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WARNING: Shock hazard. Do not allow any liquid to get inside charger. Electric shock
may result.
CAUTION: Burn hazard. To reduce the risk of injury, charge only D
batteries. Other types of batteries may burst causing personal injury and damage.
CAUTION: Under certain conditions, with the charger plugged in to 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.
• DO NOT attempt to charge the battery pack with any chargers other than the
ones in this manual. The charger and batter y pack are specifically designed to work
together.
• These chargers are not intended for any uses other than charging D
rechargeable batteries. Any other uses may result in risk of fire, electric shock or
electrocution.
• Do not expose charger to rain or snow.
• Pull by plug rather than cord when disconnecting charger. This will reduce risk of
damage to electric plug and cord.
• Make sure that cord is located so that it will not be stepped on, tripped over, or
otherwise subjected to damage or stress.
• Do not use an extension cord unless it is absolutely necessary. Use of improper
extension cord could result in risk of fire, electric shock, or electrocution.
• 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.
• 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.
Recommended Minimum Wire Size for Extension Cords
Total Length of Cord
25 ft.
50 ft.
75 ft.
7.6 m
15.2 m
22.9 m
Wire Size AWG
18
18
16
• Do not place any object on top of charger or place the charger on a soft surface
that might block the ventilation slots and result in excessive internal heat. Place
the charger in a position away from any heat source. The charger is ventilated through
slots in the top and the bottom of the housing.
• Do not operate charger with damaged cord or plug.
• Do not operate charger if it has received a sharp blow, been dropped, or otherwise
damaged in any way. Take it to an authorized service center.
• Do not disassemble charger; take it to an authorized service center when service
or repair is required. Incorrect reassembly may result in a risk of electric shock,
electrocution or fire.
• Disconnect the charger from the outlet before attempting any cleaning. This will
reduce the risk of electric shock. Removing the battery pack will not reduce this risk.
• NEVER attempt to connect 2 chargers together.
• The charger is designed to operate on standard 120V household electrical power.
Do not attempt to use it on any other voltage. This does not apply to the vehicular
charger.
Using Automatic Tune-Up™ Mode
The automatic Tune-Up™ Mode equalizes or balances the individual cells in the battery pack
allowing it to function at peak capacity. Battery packs should be tuned up weekly or after
10 charge/discharge cycles or whenever the pack no longer delivers the same amount of
work. To use the automatic Tune-Up™, place the battery pack in the charger and leave it
for at least 8 hours. The charger will cycle through the following modes.
1. The red light will blink continuously indicating that the 1-hour charge cycle has
started.
2. When the 1-hour charge cycle is complete, the light will stay on continuously and will no
longer blink. This indicates that the pack is fully charged and can be used at this time.
3. If the pack is left in the charger after the initial 1-hour charge, the charger will begin the
Automatic Tune-Up™ mode. This mode continues up to 8 hours or until the individual
cells in the battery pack are equalized. The battery pack is ready for use and can be
removed at any time during the Automatic Tune-Up™ mode.
4. Once the Automatic Tune-Up™ mode is complete, the charger will begin a maintenance
charge; the red indicator will remain lit.
Chargers
Your tool uses a D
WALT 14.4 or 18 volt charger. Be sure to read all safety instructions
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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 present at charging terminals. Do not probe
with conductive objects. Danger of electric shock or electrocution.
1. Plug the charger into an appropriate outlet before inserting battery pack.
2. Insert the battery pack into the charger. The red (charging) light will blink continuously
indicating 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 service 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 pack. Such batteries
are still usable but should not be expected to perform as much work. The charger will
indicate to replace battery pack.
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
service 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, grinding dust, metal chips,
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. Don't allow any liquid to get inside charger. Electric shock
may result.
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.
Storage Recommendations
1. The best storage place is one that is cool and dry away from direct sunlight and excess
heat or cold.
2. Long storage will not harm the battery pack or charger. Under proper conditions, they
can be stored for 5 years or more.
SAVE THESE INSTRUCTIONS FOR FUTURE USE
OPERATION
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.
Installing and Removing the Battery Pack
NOTE: Make sure your battery pack is fully charged.
WALT rechargeable
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100 ft.
125 ft.
150 ft.
30.5 m
38.1 m
45.7 m
16
14
14
FIG. 1
WALT
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FIG. 3
175 ft.
53.3 m
12
FIG. 5
WARNING: Make sure the switch is in the off position 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 (Fig. 2) and slide the battery pack firmly into the handle until you
hear the lock snap into place (Fig. 2).
To remove the battery pack from the tool, press the release buttons (A) and firmly
pull the battery pack out of the tool handle. Insert it into the charger as described in the
charger manual.
To Maintain Safe Tool Control
• Make sure the work surface is free of nails or screws. Cutting into a nail or screw
may cause the tool to jump, damaging the bit.
• Never operate the tool with one hand while holding the workpiece with the other
hand. Always clamp the material and guide the tool with both hands.
• Do not cut material lying on a hard surface. Clearance behind material to be cut must
be allowed for protruding bit.
• Disconnect battery from tool before making adjustments, changing bits, or cleaning
tool.
• Do not start the tool with bit engaged in the material. The bit may grab the
material.
Switch (Fig. 3)
To start the motor, slide the switch (B) to "I" position. To stop the motor, slide the switch
to "O" position.
Depth Guide (Fig. 4, 5)
Depth guide (C) snaps onto locators as shown. Keep depth guide in place at all times
during operation of the tool. For best results, adjust the guide using knob (D) to allow the
bit to protrude about 1/8" past the material to be cut.
Installing and Removing the Bit
This tool has a tool-free bit change system. To change bits, FIRST turn off the tool and
disconnect the battery from the tool. Remove the depth guide (C).
1. To replace bit, depress both spindle lock (E) and collet lock (F) and turn collet grip
counterclockwise.
2. Insert or remove bit.
WARNING: The bits are sharp and should be handled with great care.
CAUTION: When replacing bits, do not insert cutting flutes into the collet. This may result
in broken bits.
3. While depressing both spindle and collet locks, turn the collet grip clockwise to firmly
tighten the collet. For some heavy duty applications, it may be necessary to use a
wrench to further tighten the nut (G) while depressing the spindle lock (E).
4. Attach guide.
CAUTION: Never tighten the collet without a bit installed.
This tool comes with both 1/8" (3 mm) and 1/4" (6 mm) collets. To change collets, remove
the collet nut and insert the desired collet.
Cutting a Hole for an Electrical Outlet (Fig. 6)
WARNING: Shut off all live electric circuits to any areas where cut outs will be made.
1. Push any wiring deeply into the outlet box to avoid damage from the cutting bit.
2. Before hanging the sheet covering the outlet, mark the approximate location of the
center of the outlet on the wall board. Check the cutting bit depth against the side of
the board to be sure it will cut entirely through the material.
3. Tack the sheet in place with a few fasteners avoiding the stud holding the outlet. This
allows the wall board to flex slightly around the protruding fixture box.
4. Turn the cut-out tool on. Holding the tool firmly with both hands, plunge the bit straight
into the center of the outlet.
5. Cut to the right until the edge of the box is touched. Pull out just enough for the bit to
clear the edge of the box. Plunge in again holding the bit gently against the outside of
the box.
6. Follow the outside of the box as shown keeping slight pressure against the box. This
will minimize wandering and give you a clean precise cut.
7. Remove the waste and dust from the outlet. Finish fastening the sheet of wall board.
MAINTENANCE
WARNING: To reduce the risk of serious personal injury, turn tool off and
disconnect battery pack before making any adjustments or removing/installing
attachments or accessories.
Cleaning
WARNING: Blow dirt and dust out of all air vents with clean, dry air at least once a week.
To minimize the risk of eye injury, always wear ANSI Z87.1 approved eye protection when
performing this.
WARNING: 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.
CHARGER CLEANING INSTRUCTIONS
WARNING: Shock hazard. 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
WARNING: Since accessories, other than those offered by D
tested with this product, use of such accessories with this tool could be hazardous. To
reduce the risk of injury, only D
this product.
Recommended accessories for use with your tool are available at extra cost from your local
service center. If you need any assistance in locating any accessory, please contact D
Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286, call 1-800-4-D
(1-800-433-9258) or visit our website www.dewalt.com.
Repairs
The charger is not serviceable. There are no serviceable parts inside the charger.
To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustments
(including brush inspection and replacement) should be performed by a D
service center, a D
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Always use identical replacement parts.
Three Year Limited Warranty
D
WALT will repair, without charge, any defects due to faulty materials or workmanship
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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
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
D
WALT will maintain the tool and replace worn parts caused by normal use, for free, any
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time during the first year after purchase.
FIG. 2
B
FIG. 4
G
D
FIG. 6
C
WALT, recommended accessories should be used with
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WALT authorized service center or other qualified service personnel.
WALT tools are covered by our:
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1 YEAR FREE SERVICE
A
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F
C
WALT, have not been
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WALT
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WALT
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WALT factory
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WALT (1-800-433-9258). This
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