DeWalt DW005K User Manual

August 2001

M Cook

Introduction

Bill Of MaterialExploded

Drawing

E13120

Repair

Instructions

R11222

New

Parts

9

Marketing

Information

Main

Menu

DW005K

24V Rotary Hammer

TYPE 1

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

TYP.

1

09-05-01

E13120 / 487179-00

166

159

167

173

172

1 12

1 11

171

170

164

165

169

163

162

114

126

145

146

147

148

149

151
152

153

126

137

123

114

154

160

155

125

124

866

817

1 19

1 18

116

121

104

113

131

109

103

816

120

127

101

137

106

62

122

DW005K2C

185

129

150

175

174

DW005K

w ww.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

Black & Decker Bill of Materials - PARTS LIST

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

Black & Decker Bill of Materials - PARTS LIST

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

Black & Decker Bill of Materials - PARTS LIST

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 CHIPPING

DW005K

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 1

P1ant:

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 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

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 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 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

Product | Reports | Help |

Toolnet - Product View 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

Toolnet - Product View 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 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

Product | Reports | Help |

Toolnet - Product View 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

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 6­16mm 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 |

NEW NiMH JETSTREAM System

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 JETSTREAM Components

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

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

Jetstream

Battery & Charger

Battery & Charger

NiMH JETSTREAM Components

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

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

Jetstream

Jetstream

3.0Ah NiMH

Jetstream

Jetstream

Battery & Charger

Battery & Charger

RUN TIME Introduction of 3.0 NiMH to 24V

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

CYCLE LIFE Optimised Battery Life

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

Makita 1.7Ah NiMH & 3.0Ah NiMH

• older battery technology

• lower performance

• lower battery life

• higher life time cost

AIRCOOLED Competition

24V

3.0Ah NiMH

Jetstream

Jetstream

Battery & Charger

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

Jetstream

Battery & Charger

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

3.0Ah NiMH

Jetstream

Jetstream

Battery & Charger

Battery & Charger

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 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

NiCD Battery Packs

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

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

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

3,0 Ah NiMH-Pack
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