DEWALT DWD520 Heavy-Duty Dual Speed Hammer Drills Instruction Manual

DEWALT DWD520 Heavy-Duty Dual Speed Hammer Drills

DWD520, DWD525
1/2″ (13 mm) Heavy-Duty Dual Speed Hammer drills

DEWALT Industrial Tool Co., 701 Joppa Road, Baltimore, MD 21286 (NOV08) Part No. 657416-00 DWD520, DWD525

Copyright © 2008 DEWALT

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.

Definitions Safety Guidelines

The definitions below describe the level of severity for each signal word. Please read the manual and pay attention to these symbols.

• DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
• WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
• Used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL, CALL US TOLL FREE AT: 1-800-4-DEWALT (1-800-433-9258)

WARNING: To reduce the risk of injury, read the instruction manual.

General Power Tool Safety Warnings

WARNING:  Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE

The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

WORK AREA SAFETY

• Keep work area clean and well lit. Cluttered or 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 children and bystanders away while operating a power tool. Distractions can cause you to lose control.

ELECTRICAL SAFETY

• Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.
• Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
• Do not 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 for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock.
• When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
• If operating a power tool in a damp location is unavoidable, use a ground fault circuit interrupter (GFCI) protected supply. Use of a GFCI reduces the risk of electric shock.

PERSONAL SAFETY

• Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.
• Use personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.
• Prevent unintentional starting. Ensure the switch is in the off position before connecting to power source and/or battery pack, picking up or carrying the tool.
• Carrying power tools with your finger on the switch or energising power tools that have the switch on invites accidents.
• d) Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.
• Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
• Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts.
• If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards.

POWER TOOL USE AND CARE

• Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.
• Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
• Disconnect the plug from the power source and/or the battery pack from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.
• Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Powertools are dangerous in the hands of untrained users.
• Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
• Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
• Use the power tool, accessories and tool bits etc., in accordance with these instructions taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.

SERVICE

Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

Additional Safety Rules for Hammerdrills

• Wear ear protectors with impact drills. Exposure to noise can cause hearing loss.
• Use auxiliary handles supplied with the tool. Loss of control can cause personal injury.
• Hold power tools 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.
• Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body leaves it unstable and may lead to loss of control.
• Wear ear protectors when hammering for extented periods of time. Prolonged exposure to high intensity noise can cause hearing loss. Temporary hearing loss or serious ear drum damage may result from high sound levels generated by hammer drilling.
• Wear safety goggles or other eye protection. Hammering and drilling operations cause chips to fly. Flying particles can cause permanent eye damage. Wear a dust mask or respirator for applications that generate dust. Ear protection may be required for most applications.
• Always use the side handle supplied with the tool. Tighten the side handle securely before use. Keep a firm grip on the tool at all times. Do not attempt to operate this tool without holding it with both hands. Operating this tool with one hand will result in loss of control. Breaking through or encountering hard materials such as re-bar may be hazardous as well.
• Hammer bits and tools get hot during operation. Wear gloves when touching them.
• Do not operate this tool for long periods of time. Vibration caused by hammer action may be harmful to your hands and arms. Use gloves to provide extra cushion and limit exposure by taking frequent rest periods.
• Air vents often cover moving parts and should be avoided. Loose clothes, jewellery or long hair can be caught in moving parts.
• An extension cord must have adequate wire size (AWG or American Wire Gauge) for safety. The smaller the gauge number of the wire, the greater the capacity of the cable, that is 16 gauge has more capacity than 18 gauge. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. When using more than one extension to make up the total length, be sure each individual extension contains at least the minimum wire size. The following table shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

Minimum Gauge for Cord Sets

__

Ampere Rating

| Volts| Total Length of Cord in Feet (meters)
120V| 25 (7.6)| 50 (15.2)| 100 (30.5)| 150 (45.7)
240V| 50 (15.2)| 100 (30.5)| 200 (61.0)| 300 (91.4)
More

Than

| Not More Than| AWG
0| 6|  | 18| 16| 16| 14
6| 10| 18| 16| 14| 12
10| 12| 16| 16| 14| 12
12| 16| 14| 12| Not Recommended

WARNING

• Always use eye protection. All users and bystanders must wear eye protection that conforms to ANSI Z87.1.
• Always wear proper personal hearing protection that conforms to ANSI S12.6 (S3.19) during use. Under some conditions and duration of use, noise from this productmay contribute to hearing loss.
• ALWAYS use safety glasses. Everyday eyeglasses are NOT safety glasses.

Also use face or dust mask if cutting operation is dusty. ALWAYS WEAR CERTIFIED SAFETY EQUIPMENT:

• ANSI Z87.1 eye protection (CAN/CSA Z94.3),
• ANSI S12.6 (S3.19) hearing protection,
• NIOSH/OSHA/MSHA respiratory protection.

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.

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.

WARNING: Use of this tool can generate and/or disburse dust, which may cause serious and permanent respiratory or other injury. Always use NIOSH /OSHA-approved respiratory protection appropriate for the dust exposure. Direct particles away from face and body.

The label on your tool may include the following symbols. The symbols and their definitions are as follows:

• V……. Volts

• Hz…… hertz

• min ………………..minutes

• …………….. direct current

• …………………. Class I Construction (grounded)

• …………………. Class II Construction (double insulated)

• …/min …………… per minute

• A ………………….. amperes

• W ………………….watts

• ……………….. alternating current

• ……………….. alternating or direct current

• ………………… no load speed

• ………………… earthing terminal

• ………………… safety alert symbol

• BPM …………….. beats per minute

• RPM …………….. revolutions per minute

COMPONENTS

WARNING: Never modify the power tool or any part of it. Damage or personal injury could result.

• A. Trigger switch
• B. Reversing lever
• C. Chuck
• D. Speed/Mode selector collar
• E. Side handle

INTENDED USE

These heavy-duty hammerdrills are designed for professional drilling and hammerdrilling. DO NOT use under humid conditions or in presence of flammable liquids or gases. These heavy-duty hammerdrills are professional power tools. DO NOT let children come into contact with the tool. Supervision is required when inexperienced operators use this tool.

Side Handle

WARNING: To reduce the risk of personal injury, ALWAYS operate the tool with the side handle properly installed. Failure to do so may result in the side handle slipping during tool operation and subsequent loss of control. Hold tool with both hands to maximize control.

A side handle (E) is supplied with this hammerdrill. It clamps to the front of the gear case as shown in Figure 1 and can be rotated 360˚ for right- or left- hand use. After the side handle is rotated into position, it should be pushed rearward until the slots (F) on the lip of the side handle are aligned and fully engaged with the projecting tabs (G) on the underside of the gear case. The side handle is then securely clamped by turning clockwise until tight.

Trigger Switch

To start hammer drill, depress the trigger switch (A). To stop hammerdrill, release the trigger switch.

VARIABLE SPEED TRIGGER SWITCH

The variable speed trigger switch (A) permits speed control. The farther the trigger switch is depressed, the higher the speed of the hammerdrill.

NOTE: Use lower speeds for starting holes, drilling in plastics or ceramics or driving screws.

REVERSING LEVER

The reversing lever (B), located above the trigger switch, changes the direction of rotation of the hammerdrill and is used when backing out screws and jammed drill bits. To operate the tool in reverse, release the trigger switch and push the lever to the left (when viewed from the chuck end). To operate the drill in forward, release the trigger switch and push the lever to the right (when viewed from the chuck end). Return the reversing lever to the forward position after all operations in reverse are completed.

High/Low Speed Operation

• The two speed gear drive in the dual range hammerdrill permits effective operation over an extended range of applications with greater selection of accessories.
• For LOW SPEED operation, turn the collar (D) to the drill bit symbol for drilling position 1.
• For HIGH SPEED operation, turn the collar (D) to the drill bit symbol for drilling position 2.
• 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 collar.

CAUTION: DO NOT ATTEMPT TO CHANGE SPEEDS by turning the collar 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 collar (D) to the applicable symbol as shown in Figure 3.
• Turn the collar (D) to the drill bit symbol for drilling or to the hammer symbol for hammerdrilling, as shown in the figure.

OPERATION

• To reduce the risk of serious personal injury, turn tool off and disconnect tool from power source before making any adjustments or removing/installing attachments or accessories.
• To reduce the risk of personal injury, ALWAYS ensure workpiece is anchored or clamped firmly. If drilling thin material, use a wood “back-up” block to prevent damage to the material.
• To reduce the risk of personal injury, ALWAYS operate the tool with the side handle properly installed. Failure to do so may result in the side handle slipping during tool operation and subsequent loss of control. Hold tool with both hands to maximize control.
• Do not attempt to tighten or loosen drill bits (or any other accessory) by gripping the front part of the chuck and turning the tool on. Damage to the chuck and personal injury may occur.
• Burn Hazard. ALWAYS wear gloves when changing bits. Accessible metal parts on the tool and bits may get extremely hot during operation. Small bits of broken material may damage bare hands.

Keyed Chucks

Open chuck jaws by turning collar with fingers and insert shank of bit about 3/4″ (19 mm) into chuck (C). 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 prevent slippage. To release bit, turn chuck key counterclockwise in just one hole, then loosen the chuck by hand. Any authorized DEWALT service center can install a keyless chuck in place of a keyed chuck.

Depth Rod

To adjust the depth rod (H), loosen the handle (E) 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.

Drilling

Turn the collar to the drill bit symbol for drilling or to the hammer symbol for hammerdrilling. Install and tighten the desired drill bit in the chuck.

DRILLING OPERATION

Select the desired speed/torque range using the speed selector collar to match the speed and torque to the planned operation.

1. For WOOD, use twist bits, spade bits, power auger bits or hole saws. For METAL, use highspeed steel twist drill bits or hole saws. Use a cutting lubricant when drilling metals. The exceptions are cast iron and brass which should be drilled dry. For MASONRY, use carbide-tipped bits or masonry bits. A smooth, even flow of dust indicates the proper drilling rate.
2. Always apply pressure in a straight line with the bit. Use enough pressure to keep the drill bit biting, but do not push hard enough to stall the motor or deflect the bit.
3. Hold tool firmly with both hands to control the twisting action of the drill.
   • WARNING: Drill may stall if overloaded causing a sudden twist. Always expect the stall. Grip the drill firmly with both hands to control the twisting action and avoid injury.
4. IF DRILL STALLS, it is usually because it is being overloaded. 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.
5. To minimize stalling or breaking through the material, reduce pressure on drill and ease the bit through the last fractional part of the hole.
6. Keep the motor running when pulling the bit back out of a drilled hole. This will help prevent jamming.
7. 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.

HAMMERDRILL OPERATION

1. When drilling, use just enough force on the hammer to keep it from bouncing excessively or “rising” off the bit. Too much force will cause slower drilling speeds, overheating, and a lower drilling rate.
2. Drill straight, keeping the bit at a right angle to the work. Do not exert side pressure on the bit when drilling as this will cause clogging of the bit flutes and a slower drilling speed.
3. When drilling deep holes, if the hammer speed starts to drop off, pull the bit partially out of the hole with the tool still running to help clear debris from the hole.
4. For masonry, use carbide-tipped bits or masonry bits. A smooth even flow of dust indicates the proper drilling rate.

MAINTENANCE

WARNING: To reduce the risk of serious personal injury, turn tool off and disconnect tool from power source before making any adjustments or removing/installing attachments or accessories.

Cleaning

WARNING

• Blow dirt and dust out of all air vents with dry air at least once a week. Wear proper ANSI Z87.1 (CAN/CSA Z94.3) eye protection and proper NIOSH/OSHA/MSHA respiratory protection when performing this.
• Never use solvents or other harsh chemicals for cleaning the non-metallic parts of the tool. These chemicals may weaken the plastic materials used in these parts. Use a cloth dampened only with water and mild soap. Never let any liquid get inside the tool; never immerse any part of the tool into a liquid.

Lubrication

Your tool was properly lubricated before leaving the factory. In from two to six months, depending upon use, take or send your tool to an authorized service center for a complete cleaning, inspection and lubrication. Tools used constantly on production jobs will need relubrication more often. Also, tools “out of service” for long periods should be relubricated before being put back to work.

Accessories

WARNING: Since accessories, other than those offered by DEWALT, have not been tested with this product, use of such accessories with this tool could be hazardous. To reduce the risk of injury, only DEWALT, recommended accessories should be used with this product. Recommended accessories for use with your tool are available at extra cost from your local dealer or authorized service center. If you need assistance in locating any accessory, please contact DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286, call 1-800-4-DEWALT (1-800-433-9258) or visit our website www.dewalt.com.

MAXIMUM RECOMMENDED CAPACITIES

Repairs

To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustments (including brush inspection and replacement) should be performed by a DEWALT factory service center, a DEWALT authorized service center or other qualified service personnel. Always use 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 information, visit www.dewalt.com or call 1-800-4-DEWALT (1-800-433-9258). This warranty does not apply to accessories or damage caused where repairs have been made or attempted by others. This warranty gives you specific legal rights and you may have other rights which vary in certain states or provinces.

In addition to the warranty, DEWALT tools are covered by our

1 YEAR FREE SERVICE

DEWALT will maintain the tool and replace worn parts caused by normal use, for free, any time during the first year after purchase.

90 DAY MONEY BACK GUARANTEE

If you are not completely satisfied with the performance of your DEWALT Power Tool, Laser, or Nailer for any reason, you can return it within 90 days from the date of purchase with a receipt for a full refund – no questions asked.

LATIN AMERICA: This warranty does not apply to products sold in Latin America. For products sold in Latin America, see country-specific warranty information contained either in the packaging, call the local company or see website for warranty information.

FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are missing, call 1-800-4-DEWALT for a free replacement.

DWDXXX

• (13mm) vsR HAMMERDRIL SER

WARNING: TO REDUCE THE RISK OF INJURY, USER MUST READ INSTRUCTiON MANUAL. ALWAYS USE PROPER EYE AND RESPIRATORY PROTECTION. HIGH TORQUE ALWAYS USE SIDE HANDLE.

DEWALT INDUSTRIAL TOOL CO.

• BALTIMORE, MD 21286
• FOR SERVICE INFORMATION, CALL 1-800-4 DEWALT
• www.DeWALT.com

References

• DEWALT® Power Tools Official Site | Guaranteed Tough®

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