DeWalt DW501, DW515, DW505 Instruction Manual

DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286 (MAY04 - 1) Form No. 154725-01

DW501, DW505, DW515 Copyright © 1997, 2002, 2004

The following are trademarks for one or more DEWALT power tools: the yellow and black color scheme; the “D” shaped air intake grill; the
array of pyramids on the handgrip; the kit box configuration; and the array of lozenge-shaped humps on the surface of the tool.

INSTRUCTION MANUAL
GUIDE D'UTILISATION
MANUAL DE INSTRUCCIONES

DW501/DW505/DW515
1/2" (13mm) and 5/8" (16mm) Heavy Duty Dual Speed Range Hammerdrills
Perceuse à percussion de 13 mm (1/2 po) et 16mm (5/8 po) à deux gammes de vitesses
Rotomartillo de 13 mm (1/2") y 16mm (5/8") para trabajo pesado con doble velocidad

INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y PÓLIZA
DE GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUCTIVO ANTES
DE USAR EL PRODUCTO.

Questions? See us on the World Wide Web at www.dewalt.com

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IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS
OR ANY D

EWALT TOOL, CALL US TOLL FREE AT:

1-800-4-DEWALT (1-800-433-9258)

General Safety Rules

WARNING! READ AND UNDERSTAND ALL INSTRUCTIONS.

Failure to follow all instructions listed below may result in electric
shock, fire and/or serious personal injury.

SAVE THESE INSTRUCTIONS

WORK AREA

• Keep your work area clean and well lit. Cluttered benches and

dark areas invite accidents.

• Do not operate power tools in explosive atmospheres, such

as in the presence of flammable liquids, gases, or dust.

Power tools create sparks which may ignite the dust or fumes.

• Keep bystanders, children, and visitors away while
operating a power tool. Distractions can cause you to lose
control.

ELECTRICAL SAFETY

• Grounded tools must be plugged into an outlet properly
installed and grounded in accordance with all codes and
ordinances. Never remove the grounding prong or modify
the plug in any way. Do not use any adapter plugs. Check
with a qualified electrician if you are in doubt as to whether
the outlet is properly grounded. If the tools should electrically

malfunction or break down, grounding provides a low resistance
path to carry electricity away from the user. Applicable only to

Class I (grounded) tools.

• Double insulated tools are equipped with a polarized plug
(one blade is wider than the other.) This plug will fit in a
polarized outlet only one way. If the plug does not fit fully
in the outlet, reverse the plug. If it still does not fit, contact
a qualified electrician to install a polarized outlet. Do not

change the plug in any way. Double insulation eliminates

the need for the three wire grounded power cord and grounded
power supply system. Applicable only to Class II (double

insulated) tools.

• Avoid body contact with grounded surfaces such as pipes,
radiators, ranges and refrigerators. There is an increased risk

of electric shock if your body is grounded.

• Don’t expose power tools to rain or wet conditions. Water
entering a power tool will increase the risk of electric shock.

• Do not abuse the cord. Never use the cord to carry the tools

or pull the plug from an outlet. Keep cord away from heat,
oil, sharp edges or moving parts. Replace damaged cords
immediately. Damaged cords increase the risk of electric shock.

• When operating a power tool outside, use an outdoor
extension cord marked “W-A” or “W.” These cords are rated

for outdoor use and reduce the risk of electric shock. When
using an extension cord, be sure to use one heavy enough to
carry the current your product will draw. An undersized cord will
cause a drop in line voltage resulting in loss of power and
overheating. The following table shows the correct size to use
depending on cord length and nameplate ampere rating. If in
doubt, use the next heavier gage. The smaller the gage number,
the heavier the cord.

Minimum Gage for Cord Sets

Volts Total Length of Cord in Feet

120V 0-25 26-50 51-100 101-150
240V 0-50 51-100 101-200 201-300

Ampere Rating

More Not more AWG

Than Than
0-6 18161614
6 - 10 18 16 14 12
10-1216161412
12 - 16 14 12 Not Recommended

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Such preventative safety measures reduce the risk of starting
the tool accidentally.

• Store idle tools out of reach of children and other untrained
persons. Tools are dangerous in the hands of untrained users.

• Maintain tools with care. Keep cutting tools sharp and
clean. Properly maintained tools, with sharp cutting edges are
less likely to bind and are easier to control.

• Check for misalignment or binding of moving parts,

breakage of parts, and any other condition that may affect
the tools operation. If damaged, have the tool serviced
before using. Many accidents are caused by poorly maintained

tools.

• Use only accessories that are recommended by the
manufacturer for your model. Accessories that may be
suitable for one tool, may become hazardous when used on
another tool.

SERVICE

• Tool service must be performed only by qualified repair
personnel. Service or maintenance performed by unqualified

personnel could result in a risk of injury.

• When servicing a tool, use only identical replacement parts.

Follow instructions in the Maintenance section of this
manual. Use of unauthorized parts or failure to follow

Maintenance Instructions may create a risk of electric shock or
injury.

Additional Safety Rules for Hammer
Drills

• Hold tool by insulated gripping surfaces when performing
an operation where the cutting tool may contact hidden
wiring or its own cord. Contact with a “live” wire will make

exposed metal parts of the tool “live” and shock the operator.

• Wear safety goggles or other eye protection. Hammering and
drilling operations cause chips to fly. Flying particles can cause
permanent eye damage.

PERSONAL SAFETY

• Stay alert, watch what you are doing and use common
sense when operating a power tool. Do not use tool while
tired or under the influence of drugs, alcohol, or medication.

A moment of inattention while operating power tools may result
in serious personal injury,

• Dress properly. Do not wear loose clothing or jewelry.

Contain long hair. Keep your hair, clothing, and gloves away
from moving parts. Loose clothing, jewelry, or long hair can be

caught in moving parts.

Air vents often cover moving parts and

should also be avoided.

• Avoid accidental starting. Be sure switch is off before
plugging in. Carrying tools with your finger on the switch or
plugging in tools that have the switch on invites accidents.

• Remove adjusting keys or switches before turning the tool
on. A wrench or key that is left attached to a rotating part of the
tool may result in personal injury.

• Do not overreach. Keep proper footing and balance at all
times. Proper footing and balance enables better control of the
tool in unexpected situations.

• Use safety equipment. Always wear eye protection. Dust
mask, non-skid safety shoes, hard hat, or hearing protection
must be used for appropriate conditions.

TOOL USE AND CARE

• Use clamps or other practical way to secure and support
the workpiece to a stable platform. Holding the work by hand

or against your body is unstable and may lead to a loss of
control.

• Do not force tool. Use the correct tool for your application.
The correct tool will do the job better and safer and the rate for
which it is designed.

• Do not use tool if switch does not turn it on or off. Any tool
that cannot be controlled with the switch is dangerous and must
be repaired.

• Disconnect the plug from the power source before making

any adjustments, changing accessories, or storing the tool.

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FIGURE 1

• Wear ear protectors when hammering for extented periods
of time. Temporary hearing loss or serious ear drum damage
may result from high sound levels generated by hammer drilling.

• Always use the side handle supplied with the tool. Keep a

firm grip on the tool at all times. Do not attempt to operate this
tool without holding it with both hands.

• Do not overreach while operating the tool. Maintain a

balanced working stance at all times. When necessary, use only
properly postioned, safe, platforms and scaffolding. WORK
SAFE.

• Hammer bits and tools get hot during operation. Wear gloves

when touching them.

•

CAUTION:DO NOT TOUCH ANY METAL PARTS OF THE
TOOL when drilling or driving into walls, floors or wherever
live electrical wires may be encountered! Hold the tool only by

insulated grasping surfaces to prevent electric shock if you drill or
drive into a live wire.
WARNING: Some dust created by power sanding, sawing,

grinding, drilling, and other construction activities contains chemicals
known to cause cancer, birth defects or other reproductive harm.
Some examples of these chemicals are:

• lead from lead-based paints,

• crystalline silica from bricks and cement and other masonry
products, and

• arsenic and chromium from chemically-treated lumber (CCA).

Your risk from these exposures varies, depending on how often you
do this type of work. To reduce your exposure to these chemicals:
work in a well ventilated area, and work with approved safety
equipment, such as those dust masks that are specially designed to
filter out microscopic particles.

• Avoid prolonged contact with dust from power sanding,

sawing, grinding, drilling, and other construction activities.
Wear protective clothing and wash exposed areas with
soap and water. Allowing dust to get into your mouth, eyes, or

lay on the skin may promote absorption of harmful chemicals.

CAUTION: Wear appropriate hearing protection during use.

Under some conditions and duration of use, noise from this product
may contribute to hearing loss.

•

The label on your tool may include the following symbols.

V ........................volts

A ........................amperes

Hz ........................hertz

W ........................watts

min ........................minutes

........................alternating current

........................direct current

n

o ........................no load speed

........................Class II Construction

…/min ......................revolutions or reciprocation per minute

BPM ........................beats per minute

Side Handle

CAUTION: Always use side handle when provided and hold

hammerdrill with both hands.

A side handle is supplied with this hammerdrill. It clamps to the front
of the gear case as shown in Figure 1 and can be rotated 360˚ to
permit right or left hand use.

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NOTE: Use lower speeds for starting holes without a centerpunch,
drilling in metal, plastics or ceramics, or driving screws. Higher
speeds are better for drilling in wood and composition board and for
using abrasive and polishing accessories.

The

reversing lever

is used to reverse the hammerdrill for backing
out screws or jammed bits. It is located above the trigger, shown in
Figure 2. To reverse the hammerdrill, turn it OFF and push the
reversing lever to the left (when viewed from the chuck end). To
position the lever for forward operation, turn the hammerdrill OFF
and push the lever to the right.

High/Low Speed Operation

The two speed gear drive in the dual range hammer drill permits
effective operation over an extended range of applications with
greater selection of accessories.

For

LOW SPEED

operation, the shift knob (see Figure 3) located
on the underside of the hammerdrill should be rotated so the “low
speed” graphic is toward the front of the tool.

For

HIGH SPEED

operation, should be rotated so the “high speed”
graphic is toward the front of the tool.

FIGURE 3

LOW SPEED

SETTING

SHOFT

KNOB

Switch

To start hammerdrill, depress the trigger switch (Figure 2). To stop
hammerdrill, release the switch. To lock the trigger switch in the ON
position for continuous operation, depress the trigger switch and
push up the

locking button

. The tool will continue to run. To turn the
tool OFF, from a locked ON condition, squeeze and release the
trigger once. Before using the tool (each time), be sure that the
locking button release mechanism is working freely.

Do not lock the switch ON when drilling by hand so that you can
instantly release the trigger switch if the bit binds in the hole. The
locking button is for use only when the hammerdrill is mounted in a
drill press stand or other wise held stationary. Be sure to release the
locking mechanism before disconnecting the plug from the power
supply. Failure to do so will cause the hammerdrill to start
immediately the next time it is plugged in. Damage or injury could
result.

The

variable speed trigger switch

permits speed control. The
farther the trigger switch is depressed, the higher the speed of the
hammerdrill.

REVERSING

LEVER

TRIGGER

SWITCH

LOCKING

BUTTON

FIGURE 2

FRONT OF TOOL

HIGH SPEED

SETTING

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The gear train has been designed for shifting only when the unit is
off. It may be necessary however, to rotate the chuck slightly by hand
to align the gears while turning the shift knob. DO NOT ATTEMPT
TO CHANGE SPEEDS by turning the shift knob when the tool is
running. Doing so will damage the gear train.

Hammer/Drill Selector

To switch the tool from the drilling mode to the hammering mode (or
vice-versa) rotate the dial on the applicable symbol shown in Figure

4. For straight drilling, align the drill bit symbol toward the chuck. For
hammering, align the hammer symbol with the chuck, as shown in
the figure.NOTE: The selector must be in either drill, or hammer/drill
mode at all times. There are no operable positions between the two.

Chuck

To insert bit,

open chuck jaws by turning collar with fingers and
insert shank of bit about 3/4" (19mm) into chuck. Tighten chuck collar
by hand. Place chuck key in each of the three holes and tighten in
clockwise direction. It’s important to tighten chuck with all three
holes.

To release bit

, turn chuck key counterclockwise in just one

hole, then loosen the chuck by hand.

Operation

DRILLING

1. Always unplug the drill when attaching or changing bits or

accessories.

2. Use sharp drill bits only. For WOOD, use the low speed setting

and twist drill bits, spade bits, power auger bits, or hole saws.
For METAL, use the low speed setting and steel twist drill bits or
hole saws. For MASONRY, such as brick, cement, cinder block,
etc., use carbide-tipped bits rated for percussion drilling. Use
low speed for bits greater than 3/8”.

3. Be sure the material to be drilled is anchored or clamped firmly.

If drilling thin material, use a wood “back-up” block to prevent
damage to the material.

4. Always apply pressure in a straight line with the bit. Use enough
pressure to keep drill biting, but do not push hard enough to stall
the motor or deflect the bit.

5. Hold tool firmly to control the twisting action of the drill.

6. IF DRILL STALLS, it is usually because it is being overloaded or
improperly used. RELEASE TRIGGER IMMEDIATELY, remove
drill bit from work, and determine cause of stalling. DO NOT

CLICK TRIGGER OFF AND ON IN AN ATTEMPT TO START A
STALLED DRILL — THIS CAN DAMAGE THE DRILL.

7. To minimize stalling or breaking through the material, reduce
pressure on drill and ease the bit through the last fractional part
of the hole.

8. Keep the motor running when pulling the bit back out of a drilled
hole. This will help prevent jamming.

9. With variable speed drills there is no need to center punch the
point to be drilled. Use a slow speed to start the hole and
accelerate by squeezing the trigger harder when the hole is
deep enough to drill without the bit skipping out.

DRILLING IN METAL
USE ONLY in the “low speed” gear range. Start drilling with slow

speed and increase to full power while applying firm pressure on the
tool. A smooth even flow of metal chips indicates the proper drilling
rate. Use a cutting lubricant when drilling metals. The exceptions are
cast iron and brass which should be drilled dry. The cutting lubricants
that work best are sulphurized cutting oil or lard oil; bacon-grease will
also serve the purpose.

NOTE: Large (5/16” to 1/2”) holes in steel can be made easier if a
pilot hole (5/32” to 3/16”) is drilled first.

DRILLING IN WOOD
USE ONLY in the “low speed” gear range. Start drilling with slow

speed and increase to full power while applying firm pressure on
the tool. Holes in wood can be made with the same twist drills used

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Self-lubricating bearings are used in the tool and periodic
relubrication is not required. In the unlikely event that service is ever
needed, take your tool to an authorized service location.

Accessories

Recommended accessories for use with your tool are available at
extra cost from your distributor or local service center.

CAUTION: The use of any non-recommended accessory may be

hazardous.

MAXIMUM RECOMMENDED CAPACITIES

DW505 DW515

CHUCK CAPACITY 1/2" 5/8”
R.P.M. 0–1,100 0–2,700 0-900 - 0-2,200
BITS, METAL DRILLING 3/8" – Low speed 3/4” Low speed
WOOD, FLAT BORING 1 1/2" – Low speed 1-1/2” Low

speed

BITS, MASONRY DRILLING 3/4" Soft materials 5/8” Soft

Materials
Low speed Low speed
1/2" Concrete 5/8” Concrete

Low speed Low speed

HOLE SAWS 2-1/8" – Low speed 4” Low speed

Important

To assure product SAFETY and RELIABILITY, repairs, maintenance
and adjustment (including brush inspection and replacement) should
be performed by authorized service centers or other qualified service
organizations, always using identical replacement parts.

Three Year Limited Warranty

DEWALT will repair, without charge, any defects due to faulty
materials or workmanship for three years from the date of purchase.
This warranty does not cover part failure due to normal wear or tool
abuse. For further detail of warranty coverage and warranty repair

FIGURE 4

DRILL

SETTING

HAMMER
SETTING

for metal. These bits may overheat unless pulled out frequently to
clear chips from the flutes. Work that is apt to splinter should be
backed up with a block of wood.

DRILLING IN MASONRY

When drilling in masonry, use carbide tipped bits rated for
percussion drilling and be certain that the bit is sharp. For holes up
to 3/8” diameter use the “high speed”gear range. For holes larger
than 3/8”, use the the “low speed” gear range. Ensure that the
hammer mode is selected. Use a constant and firm force on the tool
to drill most effectively. A smooth, even flow of dust indicates the
proper drilling rate.

Depth Rod

To adjust the depth rod, loosen the handle and move rod so that the
distance between the end of the rod and the end of the bit equals the
desired drilling depth. When drilling with depth rod, stop when end of
rod reaches surface of material.

Maintenance

CLEANING & LUBRICATION

Use only mild soap and damp cloth to clean the tool. Never let any
liquid get inside the tool; never immerse any part of the tool into a
liquid.