SEPTEMBER 2003M.CHADWICK

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D25102K / CK2kg Compact Hammer

TYPE 1

D25102K In Line Pistol Grip 2 Mode, 2kg Compact Hammer

MANUFACTURING PLANTSpennymoor

LAUNCH DATESeptember 2003

BULK DATEAugust 2003

PRODUCT ENGINEERM.Chadwick

Program Manager/EngineerP.Balloni / S.Brocket

PRODUCT DETAILS

Standard Equipmentq Multi-position side handleq Depth stopq Heavy duty carrying caseSelling Propositionq Ideal for drilling anchor and fixing holes into concrete and masonry from 4 to 22mm in diameterq Electronic variable speed for total control in any applicationq Impact-stop for drilling in wood, steel, ceramic and screw driving applicationsq Safety clutch eliminates sudden high-torque reaction should the bit jamq Ergonomic rubber coated back handle design for improved comfort in useq Rounded ergonomic industrial design allows easy and comfortable handling in any applicationq Improved sealing for maximum protection from dust ingress ensuring long tool lifeq Large 22mm hammer mechanism delivers high performance with low stress to the critcal componentsq Output air slots designed to protect users' eyeApplicationsq Drilling holes in solid masonry, concrete stone from 4 to 26mm in diameter to various fixingq Drilling through holes in masonry to house pipes and cablesq Some drilling in wood and steelSpecificationsq Power Input 650 Wattsq Power Output 370 Wattsq No Load Speed 0-1100 rpmq Blows per Minute 0-4200 bpmq Impact Energy 0-2.8 Jq Tool Holder SDS-Plusq Max. Drilling Capacity [Wood] 30 mmq Max. Drilling Capacity [Metal] 13 mmq Max. Drilling Capacity [Concrete] 22 mmq Max. Drilling Capacity [Core bit] 65 mmq Weight 2.5 kg. Length 360 mm . Height 200 mm

Type No. 1 CURRENT STATUS & MAJOR CHANGES .

New product design.

QU

LAUNCH MARKETS & QUANTITIES

QS

D25102CK In Line Pistol Grip 2 Mode, 2kg Compact Hammer

MANUFACTURING PLANTSpennymoor

LAUNCH DATESeptember 2003

BULK DATEAugust 2003

PRODUCT ENGINEERM.Chadwick

Program Manager/EngineerP.Balloni / S.Brocket

PRODUCT DETAILSStandard Equipmentq multi-position side handleq depth stopq SDS-plus adapterq 3 Jaws keyed chuckq heavy duty carrying caseSelling Propositionq Ideal for drilling anchor and fixing holes into concrete and masonry from 4 to 22mm in diameterq Electronic variable speed for total control in any applicationq Impact-stop for drilling in wood, steel, ceramic and screw driving applicationsq Safety clutch eliminates sudden high-torque reaction should the bit jamq Ergonomic rubber coated back handle design for improved comfort in useq Rounded ergonomic industrial design allows easy and comfortable handling in any applicationq Improved sealing for maximum protection from dust ingress ensuring long tool lifeq Large 22mm hammer mechanism delivers high performance with low stress to the critcal componentsq Output air slots designed to protect users' eyeApplicationsq Drilling holes in solid masonry, concrete stone from 4 to 26mm in diameter to various fixingq Drilling through holes in masonry to house pipes and cablesq Some drilling in wood and steelSpecificationsq Power Input 650 Wattsq Power Output 370 Wattsq No Load Speed 0-1100 rpmq Blows per Minute 0-4200 bpmq Impact Energy 0-2.8 Jq Tool Holder SDS-Plusq Max. Drilling Capacity [Wood] 30 mmq Max. Drilling Capacity [Metal] 13 mmq Max. Drilling Capacity [Concrete] 22 mmq Max. Drilling Capacity [Core bit] 65 mmq Weight 2.5 kg. Length 360 mm . Height 200 mm

Type No. 1 CURRENT STATUS & MAJOR CHANGES .

New product design.

QU

LAUNCH MARKETS & QUANTITIES

QS

TYP.

WWW.2helpU.com 12 - 06 - 03E13616/ 577845-02

D25102 1

37

7

8

34

2

23

3240

13

14 15

12

5 4

3

18

27

35

36

21

6

19

29

17

16

35

821

31

23

861

TYP.

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D25102 1

E13617 / 577845-02

800 801

60

52 5354

50

51

62

110

111

112

113

114

115

121

93

9697

94

95

9091

9392

132

136

135134

133

846

71

72

73

74

77

76

78

79

61

55

5657

58

59

1

25

2245

70

118

75

170160

D25102C

180

182181

183

Black & Decker Bill of Materials - PARTS LIST

Page 1

Product Number D25102K---A Product Description ROTARY HAMMER Type Identifier TYPE 1

ItemNumber

QuantityPer

Part Number Part Description Variant Description TypeDescription

Market Codes Referto R.I.

1 1 585474-00 ARMATURE 230V AR - B2 - GB - QS - XE No

1 1 585474-01 ARMATURE 115V BR - LX - QU No

2 1 576690-05 FIELD 230V AR - B2 - GB - QS - XE No

2 1 576690-06 FIELD 115V BR - LX - QU No

3 1 578287-03 SWITCH LOCK-ON 230 Volts AR - B2 - GB - QS - XE No

3 1 583748-02 SWITCH LOCK-ON 120 Volt BR - LX - QU No

4 2 577830-02 BRUSH HOLDER SA 230 Volt AR - B2 - GB - QS - XE No

4 2 577830-03 BRUSH HOLDER SA 120 Volt BR - LX - QU No

5 1 585475-00 BRUSH KIT 230 Volts AR - B2 - GB - QS - XE No

5 1 585475-01 BRUSH KIT 115 Volts BR - LX - QU No

6 1 949877-01 CAPACITOR AR - B2 - GB - LX - QS - XE No

7 1 584090-00 CORD PROTECTOR No

8 1 325090-10 CORDSET U.S.120V QU No

8 1 330048-39 CORDSET XE No

8 1 573379-12 CORDSET AR No

8 1 582319-03 CORDSET (M/PLUG) QS QS No

8 1 582319-04 CORDSET (M/PLUG) GB GB No

8 1 582319-05 CORDSET (M/PLUG) 115 VOLT LX No

8 1 582573-01 CORDSET B2 No

8 1 582573-03 CORDSET BR No

12 1 582063-00 LEAD WHITE AR - B2 - GB - QS - XE No

12 1 584304-00 LEAD WHITE BR - LX - QU No

13 1 582063-01 LEAD BLUE AR - B2 - GB - QS - XE No

13 1 584304-01 LEAD BLUE BR - LX - QU No

14 1 582063-04 LEAD BLACK AR - B2 - GB - QS - XE No

14 1 584304-04 LEAD BLACK BR - LX - QU No

15 1 582063-05 LEAD VIOLET AR - B2 - GB - QS - XE No

15 1 584304-05 LEAD VIOLET BR - LX - QU No

16 1 582063-02 LEAD RED With Choke AR - B2 - GB - QS - XE No

Black & Decker Bill of Materials - PARTS LIST

Page 2

16 1 584304-02 LEAD RED With Choke LX No

16 1 584304-06 LEAD RED Without Choke BR - QU No

17 1 582063-03 LEAD YELLOW With Choke AR - B2 - GB - QS - XE No

17 1 584304-03 LEAD YELLOW With Choke LX No

17 1 584304-07 LEAD YELLOW Without Choke BR - QU No

18 1 930026-01 BUMPER No

19 1 579305-00 SELECTOR No

21 1 870052 SLEEVE No

22 2 324006-14 SCREW M4x12 Yes

23 4 326519-03 SCREW 3.5x30 Yes

25 1 330003-19 BEARING No

27 1 584008-00 SUPPORT AR - B2 - GB - QS - XE Yes

29 1 584080-00 INSERT AR - B2 - GB - QS - XE No

29 1 584551-00 INSERT 115V LX No

31 1 577826-00 BAFFLE FAN No

32 1 577810-00 FIELDCASE No

34 1 577811-00 HANDLE COVER No

35 4 330065-06 SCREW Yes

36 1 916307 CORD CLAMP No

37 1 330065-09 SCREW Yes

40 4 330065-25 SCREW Yes

45 1 577791-00 O RING No

50 1 585480-00 INTERSHAFT SA Yes

51 1 580907-00 O RING 5x1 No

52 1 578271-00 PLATE No

53 1 579564-00 HOLDER No

54 1 579552-00 SELECTOR No

55 1 584638-00 O RING 14x2 No

56 1 577809-00 LEVER No

57 1 324007-14 SCREW 4x20 Yes

58 1 579184-00 LOCK BUTTON No

Black & Decker Bill of Materials - PARTS LIST

Page 3

59 1 579179-00 SPRING No

60 1 582865-00 FILTER No

61 1 579185-00 COVER No

62 3 583981-00 SCREW 4x16 Yes

70 1 585482-00 HOUSING SA No

71 1 330003-31 BEARING No

72 1 578229-00 SEAL No

73 1 577801-00 BEARING BLOCK No

74 2 577802-00 WASHER SHIM No

75 1 584420-00 PISTON Yes

76 1 579699-00 O RING No

77 1 584421-00 RAM No

78 1 577297-00 BEARING PLATE No

79 3 324006-15 SCREW 4x16 Yes

90 1 577793-00 CLIP Yes

91 1 584426-00 BUSH No

92 1 580990-00 O RING No

93 2 577135-00 O RING 19.5 x 3.5 No

94 1 584425-00 DAMPER No

95 1 584424-00 BEAT PIECE No

96 1 584423-00 BEARING & SEAL No

97 1 577139-00 SEAL No

110 1 577797-00 WASHER No

111 1 577744-00 O RING 23 X 2 No

112 1 584427-00 CLUTCH SA Yes

113 1 579178-00 SPRING No

114 1 584422-00 CYLINDER SA Yes

115 1 577814-00 WASHER No

118 1 586501-00 GEARCASE SA No

121 4 330065-28 SCREW M4 X 30 Yes

132 1 871690 SPRING No

Black & Decker Bill of Materials - PARTS LIST

Page 4

133 1 578387-00 WASHER No

134 1 583890-00 BALL 7MM No

135 1 577928-00 TUBE No

136 1 323489-00 CAP No

160 1 575182-00 HANDLE SA Yes

170 1 798846-02 DEPTH STOP No

180 1 330034-07 CHUCK KEY No

181 1 352065 ADAPTOR No

182 1 330033-25 CHUCK 13MM No

183 1 945013-00 SCREW No

800 1 870889-02 GREASE 80 gms Yes

801 1 487130-04 GREASE 10grm Sachets Yes

821 1 569037-00 RATING PLATE DeWalt Blank. AR - B2 - BR - GB - LX - QS - XE No

846 1 585499-00 SERVICE KIT 230V AR - B2 - GB - QS - XE Yes

846 1 585500-00 SERVICE KIT 115V BR - LX - QU Yes

861 1 577646-01 KITBOX No

R11402en.rtf

R11402D25101K, D25102K, D25103K, D25104K, D25201K, D25203K INLINE HAMMER Type 1

Item No.

27 This part is only used on 230V units fitted with the Tyco Switch.

50 The Intershaft is only available as a SA.

75 Make sure the chanfer at the back of the Hollow Piston is facing the Wobble Bearing (50)

90 Avoid damage to the cylinder (114) wall when removing / refitting the snap ring.

112 The clutch is only available as a SA.

114 The Spindle is only available as a SA.

160 The side handle is only available as a SA.

846 The Service kit includes all O Rings, Seals, Brushes, Screws and Grease ( items 5,45, 51,55, 60, 62x2, 72, 76, 79x3, 92, 93x2, 97, 136, 800, 801) . Item 45 O Ring is not required whenreparing the D25104.

Lubrication.

800 Paragon Grease.SA gearbox total 60 grms. 40grms inside the Housing (70) around the hollow piston andWobble Bearing. 20grms spread over the Reduction Gear / Clutch (112) and intergear (50).5grms spread over (items 91, 92, 93, 94, 95, 96).1grm around the Steel Ball (134) and the tool holder end of Cylinder (114).

801 GLK Grease.3grms on the inside of Cylinder (114).1grm over the Ram (77) and O Ring (76).3grms inside the Hollow Piston (75).

Touque Settings.

9 2.0 Nm22 2.2 Nm23 1.0 Nm Field x 2.23 0.6 Nm Fan Baffel x 2.35 2.0 Nm Handle Cover x 235 1.5 Nm Cord Clamp x 237 2.0 Nm40 1.0 Nm57 1.5 Nm62 3.2 Nm79 3.2 Nm116 2.0 Nm121 2.0 Nm

New Parts

2KG IN LINE HAMMERD25102

Part Number Part Description

GEARCASE SA586501-00

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

07 October 2003 Page 1 of 1P1ant: SP

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

TYP.

WWW.2helpU.com 04 - 07 - 03E13671

1

COMMTOPFWD / REV SWITCH

115V

P7 P3

P4 P6

Item 13 Blue

Item 12 White

Item 14 Black

Item 17 Yellow

Item 16 Red

Item 15 Violet

2

2 11

M2

MARQUADT SWITCH 115 VOLTS.

BrownBlue

D25101 / D25102 / D25103 / D25104/ D25201 / D25203

TYP.

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1

COMMTOPFWD / REV SWITCH

120V

P7 P3

P4 P6

Item 13 Blue

Item 12 White

Item 14 Black

Item 17 Yellow

Item 16 Red

Item 15 Violet

2

2 11

M2

MARQUADT SWITCH 120 VOLTS.

BrownBlue

D25101 / D25102 / D25103 / D25104/ D25201 / D25203

TYP.

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1

TYCO SWITCH 230 VOLTS.

COMMTOPFWD / REV SWITCH

BlueBrown

230v

P1 P3

P4 P2

Item 13 Blue

Item 12 White

Item 17 Yellow

Item 16 Red

Item 15 Violet

L1 L2

M2C2

C1

M1

M1

Item 14 Black

Item 13 Blue

ENGLISH

WHITEBROWNBLUEREDYELLOWVIOLETBLACKGREEN

FRENCH

BLANCBRUNBLEUROUGEJAUNEVIOLETNOIRVERT

ITALIAN

BIANCOMARRONEBLUROSSOGIALLOVIOLANEROVERDE

GERMAN

WEISSBRAUNBLAUROTGELBVIOLETTSCHWARZGRUN

D25101 / D25102 / D25103 / D25104/ D25201 / D25203