DeWalt DW116 User manual

DEWALT Industrial Tool Company, P.O. Box 158, 626 Hanover Pike, Hampstead, MD 21074 Printed in U.S.A. (JAN95-CD-2) Form No. 158865
For Information call toll free between 8:00 a.m. to 8:00 p.m.,seven days a week. 1-800-4-DEWALT (1-800-433-9258)
DW116/117 Copyright © 1993, 1995
158865/JAN95 5/20/02 3:47 PM Page 2

INSTRUCTION MANUAL
DW116 1/2" V.S.R. Drill
DW117 1/2" V.S.R. Drill
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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).
R
1/2" KEYLESS
CHUCK
REVERSING
LEVER
TRIGGER
SWITCH
SWITCH
LOCK BUTTON
MULTI-POSITION
SIDE HANDLE
Serial Number from Nameplate Date of Purchase
Save this information for future reference
DEWALT…BUILT JOBSITE TOUGH
DEWALT high performance industrial tools are made for America’s
toughest industrial and construction applications. The design of every
tool in the line—from drills to sanders to grinders—is the result of rigorous
use on jobsites and throughout industry. Each tool is produced with
painstaking precision using advanced manufacturing systems and intense
quality control. Every tool is checked before it leaves the factory to make
sure that it meets your standards for durability, reliability and power.
DEWALT Built Jobsite Tough…WE GUARANTEE IT.
158865/JAN95 5/20/02 3:47 PM Page 4

1
WARNING: When using electric tools, basic safety
precautions should always be followed to reduce risk of fire,
electric shock, and personal injury, including the following:
READ ALL INSTRUCTIONS
Double Insulation
Double insulated tools are constructed throughout with two
separate layers of electrical insulation or one double thickness
of insulation between you and the tool’s electrical system.
Tools built with this insulation system are not intended to be
grounded. As a result, your tool is equipped with a two prong
plug which permits you to use extension cords without concern
for maintaining a ground connection.
NOTE: Double insulation does not take the place of normal
safety precautions when operating this tool. The insulation
system is for added protection against injury resulting from a
possible electrical insulation failure within the tool.
CAUTION: WHEN SERVICING USE ONLY IDENTICAL
REPLACEMENT PARTS. Repair or replace damaged cords.
Polarized Plugs
Polarized plugs (one blade is wider than the other) are used on
equipment to reduce the risk of electric shock. When provided,
this plug will fit into a polarized outlet only one way. If the plug
does not fit fully into the outlet, reverse the plug. If it still does
not fit, contact a qualified electrician to install the proper outlet.
Do not change the plug in any way.
Safety Instructions For All Tools
•KEEP WORK AREA CLEAN. Cluttered areas and benches
invite injuries.
•CONSIDER WORK AREA ENVIRONMENT. Don’t expose
power tools to rain. Don’t use power tools in damp or wet
locations. Keep work area well lit. Do not use tool in
presence of flammable liquids or gases.
•GUARD AGAINST ELECTRIC SHOCK. Prevent body
contact with grounded surfaces. For example; pipes,
radiators, ranges, and refrigerator enclosures.
•KEEP CHILDREN AWAY. Do not let visitors contact tool or
extension cord. All visitors should be kept away from work
area.
•STORE IDLE TOOLS. When not in use, tools should be
stored in dry, and high or locked-up place — out of reach of
children.
•DON’T FORCE TOOL. It will do the job better and safer at
the rate for which it was intended.
•USE RIGHT TOOL. Don’t force small tool or attachment to
do the job of a heavy-duty tool. Don’t use tool for purpose not
intended.
•DRESS PROPERLY. Do not wear loose clothing or jewelry.
They can be caught in moving parts. Rubber gloves and
non-skid footwear are recommended when working
outdoors. Wear protective hair covering to contain long hair.
•USE SAFETY GLASSES. Also use face or dust mask if
operation is dusty.
•DON’T ABUSE CORD. Never carry tool by cord or yank it to
disconnect from receptacle. Keep cord from heat, oil, and
sharp edges.
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•SECURE WORK. Use clamps or a vise to hold work. It’s
saferthanusingyourhandanditfreesbothhandstooperate
tool.
•DON’T OVERREACH. Keep proper footing and balance at
all times.
•MAINTAIN TOOLS WITH CARE. Keep tools sharp and
clean for better and safer performance. Follow instructions
for lubricating and changing accessories. Inspect tool cords
periodically and if damaged, have repaired by authorized
service facility. Inspect extension cords periodically and
replace if damaged. Keep handles dry, clean, and free from
oil and grease.
•DISCONNECT OR LOCK OFF TOOLS when not in use,
before servicing, and when changing accessories, such as
blades, bits, cutters.
•REMOVE ADJUSTING KEYS AND WRENCHES. Form
habit of checking to see that keys and adjusting wrenches
are removed from tool before turning it on.
•AVOID UNINTENTIONAL STARTING. Don’t carry tool with
finger on switch. Be sure switch is off when plugging in.
•EXTENSION CORDS. Make sure your extension cord is in
good condition. 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
0-61816 16 14
6-1018 16 14 12
10 - 12 16 16 14 12
12 - 16 14 12 Not Recommended
•OUTDOOR USE EXTENSION CORDS. When tool is used
outdoors, use only extension cords intended for use
outdoors and so marked.
•STAY ALERT. Watch what you are doing. Use common
sense. Do not operate tool when you are tired.
•CHECK DAMAGED PARTS. Before further use of the tool,
a guard or other part that is damaged should be carefully
checked to determine that it will operate properly and
perform its intended function. Check for alignment of moving
parts, binding of moving parts, breakage of parts, mounting,
and any other conditions that may affect its operation. A
guard or other part that is damaged should be properly
repaired or replaced by an authorized service center unless
otherwise indicated elsewhere in this instruction manual.
Have defective switches replaced by authorized service
center. Do not use tool if switch does not turn it on and off.
•CAUTION: When drilling or driving into walls, floors or
wherever live electrical wires may be encountered, DO NOT
TOUCH ANY METAL PARTS OF THE TOOL! Hold the tool
only by insulated grasping surfaces to prevent electric shock
if you drill or drive into a live wire.
SAVE THESE INSTRUCTIONS
2
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THE VARIABLE SPEED TRIGGER SWITCH permits speed
control – the farther the trigger is depressed, the higher the speed
of the drill. NOTE: Use lower speeds for starting holes without a
center punch, drilling in metal or plastics, driving screws or drilling
ceramics. Higher speeds are better for drilling wood and
composition boards, and for using abrasive and polishing
accessories.
THE REVERSING LEVER The reversing lever 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) as shown in Figure 2. To
operate the drill in forward for drilling holes or driving screws (as
well as other accessories) 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.
Operation
DRILLING
NOTE: Always use side handle and two-handed grip when
operating this drill.
1. Always unplug the drill when attaching or changing bits or
accessories.
2. Use sharp drill bits only. For WOOD, use twist drill bits, spade
bits, power auger bits, or hole saws. For METAL, use high
speed twist drill bits or hole saws. For MASONRY, such as
brick, cement, cinder block, etc., use carbide-tipped bits.
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.
3
R
R
REVERSING LEVER
(Shown in Reverse
Position
FIG. 1 FIG. 2
A
Motor Brushes
DEWALT uses an advanced brush system which automatically stops
the drill when the brushes wear out. This prevents serious damage to
the motor.
Switch
To start drill, depress trigger switch; to stop drill, release trigger.
To lock trigger in “ON” position for continuous operation, depress
trigger and push up locking button “A” Figure 1, then gently
release trigger. To release locking mechanism, depress trigger
fully, then release it. 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 drill is mounted in a
drill press stand or otherwise held stationary.
Be sure to release the locking button before disconnecting the plug
from the power supply. Failure to do so will cause the tool to start
immediately the next time it is plugged in. Damage or injury could
result.
158865/JAN95 5/20/02 3:47 PM Page 3

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.
Keyless Chuck
Your tool features a keyless chuck for greater convenience. To
insert a drill bit or other accessory, follow the steps listed below.
1. Unplug the drill.
2. Grasp the rear half of the chuck with one hand and use your
other hand to rotate the front half counterclockwise, as shown in
Figure 3. Rotate far enough so that the chuck opens sufficiently
to accept the desired accessory.
3. Insert the bit or other accessory about 3/4" into the chuck and
tighten securely by holding the rear half of the chuck and
rotating the front portion in the clockwise direction.
To release the accessory, repeat step 2 listed above.
WARNING: Do not attempt to tighten 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 result.
Drilling in Metal
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 sulfurized cutting oil or lard oil;
bacon-grease will also serve the purpose.
Drilling in Wood
Holes in wood can be made with the same twist drills used for metal.
These bits may overheat unless pulled out frequently to clear chips
from the flutes. For larger holes, use Power Drill Wood Bits. Work
that is apt to splinter should be backed up with a block of wood.
Drilling in Masonry
Use carbide tipped masonry bits at low speeds. Keep even force
on the drill but not so much that you crack the brittle materials. A
smooth, even flow of dust indicates the proper drilling rate.
4
FIG. 3
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5
FIG. 4 Side Handle
TURN OFF AND UNPLUG DRILL.
CAUTION: Always use side handle and hold drill with both hands.
A side handle is supplied with your drill. To install the side handle,
loosen the handle as shown in Figure 4 until the clamp portion fits
past the chuck. Slide the clamp fully past the chuck and onto the
front of the gear case, as shown in Figure 4. It can be rotated 360
degrees to permit right or left hand use. Position the side handle as
desired and firmly tighten the handle, as shown in Figure 4.
Chuck Removal
Unplug the drill. Tighten the chuck around the shorter end of a hex
key (not supplied) of 1/4" or greater size. Using a soft hammer or
piece of wood, strike the longer end in the clockwise direction, as
shown in Figure 5.
This will loosen the screw inside the chuck.
Open chuck jaws fully, insert screwdriver (or Torx tool if required)
into front of chuck between jaws to engage screw head. Remove
screw by turning clockwise (left-hand-thread). Place hex key in
chuck as shown in Figure 6. Using a wooden mallet or similar
object, strike key sharply in the counterclockwise direction. This will
loosen the chuck so that it can be unscrewed by hand.
Chuck Installation
Screw the chuck on by hand as far as it will go. Tighten the chuck
around the shorter end of a 1/4" or larger hex key (not supplied)
strike the longer end in the clockwise direction with a soft hammer,
as shown in Figure 5. Insert screw into center of chuck and tighten
(counterclockwise) securely.
LOOSEN TIGHTEN
CLAMP
FIG. 5 FIG. 6
158865/JAN95 5/20/02 3:47 PM Page 5

Maximum Recommended Capacities
CHUCK CAPACITY 1/2"
R.P.M. DW116 0-600
R.P.M. DW117 0-900
BITS, METAL DRILLING 1/2"
WOOD, FLAT BORING 1-3/4"
BITS, MASONRY DRILLING 9/16"
HOLE SAWS 3"
ACCESSORY MUST BE RATED FOR USE AT SPEED EQUAL
TO OR HIGHER THAN NAMEPLATE R.P.M. OF TOOL WITH
WHICH IT IS BEING USED.
WIRE WHEEL BRUSHES 4" Diameter Maximum
WIRE CUP BRUSHES 3" Diameter Maximum
BUFFING WHEELS 3" Diameter Maximum
RUBBER BACKING PADS 4-5/8" Diameter Maximum
6
Important
To assure product SAFETY and RELIABILITY, repairs,
maintenance, and adjustment should be performed by DEWALT
certified service centers or other qualified service organizations.
These service organizations service DEWALT tools always using
DEWALT replacement parts.
Black & Decker (U.S) Inc. industrial tool service centers are
certified for servicing DEWALT industrial tools.
Accessories
Recommended accessories for use with your tool are available at
extra cost from your local service center.
A complete listing of service centers is included on the owner’s
registration card packed with your tool.
If you need assistance in locating any accessory, please contact
DeWalt Industrial Tool Company, P.O. Box 158, 626 Hanover Pike,
Hampstead, MD 21074 or call 1-800-4-DeWALT (1-800-433-9258).
Recommended accessories for your Drill are shown in this manual.
(CAUTION: The use of any other accessory might be hazardous.)
For safety in use, the following accessories should be used only in
sizes up to the maximums shown in the table below.
158865/JAN95 5/20/02 3:47 PM Page 6

Full Warranty
DEWALT heavy duty industrial tools are warranted for one year
from date of purchase. We will repair, without charge, any defects
due to faulty materials or workmanship. Arrangements have been
made with the Industrial Tool Division of Black & Decker (U.S.)
Inc. to provide warranty repairs for DEWALT tools. Please return
the complete unit, transportation prepaid, to any Black & Decker
(U.S.) Inc. Industrial Service Center or Authorized Service Station
listed under “Tools, Electric” in the Yellow Pages. 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
from state to state.
In addition to the warranty, DEWALT tools are covered by our:
30 DAY NO RISK SATISFACTION GUARANTEE
If you are not completely satisfied with the performance of your
DEWALT heavy duty industrial tool, simply return it to the
participating seller within 30 days for a full refund. Please return the
complete unit, transportation prepaid. Proof of purchase may be
required.
See ‘Tools-Electric’
– Yellow Pages –
for Service & Sales
7
158865/JAN95 5/20/02 3:47 PM Page 7

Other DEWALT Heavy Duty Industrial
Tools Available From Your Local Dealer
DW944K 9.6V Heavy Duty Versa-Clutch Cordless 3/8"
Driver/Drill Kit with Keyless Chuck:
High performance industrial Versa-Clutch cordless
Driver/Drill has two variable speed ranges and reversing to
perform well in a wide variety of metals and wood. The
extremely versatile cordless Driver/Drill has 11 clutch
settings, a keyless chuck and delivers more power and
torque than any cordless drill in its class. Also available:
DW945K 12.0V Heavy Duty Versa-Clutch Cordless 3/8"
Driver/Drill Kit with Keyless Chuck
DW942R 7.2V Heavy Duty Cordless 3/8" VSR Drill
DW360 Heavy Duty 7-1/4" Circular Saw with Electric Brake:
High performance industrial saw has a 13 amp rating and a 2
second electric brake. It has a 50 degree bevel capacity and
steel helical gears to assure long term reliability. It delivers
more watts out and more torque than other saws in its class.
8
DW944K
DW945K
DW942R
DW360
158865/JAN95 5/20/02 3:47 PM Page 8

DW100
DW411
DW304K
DW120K 9
Other DEWALT Heavy Duty Industrial
Tools Available From Your Local Dealer
DW100 Heavy Duty 3/8" VSR Drill:
High performance industrial quality variable speed reversing
drill is designed for long life in heavy-duty professional use.
High speed (0-2500 RPM) and 4.0 amps enable the drill to
perform well in a wide variety of metals, wood, masonry and
composite materials. It also has a built-in 2-way bubble level
for drilling accuracy.
DW411 Heavy Duty 1/4 Sheet Palm Grip Sander:
High performance industrial palm grip sander has efficient
through-the-pad dust collection. Low vibration design
delivers less than half the vibration of other palm sanders
for greater comfort and durability. The sander gives fast and
efficient material removal.
DW304K Heavy Duty VS Reciprocating Saw Kit:
High performance industrial reciprocating saw has low
vibration design to reduce user fatigue. High power (6.0
amps and 1 1/8" stroke length) allows increased productivity.
Lightweight and comfortable.
DW120K Heavy Duty 1/2" Right Angle Drill Kit:
High performance industrial right angle drill is reversing and
has three speeds (400/600/900 RPM) for plumbing and
electrical applications. Powerful 7.0 amp motor easily
handles popular 2 9/16" self-feed bits.
158865/JAN95 5/20/02 3:47 PM Page 9