DW545 - Hammer DEWALT - Free user manual and instructions

USER MANUAL DW545 DEWALT

Technical diagram of a drill press with numbered parts for identification

A

4 3 2 2 16 5

B

Technical diagram showing mechanical assembly with labeled component 6 and cross-sectional view of internal structure

C

7 6 17 19 18 20 9 8 D

Technical line drawing of a mechanical tool with a 20° angle标注 (no text or symbols beyond the angle marker)

E

Technical diagram of a drill press with labeled parts 8 and 10, showing internal components and wiring connections.

F

Technical line drawing of mechanical assembly with spring-loaded components and mounting brackets (no text or symbols)

G

21 11

H

BOREHAMMER DW540/DW541/DW545 OG TILSVARENDE K-MODELLER

Tillykke!

ROTARY HAMMER DW540/DW541/DW545 AND CORRESPONDING K-MODELS

Congratulations!

You have chosen a DEWALT Power Tool. Years of experience, thorough product development and innovation make DEWALT one of the most reliable partners for professional Power Tool users.

Table of contents

Technical data en - 1

Declaration of conformity en - 2

Safety instructions en - 2

Package contents en - 3

Description en - 3

Electrical safety en - 4

Mains plug replacement (U.K. & Ireland only) en - 4

Using an extension cable en - 4

Assembly and adjustment en - 5

Instructions for use en - 6

Maintenance en - 6

Guarantee en - 7

The following symbols are used throughout this manual:

Denotes risk of personal injury, loss of life or damage to the tool in case of non-observance of the instructions in this manual.

Denotes risk of electric shock.

Technical data

		DW540 DW541 DW545
Voltage V	230	230	230
(U.K. & Ireland only)		V	240/115	240/115	240/115
Power input		W	950	1,050	1,100
Load impact		min^-1	3,180	950-2,800	1,000-2,600
Load speed		min^-1	335	100-295	105-275
Impact energy		J	5.7	1 - 5.7	1 - 8.2
Total drilling range in concrete:
- solid bits		mm	12 - 40	12 - 40	12 - 45
- core bits		mm	40 - 90	40 - 90	40 - 100
Optimum drilling range in concrete:
- solid bits mm	16 - 32	16 - 32	19 - 38
Chisel positions			8	8	8
Tool holder			SDS- max^®	SDS- max^®	SDS- max^®
Weight		kg	5.8	5.9	6.2
Fuses:
Europe		230 V tools		10 Amperes, mains
U.K. & Ireland		240 V tools 13 Amperes, in plugs

Declaration of conformity

CE

DW540, DW541, DW545 and corresponding K-models

DEWALT declares that these Power Tools have been designed in compliance with: 89/392/EEC, 89/336/EEC, 73/23/EEC, EN 50144, EN 55104, EN 55014, EN 61000-3-2 & EN 61000-3-3.

Level of sound pressure according to 86/188/EEC & 89/392/EEC, measured according to EN 50144:

	DW540 DW541 DW545
L_OA	(sound pressure) dB(A)* 97.6 97.4 96.7
L_WA	(acoustic power) dB(A) 105.6 105.4 104.7

* at the operator's ear

Take appropriate measures for the protection of hearing if the sound pressure of 85 dB(A) is exceeded.

Weighted root mean square acceleration value according to EN 50144:

	DW540 DW541 DW545
	7.4 m/s^2	7.0 m/s^2	8.6 m/s^2

Director Engineering & Product Development Horst Großmann

X. fopman

DEWALT, Idstein, Germany

Safety instructions

When using Power Tools, always observe the safety regulations applicable in your country to reduce the risk of fire, electric shock and personal injury. Read the following safety instructions before attempting to operate this product. Keep these instructions in a safe place!

General

1 Keep work area clean

Cluttered areas and benches can cause accidents.

2 Consider work area environment

Do not expose Power Tools to humidity. Keep work area well lit. Do not use Power Tools in the presence of inflammable liquids or gases.

3 Guard against electric shock

Prevent body contact with earthed surfaces (e.g. pipes, radiators, cookers and refrigerators). For use under extreme conditions (e.g. high humidity, when metal swarf is being produced, etc.) electric safety can be improved by inserting an isolating transformer or a (FI) earth-leakage circuit-breaker.

4 Keep children away

Do not let children come into contact with the tool or extension cord. Keep all people away from the work area.

5 Extension cords for outdoor use

When the tool is used outdoors, always use extension cords intended for outdoor use and marked accordingly.

6 Store idle tools

When not in use, Power Tools must be stored in a dry place and locked up securely, out of reach of children.

7 Dress properly

Do not wear loose clothing or jewellery. They can be caught in moving parts. Preferably wear rubber gloves and non-slip footwear when working outdoors. Wear protective hair covering to keep long hair out of the way.

8 Wear safety goggles

Also use a face or dust mask in case the operations produce dust or flying particles.

9 Beware of maximum sound pressure

Take appropriate measures for the protection of hearing if the sound pressure of 85 dB(A) is exceeded.

10 Secure workpiece

Use clamps or a vice to hold the workpiece. It is safer and it frees both hands to operate the tool.

11 Do not overreach

Keep proper footing and balance at all times.

12 Avoid unintentional starting

Do not carry the plugged-in tool with a finger on the switch. Be sure that the switch is released when plugging in.

13 Stay alert

Watch what you are doing. Use common sense. Do not operate the tool when you are tired.

14 Disconnect tool

Shut off power and wait for the tool to come to a complete standstill before leaving it unattended. Unplug the tool when not in use, before servicing or changing accessories.

15 Remove adjusting keys and wrenches

Always check that adjusting keys and wrenches are removed from the tool before operating the tool.

16 Use appropriate tool

The intended use is laid down in this instruction manual. Do not force small tools or attachments to do the job of a heavy-duty tool. The tool will do the job better and safer at the rate for which it was intended.

Warning! The use of any accessory or attachment or performance of any operation with this tool, other than those recommended in this instruction manual may present a risk of personal injury.

17 Do not abuse cord

Never carry the tool by its cord or pull it to disconnect from the socket. Keep the cord away from heat, oil and sharp edges.

18 Maintain tools with care

Keep the tools in good condition and clean for better and safer performance. Follow the instructions for maintenance and changing accessories. Inspect the tool cords at regular intervals and, if damaged, have them repaired by an authorized DEWALT repair agent. Inspect the extension cords periodically and replace them if damaged. Keep all controls dry, clean and free from oil and grease.

19 Check for damaged parts

Before using the tool, carefully check it for damage to ensure that it will operate properly and perform its intended function. Check for misalignment and seizure of moving parts, breakage of parts and any other conditions that

may affect its operation. Have damaged guards or other defective parts repaired or replaced as instructed. Do not use the tool if the switch is defective. Have the switch replaced by an authorized DEWALT repair agent.

20 Have your tool repaired by an authorized DEWALT repair agent

This Power Tool is in accordance with the relevant safety regulations. To avoid danger, electric appliances must only be repaired by qualified technicians.

Package contents

The package contains:

1 Rotary Hammer
1 Side handle
1 Depth adjustment rod
1 Tube of bit lubricant
1 Kitbox (K-models only)
1 Instruction manual
1 Exploded drawing

• Check for damage to the tool, parts or accessories which may have occurred during transport.
• Take the time to thoroughly read and understand this manual prior to operation.

Description (fig. A)

Your DEWALT Rotary Hammer has been designed for professional hammer drilling and light chipping, chiselling and demolition applications.

1 ON/OFF-switch
2 Electronic speed and impact control dial (DW541/DW545)
3 Power-ON indicator LED (DW541/DW545)
4 Service indicator LED (DW541/DW545)
5 Mode selector lever with safety lock (16)
6 Tool holder for SDS-max® accessories
7 Collar
8 Side handle
9 Side handle clamp wheel
10 Rear side handle position
11 Depth adjustment rod
12 Switch handle cover
13 Lower service access cover
14 Upper service access cover
15 Gearbox access cover
16 Safety lock

DW541/DW545 - Soft start feature

The soft start feature allows to build up speed slowly, thus preventing the drill bit from walking off the intended hole position when starting. The soft start feature also reduces the immediate torque reaction transmitted to the gearing and the operator if the hammer is started with the drill bit in an existing hole.

Torque limiting clutch

All Rotary Hammers are equipped with a torque limiting clutch that reduces the maximum torque reaction transmitted to the operator in case of jamming of a drill bit. This feature also prevents the gearing and electric motor from stalling. The torque limiting clutch has been factory-set and cannot be adjusted.

DW541/DW545 - Electronic speed and impact control (fig. B)

The electronic speed and impact control offers the following advantages:

• use of smaller drill bits without risk of bit breakage
• drilling into light and brittle materials without shattering
• optimal tool control for precise chiselling

DW541/DW545 - Service and power-ON indicator LEDs (fig. B)

The red service indicator LED (4) lights up when the carbon brushes are nearly worn out to indicate that the tool needs servicing. After approx. 8 hours of use the motor will automatically be shut off. The carbon brushes are not user-serviceable. Take the tool to an authorized DeWALT repair agent.

The green power-ON indicator LED (3) lights up when the tool is switched ON. If the indicator LED is lit but the tool does not start, the electrical motor may be defective. If the indicator LED does not light up and the tool does not start, the ON/OFF-switch or the mains cord may be defective.

Electrical safety

The electric motor has been designed for one voltage only. Always check that the power supply corresponds to the voltage on the rating plate.

Your DEWALT tool is double insulated in accordance with EN 50144; therefore no earth wire is required.

Mains plug replacement (U.K. & Ireland only)

• Should your mains plug need replacing and you are competent to do this, proceed as instructed below. If you are in doubt, contact an authorized DEWALT repair agent or a qualified electrician.
• Disconnect the plug from the supply.
• Cut off the plug and dispose of it safely; a plug with bared copper conductors is dangerous if engaged in a live socket outlet.
• Only fit 13 Amperes BS1363A approved plugs fitted with the correctly rated fuse (1).
• The cable wire colours, or a letter, will be marked at the connection points of most good quality plugs. Attach the wires to their respective points in the plug (see below). Brown is for Live (L) (2) and Blue is for Neutral (N) (4).
• Before replacing the top cover of the mains plug ensure that the cable restraint (3) is holding the outer sheath of the cable firmly and that the two leads are correctly fixed at the terminal screws.

Technical diagram of an electrical socket with numbered components for identification

Never use a light socket.

Never connect the live (L) or neutral (N) wires to the earth pin marked E or 12

For 115 V tools, use plugs to BS4343 standard.

Using an extension cable

If an extension cable is required, use an approved triple-core extension cable suitable for the power input of this tool (see technical data). The minimum conductor size is 1.5 mm^2 .

When using a cable reel, always unwind the cable completely.

Also refer to the table below.

Conductor size (mm2) Cable rating (Amperes)
0.75 6
1.00 10
1.50 15
2.50 20
4.00 25
Cable length (m)
7.5 15 25 30 45 60

Voltage Amperes Cable rating (Amperes)
1	1	5	0	-	2	.	0	6	6	6
		2.1	-	3.4	6	6	6	6	15	15
		3.5	-	5.0	6	6	10	15	20	20
		5.1	-	7.0	10	10	15	20	20	25
		7.1	-	12.0	15	15	20	25	25	-
		12.1	-	20.0	20	20	25	-	-	-
220/240		0	-	2.0	6	6	6	6	6	6
		2.1	-	3.4	6	6	6	6	6	6
		3.5	-	5.0	6	6	6	6	10	15
		5.1	-	7.0	10	10	10	15	15
		7.1	-	12.0	15	15	15	20	20
		12.1	-	20.0	20	20	20	20	25	-

Assembly and adjustment

Prior to assembly and adjustment always unplug the tool.

DW541/DW545 - Setting the electronic speed and impact control dial (fig. B)

- Turn the dial (2) to the desired level. The higher the number, the greater the speed and impact energy. With dial settings from “1” (low) to “7” (full power) the tool is extremely versatile and adaptable for many different applications. The required setting is a matter of experience. E.g. when using smaller diameter bits or when drilling into ceramic or brittle materials, set the dial to position “1” (low).

Selecting the operating mode (fig. B)

Your Rotary Hammer can be used in two operating modes:

Hammer drilling: simultaneous rotating and impacting - for all concrete and masonry drilling operations.

Hammering only with spindle lock: impacting only - for light chipping, chiselling and demolition applications. SDS-max ^® chisels can be locked into 8 different positions (also refer to fig. C):

• Rotate the mode selector (5) until it covers the safety lock (16).
• Lock the chisel in the required position.
• Rotate the mode selector (5) until it points to the

6 T6-symbol.0

In this mode the Rotary Hammer can also be used as a lever to free a jammed drill bit.

- Select the required operating mode by rotating the mode selector lever (5) over the safety lock (16) until it points to the symbol.

Inserting and removing SDS-max ^® accessories (fig. C)

These models use SDS-max ^® drill bits and chisels (refer to the inset in fig. C for a cross-section of an SDS-max ^® bit shank).

• Unplug the tool.
• Insert the bit shank into the tool holder locking sleeve (6) and turn the bit slightly until the sleeve snaps in position.
• Pull on the bit to check if it is properly locked. The hammering function requires the bit to be able to move axially several centimetres when locked in the tool holder.
• To remove a bit pull back the tool holder locking sleeve (6) and pull the bit out of the tool holder.

Assembling and fitting the side handle

The side handle (8) can be mounted in front or in rear position on either side of the Rotary Hammer to suit both RH- and LH-users.

Always operate the Rotary Hammer with the side handle properly assembled.

Mounting in front position (fig. D)

• Unscrew the side handle (8) and disassemble the side handle clamp (20).
• Snap the steel ring (17) over the collar (7) behind the tool holder (6). Squeeze both ends together, mount the bush (18) and insert the pin (19).

• Place the side handle clamp (20) and screw on the clamp wheel (9). Do not tighten.

• Screw the side handle (8) into the clamp wheel and tighten it.

• Rotate the side handle mounting assembly to the desired position. For drilling horizontally with a heavy drill bit, place the side handle at an angle of approx. 20^ (refer to fig. E) for optimum control.
• Lock the side handle mounting assembly in place by tightening the clamp wheel (9).

Mounting in rear position (fig. F)

The rear position is particularly useful when drilling overhead or down into a floor. Refer to fig. G.

• Unscrew the side handle (8) and remove it from the front position. Leave the side handle mounting assembly in front position so that the depth adjustment rod can still be used.
• Screw the side handle directly into one of the rear side handle positions (10) on either side of the tool.

Setting the drilling depth (fig. H)

• Insert the required drill bit.
• Loosen the clamp nut (21) and fit the depth adjustment rod (11) through the hole in the side handle clamp.
• Push the drill bit into a surface at a right angle and adjust the depth adjustment rod (11) as shown.
• Tighten the clamp nut (21).

Instructions for use

• Always observe the safety instructions and applicable regulations.
- Be aware of the location of pipework and wiring.
- Apply only a gentle pressure to the tool (approx. 20 kg). Excessive force does not speed up drilling or chiselling but decreases tool performance and may shorten tool life.

Drilling with a solid bit (fig. A)

• Set the electronic speed and impact control dial (2) (DW541/DW545).
• Set the mode selector lever (5) to the “hammer drilling” position.
• Insert the appropriate drill bit.
  • Fit and adjust the side handle (8).
• If necessary, set the drilling depth.

• Mark the spot where the hole is to be drilled.

• Place the drill bit on the spot and press the ON/OFF-switch (1).

• To stop the tool, release the ON/OFF-switch (1). Always switch OFF the tool when work is finished and before unplugging.

Drilling with a core bit (fig. A)

• Turn the electronic speed and impact control dial (2) (DW541/DW545) to medium or high speed position.
• Set the mode selector lever (5) to the “hammer drilling” position.
  • Fit and adjust the side handle (8).
• Insert the appropriate core bit.
• Assemble the centerdrill into the core bit.
• Place the centerdrill on the spot and press the ON/OFF-switch (1). Drill until the core penetrates into the concrete approx. 1 cm.
• Stop drilling and remove the centerdrill. Place the core bit back into the hole and continue drilling.
• When drilling through a structure thicker than the depth of the core bit, break away the round cylinder of concrete or core inside the bit at regular intervals. To avoid unwanted breaking away of concrete around the hole, first drill a hole the diameter of the centerdrill completely through the structure. Then drill the cored hole halfway from each side.
• To stop the tool, proceed as described above.

Chipping and chiselling (fig. A)

• Set the electronic speed and impact control dial (2) (DW541/DW545).
• Set the mode selector lever (5) to the “hammering only with spindle lock” position.
• Insert the appropriate chisel and rotate it by hand to lock it into one of 8 positions.
  • Fit and adjust the side handle (8).
• Press the ON/OFF-switch (1) and start working.
• To stop the tool, proceed as described above.

Various types of SDS-max ^® drill bits and chisels are available as an option.

Consult your dealer for further information on the appropriate accessories.

Maintenance (fig. A)

Your DeWALT Power Tool has been designed to operate over a long period of time with a minimum of

maintenance. Continuous satisfactory operation depends upon proper tool care and regular cleaning.

The Rotary Hammer is not user-serviceable. Take the tool to an authorized DeWALT repair agent as soon as the service indicator LED (4) (DW541/DW545) lights up. For the DW540, an overhaul is recommended after approximately 80 hours of use.

Lubrication

Your Power Tool requires no additional lubrication.

Cleaning

Keep the ventilation slots clear and regularly clean the housing with a soft cloth.

Unwanted tools and the environment

Take your tool to an authorized DEWALT repair agent where it will be disposed of in an environmentally safe way.

GUARANTEE

• 30 DAY NO RISK SATISFACTION GUARANTEE •

If you are not completely satisfied with the performance of your DEWALT tool, simply return it within 30 days, complete as purchased, to a participating Dealer, or an authorized DEWALT repair agent, for a full refund or exchange. Proof of purchase must be produced.

• ONE YEAR FREE SERVICE CONTRACT •

If you need maintenance or service for your DEWALT tool, in the 12 months following purchase, it will be undertaken free of charge at an authorized DEWALT repair agent. Proof of purchase must be produced. Includes labour and spare parts for Power Tools. Excludes accessories.

• ONE YEAR FULL WARRANTY •

If your DEWALT product becomes defective due to faulty materials or workmanship within 12 months from the date of purchase, we guarantee to replace all defective parts free of charge or, at our discretion, replace the unit free of charge provided that:

• The product has not been misused.
• Repairs have not been attempted by unauthorized persons.
- Proof of purchase date is produced. This guarantee is offered as an extra benefit and is additional to consumers statutory rights.

For the location of your nearest authorized DEWALT repair agent, please use the appropriate telephone number on the back of this manual.

MARTILLO ROTATIVO DW540/DW541/DW545 Y MODELOS K CORRESPONDIENTES

¡Enhorabuena!

Director Engineering & Product Development Horst Großmann

X. fopman

L'emballage contient:

DW540, DW541, DW545 e modelli K correspondenti

Director Engineering & Product Development Horst Großmann

X. Jopmann

Director Engineering & Product Development Horst Großmann

X. fopman

DEWALT, Idstein, Tyskland

Sikkerhetsforskrifter

DW541/DW545 - Myk start

Director Engineering & Product Development Horst Großmann

X. fopman

15 Tire as chaves de ajuste

Director Engineering & Product Development Horst Großmann

X. fopman

DEWALT, Idstein, Saksa

Turvallisuusohjeet

Director Engineering & Product Development Horst Großmann

X. fopman

DEWALT, Idstein, Tyskland

Säkerhetsinstruktioner

Calpe House Rock Hill

Black Rock, Co. Dublin

Fax: [phone]

Italia

DEWALT

Viale Elvezia 2

20052 Monza (Mi)

Tel: [phone]

Fax: [phone]

Nederland

DEWALT Tel: [phone]

Florijnstraat 10

4879 AH Etten-Leur

Fax: [phone]

www.dewalt.benelux.com

Norge

DEWALT

Strømsveien 344

1011 Oslo

Tel: [phone]

Fax: [phone]

www.dewalt-nordic.com

Österreich

DEWALT