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4. Once the Automatic Tune-Up™ Mode is complete the charger will transition to a mainte-
nance charge; the indicator light shuts off when the Automatic Tune-Up™ Mode is complete.
SAVE THESE INSTRUCTIONS FOR FUTURE USE
Chargers
Your tool uses a DEWALT charger. Your battery can be charged in DEWALT 1 Hour Chargers,
15 Minute Chargers or Vehicular 12 Volt Charger. Be sure to read all safety instructions before
using your charger. Consult the chart at the end of this manual for compatibility of chargers and
battery packs.
Charging Procedure
DANGER: Electrocution hazard. 120 volts are present at charging terminals. Do not probe with
conductive objects.
1. Plug the charger into an appropriate outlet as shown in Figure 1.
2. Insert the battery pack into the charger. The red (charging) light will blink continuously indi-
cating that the charging process has started.
3. The completion of charge will be indicated by the red light remaining ON continuously. The
pack is fully charged and may be used at this time or left in the charger.
Indicator Light Operation
Charge Indicators
Some chargers are designed to detect certain problems that can arise with battery packs.
Problems are indicated by the red light flashing at a fast rate. If this occurs, re-insert battery
pack into the charger. If the problem persists, try a different battery pack to determine if the
charger is OK. If the new pack charges correctly, then the original pack is defective and should
be returned to a service center or other collection site for recycling. If the new battery pack
elicits the same trouble indication as the original, have the charger tested at an authorized ser-
vice center.
HOT/COLD PACK DELAY
Some chargers have a Hot/Cold Pack Delay feature: when the charger detects a battery that is
hot, it automatically starts a Hot Pack Delay, suspending charging until the battery has cooled.
After the battery has cooled, the charger automatically switches to the Pack Charging mode.
This feature ensures maximum battery life. The red light flashes long, then short while in the Hot
Pack Delay mode.
PROBLEM POWER LINE
Some chargers have a Problem Power Line indicator. When the charger is used with some
portable power sources such as generators or sources that convert DC to AC, the charger may
temporarily suspend operation, flashing the red light with two fast blinks followed by a
pause. This indicates the power source is out of limits.
LEAVING THE BATTERY PACK IN THE CHARGER
The charger and battery pack can be left connected with the red light glowing indefinitely. The
charger will keep the battery pack fresh and fully charged.
NOTE: A battery pack will slowly lose its charge when kept out of the charger. If the battery pack
has not been kept on maintenance charge, it may need to be recharged before use. A battery
pack may also slowly lose its charge if left in a charger that is not plugged into an appropriate
AC source.
WEAK BATTERY PACKS: Chargers can also detect a weak battery. Such batteries are still
usable but should not be expected to perform as much work. In such cases, about 10 seconds
after battery insertion, the charger will beep rapidly 8 times to indicate a weak battery condition.
The charger will then go on to charge the battery to the highest capacity possible.
Important Charging Notes
1. Longest life and best performance can be obtained if the battery pack is charged when the
air temperature is between 65°F and 75°F (18°- 24°C). DO NOT charge the battery pack in
an air temperature below +40°F (+4.5°C), or above +105°F (+40.5°C). This is important and
will prevent serious damage to the battery pack.
2. The charger and battery pack may become warm to touch while charging. This is a normal
condition, and does not indicate a problem. To facilitate the cooling of the battery pack after
use, avoid placing the charger or battery pack in a warm environment such as in a metal
shed, or an uninsulated trailer.
3. If the battery pack does not charge properly:
a. Check current at receptacle by plugging in a lamp or other appliance
b. Check to see if receptacle is connected to a light switch which turns power off when you
turn out the lights.
c. Move charger and battery pack to a location where the surrounding air temperature is
approximately 65°F - 75°F (18°- 24°C).
d. If charging problems persist, take the tool, battery pack and charger to your local ser-
vice center.
4. The battery pack should be recharged when it fails to produce sufficient power on jobs which
were easily done previously. DO NOT CONTINUE to use under these conditions. Follow the
charging procedure. You may also charge a partially used pack whenever you desire with no
adverse affect on the battery pack.
5. Under certain conditions, with the charger plugged into the power supply, the exposed
charging contacts inside the charger can be shorted by foreign material. Foreign materials
of a conductive nature such as, but not limited to, steel wool, aluminum foil, or any buildup
of metallic particles should be kept away from charger cavities. Always unplug the charger
from the power supply when there is no battery pack in the cavity. Unplug charger before
attempting to clean.
6. Do not freeze or immerse charger in water or any other liquid.
WARNING: Shock hazard. Do not allow any liquid to get inside charger.
CAUTION: Never attempt to open the battery pack for any reason. If the plastic housing of the
battery pack breaks or cracks, return to a service center for recycling.
Important!
This product is not user servicable. There are no user servicable parts inside the charger.
Servicing at an authorized service center is required to avoid damage to static sensitive internal
components.
READ ALL OF THE INSTRUCTIONS IN THE BATTERY CHARGER MANUAL BEFORE
ATTEMPTING TO CHARGE THE BATTERY PACK FOR YOUR TOOL.
Always use correct battery pack (pack supplied with tool or replacement pack exactly like it.) Never
install any other battery pack. It will ruin your tool and may create a hazardous condition.
Installing and Removing the Battery Pack (Fig. 2, 3)
NOTE: Make sure your battery pack is fully charged.
CAUTION: Lock trigger switch before removing or installing battery.
To install the battery pack into the tool handle, align the base of the tool with the notch inside
the tool’s handle and slide the battery pack firmly into the handle until you hear the lock snap
into place as shown in Figure 2.
To remove the battery pack from the tool, press the release buttons and firmly pull the bat-
tery pack out of the tool handle. Insert it into the charger as described in the charger manual.
Variable Speed Switch
To turn the tool on, squeeze the trigger switch. To turn the tool off, release the trigger switch.
Your tool is equipped with a brake. The chuck will stop as soon as the trigger switch is fully
released.
The variable speed switch enables you to select the best speed for a particular application. The
farther you squeeze the trigger, the faster the tool will operate. Use lower speeds for starting
holes without a centerpunch, drilling in metals or plastics, driving screws and drilling ceramics,
or in any application requiring high torque. Higher speeds are better for drilling in wood, wood
compositions and for using abrasive and polishing accessories. For maximum tool life, use vari-
able speed only for starting holes or fasteners.
NOTE: Continuous use in variable speed range is not recommended. It may damage the switch
and should be avoided.
Forward/Reverse Control Button (Fig. 3)
A forward/reverse control button determines the direction of the tool and also serves as a lock
off button. To select forward rotation, release the trigger switch and depress the forward/reverse
control button on the right side of the tool.To select reverse, depress the forward/reverse control
button on the left side of the tool. The center position of the control button locks the tool in the
off position. When changing the position of the control button, be sure the trigger is released.
NOTE: The first time the tool is run after changing the direction of rotation, you may hear a click
on start up. This is normal and does not indicate a problem.
Dual Range Gearing
The dual range feature of your tool allows you to shift gears for greater versatility. To select the low
speed, high torque setting, turn the tool off and permit to stop. Slide the gear shifter forward
(towards the chuck). To select the high speed, low torque setting, turn the tool off and permit to
stop. Slide the gear shifter back (away from chuck). NOTE: Do not change gears when the tool is
running. If you are having trouble changing gears, make sure that the dual range gear shifter is
either completely pushed forward or completely pushed back.
Lubrication
Your tool was properly lubricated before leaving the factory. Within two to six months, depend-
ing upon use, take or send your tool to a Service Center, or authorized service station, for a com-
plete 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.
Repairs
To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustments should be
performed by a DEWALT factory service center, a DEWALT authorized service center or other
qualified service personnel. Always use identical replacement parts.
FIG. 3 FIG. 4
CHANGING CLUTCHES
1. Remove clutch housing by unscrewing (left-hand thread).
2. Clamp tool or clutch housing in a resilient clamp.USE CARE, the clutch housing can be
easily damaged.
3. Remove round clutch retaining rings with a very small screwdriver (Fig. 4).
4. Install new clutches and new retaining rings. Be careful to assemble the intermediate clutch
large end first toward the unit and then the spring. The spring should run against the output
clutch.
NOTE: If the output spindle slides toward inside of gear case, remove gear case and push out-
put spindle forward to expose retaining ring groove. Reassemble dead spindle spring allowing
no more than 1/4" projecting from end of spindle.
5. Relubricate clutches (see Parts Bulletin for D
EWALT lubricants identification).
LUBRICATION
All ball and needle bearings are factory lubricated for the life of the bearing.
CLUTCH LUBRICATION
1. Remove clutch housing by unscrewing (left-hand thread).
2. Lightly brush clutch faces.
Maintenance
CLEANING: Blow dirt and dust out of all air vents with dry air at least once a week. Wear
safety glasses when performing this operation. Exterior plastic parts may be cleaned with a
damp cloth and mild detergent. Although these parts are highly solvent resistant, NEVER use
solvents.
CHARGER CLEANING INSTRUCTIONS
WARNING: Disconnect the charger from the AC outlet before cleaning. Dirt and grease may
be removed from the exterior of the charger using a cloth or soft non-metallic brush. Do not use
water or any cleaning solutions.
Accessories
Recommended accessories for use with your tool are available at extra cost from your local deal-
er or authorized service center. If you need assistance in locating any accessory, please contact
D
EWALT 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.
CAUTION: The use of any other accessory not recommended for use with this tool could be
hazardous.
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-D
EWALT (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, D
EWALT tools are covered by our:
1 YEAR FREE SERVICE
D
EWALT will maintain the tool and replace worn parts caused by normal use, for free, any time
during the first year after purchase.
2 YEARS FREE SERVICE ON
XRP
™ BATTERY PACKS
DC9096, DC9091 and DC9071
90 DAY MONEY BACK GUARANTEE
If you are not completely satisfied with the performance of your D
EWALT 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.
RECONDITIONED PRODUCT: Reconditioned product is covered under the 1 Year Free
Service Warranty. The 90 Day Money Back Guarantee and the Three Year Limited Warranty do
not apply to reconditioned product.
FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are miss-
ing, call 1-800-4-D
EWALT for a free replacement.
FIG. 1 FIG. 2
POUR TOUTE QUESTION OU REMARQUE AU SUJET DE CET OUTIL OU DE TOUT AUTRE
OUTIL D
EWALT, COMPOSER LE NUMÉRO SANS FRAIS :
1 800 4-DEWALT (1 800 433-9258)
Importantes mesures de sécurité – Pour tous les outils
alimentés par des piles
AVERTISSEMENT! Lire et comprendre toutes les directives. Le non-respect
de toutes les directives suivantes présente des risques de secousses élec-
triques, d'incendie ou de blessures graves.
CONSERVER CES MESURES.
ZONE DE TRAVAIL
• S'assurer que la zone de travail est propre et bien éclairée. Des établis encombrés et des
endroits sombres présentent des risques d'accidents.
• Ne pas utiliser des outils électriques en présence de vapeurs explosives (comme
celles dégagées par des liquides, des gaz ou des poussières inflammables). Le moteur
des outils électriques génère des étincelles qui peuvent enflammer les poussières ou les
vapeurs.
• Éloigner les curieux, les enfants et les visiteurs de la zone de travail lorsqu'on utilise
un outil électrique. Une distraction peut entraîner la perte de maîtrise de l'outil.
MESURES DE SÉCURITÉ RELATIVES À L'ÉLECTRICITÉ
• Manipuler le cordon avec soin. Ne jamais se servir du cordon afin de transporter l'outil
ni tirer sur le cordon pour débrancher l'outil. Éloigner le cordon des sources de
chaleur, des flaques d'huile, des arêtes tranchantes et des pièces mobiles. Remplacer
immédiatement les cordons endommagés. Les cordons endommagés augmentent les
risques de secousses électriques.
• Il faut recharger un outil alimenté par des piles intégrées ou par un ensemble de piles
amovible seulement à l'ide du chargeur spécifié pour le type de piles. Un chargeur qui
convient à un type de piles peut présenter des risques d'incendie lorsqu'on s'en sert avec un
autre type de piles.
• Utiliser un outil alimenté par des piles seulement avec le type spécifié de piles.
L'utilisation de tout autre type de piles peut présenter des risques d'incendie.
SÉCURITÉ PERSONNELLE
• Demeurer vigilant, prendre soin et faire preuve de jugement lorsqu'on utilise un outil
électrique. Ne pas s'en servir lorsqu'on est fatigué ou affaibli par des drogues, de l'al-
cool ou des médicaments. De graves blessures peuvent résulter d'un moment d'inattention
lors de l'utilisation d'un outil électrique.
• Porter des vêtements appropriés; ne pas porter de vêtements amples, de gants ni de
bijoux, et couvrir ou attacher les cheveux longs, car ceux-ci peuvent rester coincés dans les
pièces mobiles. Se tenir éloigné des évents puisque ces derniers pourraient camoufler des
pièces mobiles.
• Éviter les démarrages accidentels. S'assurer que l'interrupteur est en position hors
tension avant de brancher l'outil. Afin d'éviter les risques de blessures, ne pas transporter
l'outil avec le doigt sur l'interrupteur ni insérer un ensemble de piles dans un outil dont l'in-
terrupteur est en position sous tension.
• Enlever les clés de réglage avant de mettre l'outil sous tension. Une clé qui est laissée
sur une pièce rotative de l'outil présente des risques de blessures.
• Ne pas dépasser sa portée. Garder son équilibre en tout temps. On s'assure d'une
meilleure maîtrise de l'outil dans des situations imprévues grâce à une position stable et un
bon équilibre.
• Porter de l'équipement de sécurité. Toujours porter des lunettes de sécurité. Dans cer-
taines conditions, il faut porter des masques respiratoires, des chaussures antidérapantes,
un casque de sécurité ou des protège-tympans.
UTILISATION ET ENTRETIEN DE L'OUTIL
• Utiliser des pinces de serrage ou de tout autre moyen pratique afin de fixer et de
soutenir la pièce à ouvrer sur une plate-forme stable. La pièce est instable lorsqu'elle est
retenue par la main ou le corps de l'utilisateur. Cela présente des risques de perte de maîtrise
de l'outil.