dw005k 24v rotary hammer - 2helpu · dw005k 24v rotary hammer ... dw 05k w .2helpu com 132 102 110...

August 2001M Cook

IntroductionBill Of MaterialExploded

Drawing

E13120

RepairInstructions

R11222

NewParts

9

MarketingInformation

MainMenu

DW005K24V Rotary Hammer

TYPE 1

Introduction

24 Volt heavy duty SDS-Plus combination hammer based on the existing unitDW004K but with additional chipping action and “Jet stream air cooled” 3.0amp hour NiMH batteries and chargers.

Launch Details

Manufacturing PlantService Parts WarehouseLaunch MarketsLaunch Date

SpennymoorPerth AvenueGB-QWSeptember 2001

Technical Information

VoltageAmp HourPower OutputNo Load SpeedBlowsImpact energy

243.0 (NiMH) 2.0 (NiCAD)460 Watts0-1100 rpm0-4200 bpm2.0 joules

TYP.

1

09-05-01E13120 / 487179-00

166159

167

173172

112

111171170

164

165

169163

162

114

126

145 146

147148

149

151

152

153

126

137 123

114 154

160

155

125

124

866

817

119

118116

121

104

113

131109 103

816

120

127

101137

106

62

122

DW005K2C

185

129

150

175

174

DW005K

www.2helpU.com

132

102

110108

107

184

800 801 802

142143

144

139138

181

157

158

161

156

130

188

187182183

179

Black & Decker Bill of Materials - PARTS LIST

Page 1

Product Number DW005K----A Product Description ROTARY HAMMER Type Identifier TY 1

ItemNumber

QuantityPer

Part Number Part Description Variant Description TypeDescription

Market Codes Referto 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

New Parts

24V HAMMER CHIPPINGDW005K

Part Number Part Description

PLATE327081-01

GEARCASE SA329941-02

CLUTCH SA487401-01

PLATE577058-00

WASHER578387-00

SPINDLE SA578473-00

BATTERY PACK578671-01

CHARGER SA578672-00

CHARGER SA578672-01

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 1P1ant: SP

Please DO NOT order any parts until a Service Change Note is published.

R11222EN.rtf

R11222

BHA24K - DW004K - DW005K Cordless 24 volt Rotary Hammer

Use only genuine grease (800) 870889-49 to maintain performance and reliability, it has been speciallydeveloped 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 thespindle (149), main gear (167) and Intershaft (171). A generous smear should be applied around all matingsurfaces.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 interfaceswith intergear (171)

Ensure the notches on the field magnet (102) are orientated correctly on re-assembly. If not correct, thenthe 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

Toolnet - Product View Page 1 of 2

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

Print this page

DW005K2C Product Sales Sheet24.0 volt Heavy Duty SDS-Plus Combination HammerShort 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 |



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 VBattery NiCd 2.0 AhPower Output 460 WattsNo Load Speed 0-1100 rpmImpact Energy 2.0 JBlows per Minute 0-4200 bpmTool Holder SDS-PlusMax. Drilling Capacity [Wood] 30 mmMax. Drilling Capacity [Metal] 13 mmMax. Drilling Capacity [Concrete] 20 mmWeight 4.2 kgLength 348 mmHeight 215 mm

Standard Equipment1 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



Print this page

DW005K2H Product Sales Sheet24.0 V Heavy Duty SDS-Plus Combination HammerShort 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




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 VBattery NiMH 3.0 AhPower Output 460 WattsNo Load Speed 0-1100 rpmImpact Energy 2.0 JBlows per Minute 0-4200 bpmTool Holder SDS-PlusMax. Drilling Capacity [Wood] 30 mmMax. Drilling Capacity [Metal] 13 mmMax. Drilling Capacity [Concrete] 20 mmWeight 4.2 kgLength 348 mmHeight 215 mm

Standard Equipment1 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

Toolnet - Product Node Features View 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


NEW NiMH JETSTREAM System

24V

DE024124V, 3.0Ah NiMH JetstreamJetstream Battery

DE024624V, NiCd + NiMH JetstreamJetstream Charger

charges NiCD in appx 60 Mincharges NiMH in appx 75 Min

!!!! DE0245 not optimised for NiMH

3.0A

h N

iMH

Jet

stre

am

Jets

trea

m B

atte

ry &

Cha

rger

Bat

tery

& C

harg

er

NiMH JETSTREAM Components

NiMH Aircooled Battery grows 12mm in length toaccommodate the specially designed cooling channels

Special MeshMaterial to

prevent largerparticles of debris

from enteringOLD NEW

OLD NEW

24V

3.0A

h N

iMH

Jet

stre

am

Jets

trea

m B

atte

ry &

Cha

rger

Bat

tery

& C

harg

er


Cool Air pressed into Battery byCharger to cool down Battery beforeand during the Charge in order tomaintain the battery chemistry atlow temperature levels

Hot Air is channelled from the centre of the cells through to the vents in outer shell

24V

3.0A

h N

iMH

Jet

stre

am

Jets

trea

m B

atte

ry &

Cha

rger

Bat

tery

& C

harg

er


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

3.0A

h N

iMH

Jet

stre

am

Jets

trea

m B

atte

ry &

Cha

rger

Bat

tery

& C

harg

er

2.5Ah Output

User Needs vs. Project Scope

24V

• Run Time NiMH JETSTREAM offers 50%+ capacity

• Cycle Life NiMH Jeststream has same battery life as NiCD

Optimised Value for Money with NiMH JetstreamJetstream

3.0A

h N

iMH

Jet

stre

am

Jets

trea

m B

atte

ry &

Cha

rger

Bat

tery

& C

harg

er

RUN TIME Introduction of 3.0 NiMH to 24V

50% more Capacity with 3.0Ah NiMH JetstreamJetstream Battery

0

20

40

60

80

100

120

140

160

DW005K 2.0Ah DW005K 3.0Ah

Num

ber

of 6

x 4

0mm

Hole

s

Source: typical Rotary Hammer Application drilling 6x40mm holes into hard concrete

24V

+ 50%more Holes drilled per Chargewith 3.0Ah NiMH

3.0A

h N

iMH

Jet

stre

am

Jets

trea

m B

atte

ry &

Cha

rger

Bat

tery

& C

harg

er

CYCLE LIFE Optimised Battery Life

0

20

40

60

80

100

120

2.0Ah NiCD 3.0Ah NiMH

Life

Cyc

le P

erce

nta

ges

Non-AC

Jetstream

Makita - AC

Base 100%2.0Ah NiCD

TodayNiMH = 100%life of 2.0Ah !

Same battery cycle life of Non-Aircooled 2.0 Ah *

3.0Ah NiMH JetstreamJetstream same battery life as 2.0Ah NiCD * * under hot charging condition onlyunder hot charging condition only

* simulated life cycles with DW008 cutting 50x100mm & 100x100mm Wood must contain 75% of 1st 10A CC discharge

Makita50%of DEWALT

24V

3.0A

h N

iMH

Jet

stre

am

Jets

trea

m B

atte

ry &

Cha

rger

Bat

tery

& C

harg

er

Makita 1.7Ah NiMH & 3.0Ah NiMH• older battery technology• lower performance• lower battery life• higher life time cost

AIRCOOLED Competition

24V

3.0A

h N

iMH

Jet

stre

am

Jets

trea

m B

atte

ry &

Cha

rger

Bat

tery

& C

harg

er

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

3.0A

h N

iMH

Jet

stre

am

Jets

trea

m B

atte

ry &

Cha

rger

Bat

tery

& C

harg

er

Operation ModesOPERATION 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 thebattery’s series string that may have less charge than the others at the terminationof the fast charge cycle. The lower current (83mA) is prevents cell damage duringthis overcharge period.

• Maintenance mode current (63mA) overcomes self discharge of the cells in thebattery pack. Battery pack removal stops all charging and returns the charger tostandby mode.

• Tune up mode combines fast charge, equalization, maintenance into a 4h charge

3.0A

h N

iMH

Jet

stre

am

Jets

trea

m B

atte

ry &

Cha

rger

Bat

tery

& C

harg

er

24V

• 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 directlyinterpreting 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 NiMH2.5A 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 Ccold pack charge delay cold pack charge delay3.

0Ah

NiM

H J

etst

ream

Je

tstr

eam

Bat

tery

& C

harg

erB

atte

ry &

Cha

rger

24V

NiCD Battery Packs

Normal Mode Tune-up ModePack Temp Charge Rate Pack Temp Charge Rate

hot pack charge delay hot pack charge delay

55 deg C2.5A 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 Ccold 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 JetstreamJetstream3.0A

h N

iMH

Jet

stre

am

Jets

trea

m B

atte

ry &

Cha

rger

Bat

tery

& C

harg

er

24V

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 JetstreamJetstream 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 immediatelyWith the JetstreamJetstream battery system it is ….…. best when the battery is charged immediately due to the instant cool down process

24V

3.0A

h N

iMH

Jet

stre

am

Jets

trea

m B

atte

ry &

Cha

rger

Bat

tery

& C

harg

er

3,0 Ah NiMH-PackDE 0241

Aircooled ChargerDE 0246

2,0 Ah NiCd-PackDE 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

• JetstreamJetstream (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”

3.0A

h N

iMH

Jet

stre

am

Jets

trea

m B

atte

ry &

Cha

rger

Bat

tery

& C

harg

er

24V

dw005k 24v rotary hammer - 2helpu · dw005k 24v rotary hammer ... dw 05k w .2helpu com 132 102 110...

Documents