock on the trigger, pull the trigger and press the lock button. Release the trigger.
  2. To unlock the trigger, pull and release the trigger.

Power and Service Indicators

When the tool is plugged in, the Power Indicator will light. Unplug the tool before changing accessories or making adjustments. When the tool is in need of service (for example, brushes need to be changed), the Service Indicator will light. Stop using the tool and return it to the nearest MILWAUKEE service facility for repairs.

Operating and Operator Force

Position the tool, grasp the handles firmly and pull the trigger. Always hold the tool securely using both handles to maintain control. These hammers feature the Anti-Vibration System to provide the operator with comfort without sacrificing power or performance. Insulating elements absorb vibration when hammering and drilling. Ideal operator force compresses the handle slightly and allows the tool to work aggressively while the handle provides maximum vibration dampening. Excessive operator force compresses the handle too far and reduces the vibration dampening. Users will be able to feel the difference and should adjust the force to the handle accordingly.

A smooth, even flow of dust indicates the proper drilling rate. If the speed begins to drop off when drilling large or deep holes, pull the bit partially out of the hole while the tool is running to help clear dust. Do not use water to settle the dust since it will clog the bit flutes and tend to make the bit bind in the hole. If the bit should bind, a built-in, non-adjustable slip clutch prevents the bit from turning. If this occurs, stop the tool, free the bit and begin again. Do not let the bit spin in the hole without cutting. Do not attempt to drill through steel reinforcing rods. Both actions will damage the carbide.

Cold Hammering

If the hammer is stored for a long period of time or at cold temperatures, the lubrication may become stiff and the tool may not hammer initially or the hammering may be weak. If this happens:

  1. Insert a chisel into the tool.
  2. Pull the trigger and apply the chisel against a scrap piece of concrete.
  3. Turn the tool On and Off every few seconds. After 15 seconds to 2 minutes, the tool will start hammering normally. The colder the hammer is, the longer it will take to warm up.

WARNING: Use MILWAUKEE core bits. Do not use LHS (Large Hole System) Components with these rotary hammers. The bits could fail, breaking apart at the threaded stud and causing injury and property damage.

Using Rotary Percussion Core Bits

Core bits are useful for drilling larger holes for conduit and pipe. MILWAUKEE Heavy-Duty Core Bits have heat-treated steel bodies with durable carbide tips. These core bits are specially designed for fast, accurate drilling with combined hammering and rotary action.

  1. Clean and lubricate the threads on the adapter and core bit to make later removal easier. Screw the threaded end of the adapter into the rear of the core bit.
  2. Push the guide plate onto the pointed end of the center pin. Insert the center pin and guide plate assembly into the core bit. Be sure the small end of the center pin is securely placed into the hole in the center of the core bit.
  3. Insert the adapter into the nose of the tool. Set the action selector to the hammering with rotation setting.
  4. Press the center pin firmly against your center mark, hold the tool firmly and pull the trigger. NOTE: If a center pin and guide plate are not available, use a template or notched board to start the hole.
  5. After drilling to about the depth of the core bit teeth, remove the center pin and guide plate from the core bit. Resume drilling.
  6. To change the core bit, hold the tool upwards, pointing it away from your body, and run the tool allowing rotation and impacting for about five seconds to loosen the core bit from the adapter shank. NOTE: To make deeper holes, remove the core bit, break and remove the core. Resume drilling. When drilling long or deep holes, after each inch of penetration pull the bit partially out of the hole while the tool is running, to help clear dust from the bit flutes. Dust can clog the bit flutes and can make the bit bind in the hole. If this occurs, stop the tool, free the bit and begin again.

Drilling Large Diameter Holes with Core Bits

When drilling holes with large diameter core bits, dust may build up in the cut and can cause the tool to stall, bind, or cut slowly. By creating an opening for the dust to escape, drilling time, bit stress, and tool stress can be reduced.

  1. Start the cut as normal.
  2. Once the bit is firmly established in the cut (about 1/4" deep), remove the bit from the cut.
  3. Remove the bit from the tool.
  4. Install a standard fluted bit, approximately 7/8" in diameter, onto the tool.
  5. Drill a perpendicular hole through the kerf of the large hole.
    • Depending on the location of the work, the hole should either break through the other side of the hole/floor or extend 4"-5" past the end of the workpiece (such as into the dirt below a concrete slab).
    • If dust builds up in the hole, vacuum it out and continue drilling.
    • If drilling through a wall, the hole for dust should be drilled on the lowest part of the large hole kerf as the dust will fall there when drilling and can be evacuated more easily.
  6. Reinstall the core bit and continue drilling. Dust and debris will fall through the hole and optimize the cutting ability of the bit.

NOTE: If unable to drill a hole in the kerf, pull back on the bit with the hammer running. This will remove some of the dust and debris from the cut. Repeat this for every inch of drilling. If necessary, vacuum dust and debris from the cut and surrounding area.

7. For core bits, once the maximum core bit depth is drilled, the core must be broken and removed:

Maintenance

WARNING: To reduce the risk of injury, always unplug the tool before performing any maintenance. Never disassemble the tool. Contact a MILWAUKEE service facility for ALL repairs.

Maintaining Tools

Keep your tool in good repair by adopting a regular maintenance program. Inspect your tool for issues such as undue noise, misalignment or binding of moving parts, breakage of parts, or any other condition that may affect the tool operation. Return the tool to a MILWAUKEE service facility for repair. After six months to one year, depending on use, return the tool to a MILWAUKEE service facility for inspection.

WARNING: To reduce the risk of personal injury, electric shock and damage, never immerse your tool in liquid or allow a liquid to flow inside it.

Cleaning

Clean dust and debris from vents. Keep handles clean, dry and free of oil or grease. Use only mild soap and a damp cloth to clean, since certain cleaning agents and solvents are harmful to plastics and other insulated parts. Some of these include gasoline, turpentine, lacquer thinner, paint thinner, chlorinated cleaning solvents, ammonia and household detergents containing ammonia. Never use flammable or combustible solvents around tools.

Repairs

For repairs, return the tool to the nearest service center.

Accessories

WARNING: Use only recommended accessories. Others may be hazardous.

For a complete listing of accessories, go online to www.milwaukeetool.com or contact a distributor.

Service Information

Service - United States

1-800-SAWDUST (1.800.729.3878)
Monday-Friday, 7:00 AM - 6:30 PM CST
or visit www.milwaukeetool.com

Contact Corporate After Sales Service Technical Support with technical, service/repair, or warranty questions.

Email: metproductsupport@milwaukeetool.com

Become a Heavy Duty Club Member at www.milwaukeetool.com to receive important notifications regarding your tool purchases.

Service - Canada

Milwaukee Tool (Canada) Ltd
1.800.268.4015
Monday-Friday, 7:00 AM - 4:30 PM CST
or visit www.milwaukeetool.ca

Limited Warranty

USA & CANADA

Every MILWAUKEE power tool* (see exceptions below) is warranted to the original purchaser only to be free from defects in material and workmanship. Subject to certain exceptions, MILWAUKEE will repair or replace any part on an electric power tool which, after examination, is determined by MILWAUKEE to be defective in material or workmanship for a period of five (5) years** after the date of purchase unless otherwise noted. Return of the power tool to a MILWAUKEE factory Service Center location or MILWAUKEE Authorized Service Station, freight prepaid and insured, is required. A copy of the proof of purchase should be included with the return product. This warranty does not apply to damage that MILWAUKEE determines to be from repairs made or attempted by anyone other than MILWAUKEE authorized personnel, misuse, alterations, abuse, normal wear and tear, lack of maintenance, or accidents.

Normal Wear: Many power tools need periodic parts replacement and service to achieve best performance. This warranty does not cover repair when normal use has exhausted the life of a part including, but not limited to, chucks, brushes, cords, saw shoes, blade clamps, o-rings, seals, bumpers, driver blades, pistons, strikers, lifters, and bumper cover washers.

*This warranty does not cover Air Nailers & Staplers; Airless Paint Sprayer; Cordless Battery Packs; Gasoline Driven Portable Power Generators; Hand Tools; Hoist - Electric, Lever & Hand Chain; M12™ Heated Gear; Reconditioned Product; and Test & Measurement Products. There are separate and distinct warranties available for these products.

**The warranty period for Job Site Radios, M12™ Power Port, M18™ Power Source, Jobsite Fan and Trade Titan™ Industrial Work Carts is one (1) year from the date of purchase. The warranty period for the Drain Cleaning Cables is two (2) years from the date of purchase. The warranty period for the M18™ Compact Heat Gun and the 8 Gallon Dust Extractor is three (3) years from the date of purchase. The warranty period for the LED in the LED Work Light and the LED Upgrade Bulb for the Work Light is the lifetime of the product subject to the limitations above. If during normal use the LED or LED Bulb fails, the part will be replaced free of charge.

Warranty Registration is not necessary to obtain the applicable warranty on a MILWAUKEE power tool product. The manufacturing date of the product will be used to determine the warranty period if no proof of purchase is provided at the time warranty service is requested.

ACCEPTANCE OF THE EXCLUSIVE REPAIR AND REPLACEMENT REMEDIES DESCRIBED HEREIN IS A CONDITION OF THE CONTRACT FOR THE PURCHASE OF EVERY MILWAUKEE PRODUCT. IF YOU DO NOT AGREE TO THIS CONDITION, YOU SHOULD NOT PURCHASE THE PRODUCT. IN NO EVENT SHALL MILWAUKEE BE LIABLE FOR ANY INCIDENTAL, SPECIAL, CONSEQUENTIAL OR PUNITIVE DAMAGES, OR FOR ANY COSTS, ATTORNEY FEES, EXPENSES, LOSSES OR DELAYS ALLEGED TO BE AS A CONSEQUENCE OF ANY DAMAGE TO, FAILURE OF, OR DEFECT IN ANY PRODUCT INCLUDING, BUT NOT LIMITED TO, ANY CLAIMS FOR LOSS OF PROFITS. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES, WRITTEN OR ORAL. TO THE EXTENT PERMITTED BY LAW, MILWAUKEE DISCLAIMS ANY IMPLIED WARRANTIES, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE OR PURPOSE; TO THE EXTENT SUCH DISCLAIMER IS NOT PERMITTED BY LAW, SUCH IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THE APPLICABLE EXPRESS WARRANTY AS DESCRIBED ABOVE. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

This warranty applies to product sold in the U.S.A. and Canada only. Please consult the 'Service Center Search' in the Parts & Service section of MILWAUKEE's website www.milwaukeetool.com or call 1.800.SAWDUST (1.800.729.3878) to locate your nearest service facility for warranty and non-warranty service on a Milwaukee electric power tool.

Mexico, Central America & Caribbean

TECHTRONIC INDUSTRIES' warranty is for 5 years since the original purchase date. This warranty card covers any defect in material and workmanship on this Product. To make this warranty valid, present this warranty card, sealed/stamped by the distributor or store where you purchased the product, to the Authorized Service Center (ASC). Or, if this card has not been sealed/stamped, present the original proof of purchase to the ASC. Call toll-free 01 (800) 030-7777 to find the nearest ASC, for service, parts, accessories or components.

Procedure to make this warranty valid: Take the product to the ASC, along with the warranty card sealed/stamped by the distributor or store where you purchased the product, and any faulty piece or component will be replaced without cost for you. We will cover all freight costs relative with this warranty process.

Exceptions: This warranty is not valid in the following situations:

Note: If cord set is damaged, it should be replaced by an Authorized Service Center to avoid electric risks.

SERVICE AND ATTENTION CENTER: Call 01 (800) 030-7777

IMPORTED AND COMMERCIALIZED BY TECHTRONIC INDUSTRIES MEXICO, SA DE CV Av President Masarik #29 piso 7, Col. Polanco V Sección CP 11560, Deleg. Miguel Hidalgo, CDMX

Model: _________________________ Date of Purchase: _________________________ Distributor or Store Stamp: _________________________

Models: 5426-21, 5446-21, 5426-21 SDS Max Rotary Hammer, SDS Max Rotary Hammer, Rotary Hammer, Hammer

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