DeWalt DW005K Manual 

Exploded Drawing E13120 Repair Instructions R11222 New Parts 9 Marketing Information Main Menu DW005K 24V Rotary Hammer TYPE 1

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

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

Page 1 Product Number DW005K----A Product Description ROTARY HAMMER Type Identifier TY 1 Item Number Quantity Per Part Number Part Description Variant Description Type Description Market Codes Refer to R.I. 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

Page 2 126 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 3 164 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

DW005K Part Number Part Description PLATE 327081-01 GEARCASE SA 329941-02 CLUTCH SA 487401-01 PLATE 577058-00 WASHER 578387-00 SPINDLE SA 578473-00 BATTERY PACK 578671-01 CHARGER SA 578672-00 CHARGER SA 578672-01 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 15 August 2001 Page 1 of 1 P1ant: SP Please DO NOT order any parts until a Service Change Note is published.

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

Page 1 of 2 http://speswebfe1/toolnet_anonymous/ProductView.asp?ProductID=95&HierarchyID=16 15/08/01 Print this page DW005K2C Product Sales Sheet 24.0 volt Heavy Duty SDS-Plus Combination Hammer Short Description Exclusive SKU: NO Representative SKU: Type: Not Set 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. Rotation- stop for light chiselling applications The revolutionary 57mm fan cooled motor provides performance equivalent to corded tools Optimised true electro- pneumatic 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 Product | Reports | Help |

Page 2 of 2 http://speswebfe1/toolnet_anonymous/ProductView.asp?ProductID=95&HierarchyID=16 15/08/01 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

Page 1 of 2 http://speswebfe1/toolnet_anonymous/ProductView.asp?ProductID=96&HierarchyID=16 15/08/01 Print this page DW005K2H Product Sales Sheet 24.0 V Heavy Duty SDS-Plus Combination Hammer Short Description Exclusive SKU: NO Representative SKU: Type: Not Set 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. Rotation- stop for light chiselling applications The revolutionary 57mm fan cooled motor provides performance equivalent to corded tools Optimised true electro- pneumatic 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 Product | Reports | Help |

Page 2 of 2 http://speswebfe1/toolnet_anonymous/ProductView.asp?ProductID=96&HierarchyID=16 15/08/01 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

Page 1 of 1 http://speswebfe1/toolnet.../ProductNodeFeaturesView.asp?hierarchyid=16&productID=9 15/08/01 Rotary Hammers Feature And Benefits Features Benefits High drilling rate / speed and power 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 Holes per charge 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. Optimum performance in the key cordless hammer drilling diameters The hammer configuration has been optimised for the 6- 16mm range. (research has identified these as the key diameters for the cordless user) Easy engagement force (operating pressure) 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 Effective protection for both operator an machine should the tool jam Safety clutch Product | Reports | Help |

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

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

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 Jetstream Battery & Charger Battery & Charger

Centrifugal Fan: 0.6m3/min Cooling • DE0245 remains for NiCD in 2002 • DE0246 optimised for charging NIMH (+NiCD) • DE0245 not capable of charging NIMH due to thermal damage 24V • 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 3.0Ah NiMH Jetstream Jetstream Battery & Charger Battery & Charger 2.5Ah Output

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

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

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

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

• Air circulates mostly around the outside of the cell packs not inside where most heat is generated 24V 3.0Ah NiMH Jetstream Jetstream Battery & Charger Battery & Charger

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 3.0Ah NiMH Jetstream Jetstream Battery & Charger Battery & Charger 24V

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. Fast Charge Mode 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 3.0Ah NiMH Jetstream Jetstream Battery & Charger Battery & Charger 24V

Normal Mode Tune-up Mode Pack Temp Charge Rate Pack Temp Charge Rate hot pack charge delay hot pack charge delay 55 deg C 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 Jetstream 3.0Ah NiMH Jetstream Jetstream Battery & Charger Battery & Charger 24V

• 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 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 Jetstream battery system it is …. …. best when the battery is charged immediately due to the instant cool down process 24V 3.0Ah NiMH Jetstream Jetstream Battery & Charger Battery & Charger

DE 0241 Aircooled Charger DE 0246 2,0 Ah NiCd-Pack DE 0240 Charger DE 0245 2001 & 2002 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 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” 3.0Ah NiMH Jetstream Jetstream Battery & Charger Battery & Charger 24V