DW005K 24V Rotary Hammer

DW005K 24V Rotary Hammer TYPE 1 Introduction Exploded Drawing Bill Of Material Repair Instructions E13120 R11222 New Parts 9 Marketing Information Main Menu August 2001 M Cook

Introduction 24 Volt heavy duty SDS-Plus combination hammer based on the existing unit DW004K but with additional chipping action and Jet stream air cooled 3.0 amp hour NiMH batteries and chargers. Launch Details Manufacturing Plant Service Parts Warehouse Launch Markets Launch Date Spennymoor Perth Avenue GB-QW September 2001 Technical Information Voltage Amp Hour Power Output No Load Speed Blows Impact energy 24 3.0 (NiMH) 2.0 (NiCAD) 460 Watts 0-1100 rpm 0-4200 bpm 2.0 joules

DW005K TYP. 1 183 179 126 129 182 114 DW005K2C 184 144 142 143 139 138 137 123 124 147 148 188 187 145 146 149 151 152 150 153 126 161 114 154 155 156 157 158 181 125 165 166 159 167 160 130 122 866 162 817 164 169 163 170 171 111 173 172 112 119 118 116 132 121 113 104 185 110 102 107 108 131 109 103 816 127 101 137 120 174 106 62 800 801 802 E13120 / 487179-00 www.2helpu.com 175 09-05-01

Black & Decker Bill of Materials - PARTS LIST Item Quantity Number Per Product Number DW005K----A Product Description ROTARY HAMMER Type Identifier TY 1 Part Number Part Description Variant Description Type Description Page 1 Market Codes 62 1 487135-00 CHARGER SA NiCAD 2.0ah GB No 62 1 487135-01 CHARGER SA NiCAD 2.0ah QW No 62 1 578672-00 CHARGER SA NiMH 3.0ah GB No 62 1 578672-01 CHARGER SA NiMH 3.0ah QW No 101 1 487132-00 ARMATURE SA No 102 1 487133-00 MAGNET SA Yes 103 1 487136-00 SWITCH SA No 104 2 487114-00 BRUSH & LEAD No 106 1 387530-02 TERMINAL BLOCK No 107 1 487154-00 BRUSH FRAME No 108 2 445860-00 BRUSH SPRING No 109 1 487086-00 KNOB No 110 2 330065-03 SCREW No 111 1 329956-01 SLIDER No 112 1 329957-01 LEVER No 113 1 329861-01 MOTOR HOUSING SA No 114 1 487100-00 COVER SA No 116 1 330003-60 BEARING No 118 1 935030 SLEEVE No 119 1 329794-00 SCREW No 120 1 329955-00 COVER No 121 1 329860-01 HANDLE COVER No 122 1 330065-08 SCREW No 123 2 329876-00 SPRING No 124 1 329948-01 BLOCK RH Yes 125 1 329948-00 BLOCK LH Yes 126 2 329950-00 BUTTON RELEASE No 127 1 330065-06 SCREW No 129 3 330065-15 SCREW No Refer to R.I.

Black & Decker Bill of Materials - PARTS LIST 126 2 329950-00 BUTTON RELEASE No 127 1 330065-06 SCREW No 129 3 330065-15 SCREW No 130 1 487088-00 INSERT No 131 1 323395-32 SPRING No 132 1 930026-01 BUMPER No 137 5 324044-02 SCREW No 138 1 323489-00 CAP No 139 1 576756-00 COLLAR No 142 1 578387-00 WASHER No 143 1 871690 SPRING No 144 1 324432-00 WASHER SA No 145 1 329941-02 GEARCASE SA No 146 1 329907-00 WASHER No 147 1 487033-00 BALL No 148 1 325880-05 PIN 3 x 23.8 No 149 1 578473-00 SPINDLE SA No 150 1 916323 SEAL 10.5 x 1.5 No 151 1 327119-00 LEVER No 152 1 323924-08 SCREW No 153 1 328809-00 COVER No 154 1 329935-00 HOUSING BEARING No 155 1 328507-00 SHIELD No 156 1 323572-00 SEAL No 157 1 323395-17 SPRING No 158 1 327081-01 PLATE No 159 1 326467-00 DETENT No 160 1 327094-01 CAM No 161 1 327093-00 FILTER No 162 1 578951-00 RAM SA No 163 1 577168-00 O RING No Page 2

Black & Decker Bill of Materials - PARTS LIST 164 1 487143-00 AXLE No 165 1 327072-00 SHIM No 166 1 323762-02 CIRCLIP No 167 1 487401-01 CLUTCH SA No 169 1 487067-00 PISTON No 170 1 323395-33 SPRING No 171 1 329937-00 INTER SHAFT SA No 172 1 324430-03 BEARING AXIAL Yes 173 1 324431-03 WASHER 7 Yes 174 1 939794-02 HANDLE SIDE SA No 175 1 875715 DEPTH STOP No 179 1 798723-11 CHUCK KEYLESS DW005K2C No 181 1 329211-00 SLEEVE No 182 1 352065 ADAPTOR DW005K2C No 183 1 945013-00 SCREW DW005K2C No 184 1 487178-00 SEAL No 185 1 329862-00 BAFFLE FAN No 187 1 577058-00 PLATE No 188 1 930553 SCREW No 800 1 870889-49 GREASE 5KG Yes 801 1 328771-03 GREASE BIT Yes 802 1 487130-02 GREASE 100 GMS No 816 1 329867-01 BRAND LABEL No 817 1 329866-02 RATING PLATE No 866 1 487134-00 BATTERY PACK NiCAD 2.0ah No 866 1 578671-01 BATTERY PACK NIMH 3.0ah No Page 3

New Parts DW005K 24V HAMMER CHIPPING Part Number Part Description 327081-01 329941-02 487401-01 577058-00 578387-00 578473-00 578671-01 578672-00 578672-01 PLATE GEARCASE SA CLUTCH SA PLATE WASHER SPINDLE SA BATTERY PACK CHARGER SA CHARGER SA Any queries please contact the European Service Support Group Martin Cook : 0044 1753 500640 Steve Hurt : 0044 1753 500830 Martin Chadwick : 0044 1753 500540 Sean Holden : 0044 1753 500583 Please DO NOT order any parts until a Service Change Note is published. 15 August 2001 P1ant: SP Page 1 of 1

R11222 BHA24K - DW004K - DW005K Cordless 24 volt Rotary Hammer Use only genuine grease (800) 870889-49 to maintain performance and reliability, it has been specially developed for these units. The unit is lubricated with approximately 60gms of grease. A special assembly grease (802) should be used when re-assembling these units, especially around the spindle (149), main gear (167) and Intershaft (171). A generous smear should be applied around all mating surfaces. The tool bit grease (801) is available in a 100 gm tube under part number 328771-03. Ensure the needle rollers on axial bearing (172) face towards washer (173) and the smooth side interfaces with intergear (171) Ensure the notches on the field magnet (102) are orientated correctly on re-assembly. If not correct, then the unit could run in reverse. Items (124 & 125) battery retainer latches are left and right hand orientated and cannot be swapped over. Static control precautions must be taken when handling the switch R11222EN.rtf

Toolnet - Product View Page 1 of 2 Product Reports Help Print this page DW005K2C 24.0 volt Heavy Duty SDS-Plus Combination Hammer Short Description Exclusive SKU: NO Representative SKU: Type: Not Set Product Sales Sheet Status: Live Launch Date: 1/13/01 Discontinued Date: Selling Proposition Powerful cordless solution for drilling anchor and fixing holes into concrete and masonry from 4 to 20 mm in diameter The most holes per charge, the most run time, the highest performance from a 24 volt platform. Impact-stop for rotary only drilling in wood, ceramic and steel etc. Rotationstop for light chiselling applications The revolutionary 57mm fan cooled motor provides performance equivalent to corded tools Optimised true electropneumatic mechanism delivers higher drilling speed and longer run time Outstanding ergonomic D-Handle design with soft grip provides a comfortable and secure grip in any http://speswebfe1/toolnet_anonymous/productview.asp?productid=95&hierarchyid=16 15/08/01

Toolnet - Product View Page 2 of 2 grip in any application Spring loaded battery latch mechanism for quicker battery change Forward, reverse and variable speed switch for smooth controllable use Modular design for easy access to key components and excellent serviceability Specifications Voltage 24.0 V Battery NiCd 2.0 Ah Power Output 460 Watts No Load Speed 0-1100 rpm Impact Energy 2.0 J Blows per Minute 0-4200 bpm Tool Holder SDS-Plus Max. Drilling Capacity [Wood] 30 mm Max. Drilling Capacity [Metal] 13 mm Max. Drilling Capacity [Concrete] 20 mm Weight 4.2 kg Length 348 mm Height 215 mm Standard Equipment 1 hour charger 2 batteries multi-position side handle 4 piece extreme SDS Plus drill bit set 13 mm keyless chuck SDS Plus adapter heavy duty carrying case http://speswebfe1/toolnet_anonymous/productview.asp?productid=95&hierarchyid=16 15/08/01

Toolnet - Product View Page 1 of 2 Product Reports Help Print this page DW005K2H 24.0 V Heavy Duty SDS-Plus Combination Hammer Short Description Exclusive SKU: NO Representative SKU: Type: Not Set Product Sales Sheet Status: Live Launch Date: 1/13/01 Discontinued Date: Selling Proposition Powerful cordless solution for drilling anchor and fixing holes into concrete and masonry from 4 to 20 mm in diameter The most holes per charge, the most run time, the highest performance from a 24 volt platform. Impact-stop for rotary only drilling in wood, ceramic and steel etc. Rotationstop for light chiselling applications The revolutionary 57mm fan cooled motor provides performance equivalent to corded tools Optimised true electropneumatic mechanism delivers higher drilling speed and longer run time Outstanding ergonomic D-Handle design with soft grip provides a comfortable and secure grip in any http://speswebfe1/toolnet_anonymous/productview.asp?productid=96&hierarchyid=16 15/08/01

Toolnet - Product View Page 2 of 2 grip in any application Spring loaded battery latch mechanism for quicker battery change Forward, reverse and variable speed switch for smooth controllable use Modular design for easy access to key components and excellent serviceability Specifications Voltage 24.0 V Battery NiMH 3.0 Ah Power Output 460 Watts No Load Speed 0-1100 rpm Impact Energy 2.0 J Blows per Minute 0-4200 bpm Tool Holder SDS-Plus Max. Drilling Capacity [Wood] 30 mm Max. Drilling Capacity [Metal] 13 mm Max. Drilling Capacity [Concrete] 20 mm Weight 4.2 kg Length 348 mm Height 215 mm Standard Equipment 1 hour charger 2 batteries multi-position side handle 4 piece extreme SDS Plus drill bit set 13 mm keyless chuck SDS Plus adapter heavy duty carrying case http://speswebfe1/toolnet_anonymous/productview.asp?productid=96&hierarchyid=16 15/08/01

Toolnet - Product Node Features View Page 1 of 1 Product Reports Help Rotary Hammers Features High drilling rate / speed and power Holes per charge Optimum performance in the key cordless hammer drilling diameters Easy engagement force (operating pressure) Effective protection for both operator an machine should the tool jam Feature And Benefits Benefits New improved PM57 motor gives this cordless hammer the same performance as its corded counterparts, driving the optimised low friction gearbox and mechanism this hammer delivers like no other The low friction transmission of the hammer means more battery power is used for drilling, less is wasted in internal losses, generating more holes per charge. The 3.0Ah NiMH Battery delivers 50% more holes per charge than a standard 2.0Ah NiCd one. The hammer configuration has been optimised for the 6-16mm range. (research has identified these as the key diameters for the cordless user) The truly Pneumatic hammer mechanism means the unit effectively drills itself, in comparison to the Bosch mechanical mechanism, the engagement and operating force is noticeably lower Safety clutch http://speswebfe1/toolnet.../productnodefeaturesview.asp?hierarchyid=16&productid=9 15/08/01

24V 3.0Ah NiMH Jetstream Battery & Charger NEW NiMH JETSTREAM System DE0241 24V, 3.0Ah NiMH Jetstream Battery DE0246 24V, NiCd + NiMH Jetstream Charger charges NiCD in appx 60 Min charges NiMH in appx 75 Min!!!! DE0245 not optimised for NiMH

24V 3.0Ah NiMH Jetstream Battery & Charger OLD NiMH JETSTREAM Components NiMH Aircooled Battery grows 12mm in length to accommodate the specially designed cooling channels OLD NEW NEW Special Mesh Material to prevent larger particles of debris from entering

24V 3.0Ah NiMH Jetstream Battery & Charger NiMH JETSTREAM Components Cool Air pressed into Battery by Charger to cool down Battery before and during the Charge in order to maintain the battery chemistry at low temperature levels Hot Air is channelled from the centre of the cells through to the vents in outer shell

24V 3.0Ah NiMH Jetstream Battery & Charger Centrifugal Fan: 0.6m 3 /min Cooling NiMH JETSTREAM Components 2.5Ah Output DE0245 remains for NiCD in 2002 DE0246 optimised for charging NIMH (+NiCD) DE0245 not capable of charging NIMH due to thermal damage The fan will turn on for appx. 6 seconds when powered from the AC mains The fan stays on during hot pack delay, fast charge, and equalization charge. Below 10 C pack temperature the fan stays off In standby the fan turns on occasionally to blow off dust

24V 3.0Ah NiMH Jetstream Battery & Charger User Needs vs. Project Scope Run Time NiMH JETSTREAM offers 50%+ capacity Cycle Life NiMH Jeststream has same battery life as NiCD Optimised Value for Money with NiMH Jetstream

24V 3.0Ah NiMH Jetstream Battery & Charger RUN TIME Introduction of 3.0 NiMH to 24V Number of 6 x 40mm Holes 160 140 120 100 80 60 40 20 0 DW005K 2.0Ah Source: typical Rotary Hammer Application drilling 6x40mm holes into hard concrete + 50%more Holes drilled per Charge with 3.0Ah NiMH DW005K 3.0Ah 50% more Capacity with 3.0Ah NiMH Jetstream Battery

24V 3.0Ah NiMH Jetstream Battery & Charger CYCLE LIFE Optimised Battery Life Life Cycle Percentages 120 100 80 60 40 20 0 Same battery cycle life of Non-Aircooled 2.0 Ah * 2.0Ah NiCD NiMH = 100%life of 2.0Ah! 3.0Ah NiMH Makita 50%of DEWALT Base 100% 2.0Ah NiCD Today Non-AC Jetstream Makita - AC * simulated life cycles with DW008 cutting 50x100mm & 100x100mm Wood must contain 75% of 1st 10A CC discharge 3.0Ah NiMH Jetstream same battery life as 2.0Ah NiCD * under hot charging condition only

24V 3.0Ah NiMH Jetstream Battery & Charger AIRCOOLED Competition Makita 1.7Ah NiMH & 3.0Ah NiMH older battery technology lower performance lower battery life higher life time cost

24V 3.0Ah NiMH Jetstream Battery & Charger AIRCOOLED Competition Makita NiCD + NiMH Aircooled Charging System Air circulates mostly around the outside of the cell packs not inside where most heat is generated

24V 3.0Ah NiMH Jetstream Battery & Charger Operation Modes OPERATION MODE LED INDICATION ACTION Pack Charging _ leave pack in charger Pack Charged goes into equalization & maintenance Temperature Delay _. _. _. charger waits for battery to cool down Defective Pack......... contact DEWALT service Tune-up Mode... _ only use occasionally (4h charge mode) Problem Powerline.......... no charge, resumes when voltage is within 195-265V/100-140V(UK) Equalization charge interval provides an additional charge to those cells in the battery s series string that may have less charge than the others at the termination of the fast charge cycle. The lower current (83mA) is prevents cell damage during this overcharge period. Maintenance mode current (63mA) overcomes self discharge of the cells in the battery pack. Battery pack removal stops all charging and returns the charger to standby mode. Tune up mode combines fast charge, equalization, maintenance into a 4h charge

24V 3.0Ah NiMH Jetstream Battery & Charger Fast Charge Mode The ID resistor in the battery pack identifies the chemistry (NiCD/NiMH) and capacity (2.0Ah/3.0Ah) of the pack. The Jetstream charger determines if a pack is hot or cool by directly interpreting the thermistor value transmitted to it via a signal terminal. NiMH Battery Packs Normal Mode Tune-up Mode Pack Temp Charge Rate Pack Temp Charge Rate hot pack charge delay hot pack charge delay 45 deg C NiMH 2.5A fast charge (Note 1) 40 deg C 2.5A fast charge (Note 1) + + X hours equalization @ 83mA X hours equalization @ 83mA + + maintenance at 63mA maintenance at 63mA 0 deg C 0 deg C cold pack charge delay cold pack charge delay

24V 3.0Ah NiMH Jetstream Battery & Charger NiCD Battery Packs Normal Mode Tune-up Mode Pack Temp Charge Rate Pack Temp Charge Rate 55 deg C hot pack charge delay hot pack charge delay 2.5A fast charge (Note 1) 45 deg C 2.5A fast charge (Note 1) + + X hours equalization @ 83mA X hours equalization @ 83mA + + maintenance at 63mA maintenance at 63mA -10 deg C -10 deg C cold pack charge delay cold pack charge delay Pack temperature limits charging on low side (continuous cold delay) Ambient temperature limits charging on the high side (continuous hot delay) As NiMH by its composition operates at a higher pack temperature range, extended hot delay & cell evaporation is only avoided by Jetstream

24V 3.0Ah NiMH Jetstream Battery & Charger Important Note to Remember User expectations are higher for 24V tools as the types of applications require more capacity out of the battery and the users cycle more often through battery packs The Jetstream battery system is a must-have to ensure optimised life-time performance of 3.0Ah NiMH Generally it is for any battery.. bad to be hot. worse to be hot and charged immediately With the Jetstream battery system it is.. best when the battery is charged immediately due to the instant cool down process

24V 3.0Ah NiMH Jetstream Battery & Charger 2002 Complete 24V Charging System We will keep 2.0Ah Non-Aircooled NiCD battery and charger along with the new 3.0Ah Aircooled NiMH battery and charger Jetstream (Aircooled) is positioned as the NiMH-Enabling Technology Non-Aircooled 2.0Ah NiCD remains as cost effective solution Access. packaging & tool manuals identify NiMH charging only with DE0246 Labels on DE0245 are changed to call out NiCD-charging only 3,0 Ah NiMH-Pack DE 0241 Aircooled Charger DE 0246 2001 & 2002 2,0 Ah NiCd-Pack DE 0240 Charger DE 0245