INSTRUCTION MANUAL DC820-XE, DC830-XE, DW059-XE 13 mm (1/2") CORDLESS IMPACT WRENCHES DC825-XE, DC827-XE, DC835-XE, DC845-XE 6.35 mm (1/4") CORDLESS IMPACT DRIVERS The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool. 1) WORK AREA SAFETY a) Keep work area clean and well lit. Cluttered or dark areas invite accidents. b) Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes. c) Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control. 2) ELECTRICAL SAFETY a) Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock. b) Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded. c) Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. d) Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock. e) 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. f) If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock. 3) PERSONAL SAFETY a) Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury. Definitions: Safety Guidelines The definitions below describe the level of severity for each signal word. Please read the manual and pay attention to these symbols. DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. CAUTION: Used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL, CALL US AT: 1800 654 155 (Aust) or 09 259 1111 (NZ). SAFETY INSTRUCTIONS FOR POWER TOOLS 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. WARNING: To reduce the risk of injury, read the instruction manual. GENERAL POWER TOOL SAFETY WARNINGS WARNING! Read all safety warnings and all instructions Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE 1 operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools. f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control. g) Use the power tool, accessories and tool bits etc., in accordance with these instructions taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation. 5) BATTERY TOOL USE AND CARE a) Recharge only with the charger specified by the manufacturer. A charger that is suitable for one type of battery pack may create a risk of fire when used with another battery pack. b) Use power tools only with specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire. c) When battery pack is not in use, keep it away from other metal objects like paper clips, coins, keys, nails, screws, or other small metal objects that can make a connection from one terminal to another. Shorting the battery terminals together may cause burns or a fire. d) Under abusive conditions, liquid may be ejected from the battery, avoid contact. If contact accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the battery may cause irritation or burns. 6) SERVICE a) Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained. b) Use personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries. c) Prevent unintentional starting. Ensure the switch is in the off position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energising power tools that have the switch on invites accidents. d) Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury. e) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. f) Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts. g) If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards. 4) POWER TOOL USE AND CARE a) Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed. b) Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired. c) Disconnect the plug from the power source and/or the battery pack from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally. d) Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users. e) Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s 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. 240 V AC means your tool will operate on alternating current. As little as 10% lower voltage can cause loss of power and can result in overheating. All DEWALT tools are factory tested; if this tool does not operate, check the power supply. Your DEWALT tool is double insulated, therefore no earth wire is required. 2 • Young children and the infirm. This appliance is not intended for use by young children or infirm persons without supervision. Young children should be supervised to ensure that they do not play with this appliance. • Replacement of the supply cord. If the supply cord is damaged, it must be replaced by the manufacturer or an authorised DEWALT Service Centre in order to avoid a hazard. WARNING: ALWAYS use safety glasses. Everyday eyeglasses are NOT safety glasses. Also use face or dust mask if cutting operation is dusty. ALWAYS WEAR CERTIFIED SAFETY EQUIPMENT: • ANSI Z87.1 eye protection (CAN/CSA Z94.3), • ANSI S12.6 (S3.19) hearing protection, • NIOSH/OSHA/MSHA respiratory protection. WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are: • lead from lead-based paints, • crystalline silica from bricks and cement and other masonry products, and • arsenic and chromium from chemically-treated lumber (CCA). Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles. • Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling, and other construction activities. Wear protective clothing and wash exposed areas with soap and water. Allowing dust to get into your mouth, eyes, or lay on the skin may promote absorption of harmful chemicals. WARNING: Use of this tool can generate and/or disburse dust, which may cause serious and permanent respiratory or other injury. Always use NIOSH/OSHA approved respiratory protection appropriate for the dust exposure. Direct particles away from face and body. WARNING: Always use eye protection. All users and bystanders must wear eye protection that conforms to ANSI Z87.1. WARNING: ALWAYS wear proper personal hearing protection that conforms to ANSI S12.6 (S3.19) during use. Under some conditions and duration of use, noise from this product may contribute to hearing loss. CAUTION: When not in use, place tool on its side on a stable surface where it will not cause a tripping or falling hazard. Some tools with large battery packs will stand upright on the battery pack but may be easily knocked over. Extension Cords CAUTION: Use only extension cords that are approved by the country’s Electrical Authority. Before using extension cords, inspect them for loose or exposed wires, damaged insulation and defective fittings. Replace the cord if necessary. MINIMUM GAGE FOR CORD SETS For Cable length (m): 7.5 15 25 30 45 60 Use Cable with minimum rating (Amperes) Tool Amperes 0 - 3.4 7.5 7.5 7.5 7.5 7.5 7.5 3.5 - 5.0 7.5 7.5 7.5 7.5 10 15 5.1 - 7.0 10 10 10 10 15 15 7.1 - 12.0 15 15 15 15 20 20 12.1 - 20.0 20 20 20 20 25 – Safety Warnings for Impact Drivers and Wrenches • Hold tool by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring. Contact with a “live” wire will make exposed metal parts of the tool “live” and shock the operator. • Wear safety goggles or other eye protection. Hammering and drilling operations cause chips to fly. Flying particles can cause permanent eye damage. • Bits, sockets and tools get hot during operation. Wear gloves when touching them. • Do not operate this tool for long periods of time. Vibration caused by tool action may be harmful to your hands and arms. Use gloves to provide extra cushion and limit exposure by taking frequent rest periods. 3 • The label on your tool may include the following symbols. The symbols and their definitions are as follows: V ................. volts A ...............amperes Hz ............... hertz W ..............watts ...........alternating current min ............. minutes no ..............no load speed .......... direct current .............. Class I Construction .............earthing terminal ................... (grounded) .............safety alert symbol ............... Class II Construction …/min .......revolutions per minute ................... (double insulated) BPM ..........beats per minute DANGER: Electrocution hazard. Never attempt to open the battery pack for any reason. If battery pack case is cracked or damaged, do not insert into charger. Do not crush, drop or damage battery pack. Do not use a battery pack or charger that has received a sharp blow, been dropped, run over or damaged in any way (i.e., pierced with a nail, hit with a hammer, stepped on). Electric shock or electrocution may result. Damaged battery packs should be returned to service center for recycling. NOTE: Battery storage and carrying caps are provided for use whenever the battery is out of the tool or charger. Remove cap before placing battery in charger or tool. WARNING: Fire hazard. Do not store or carry battery so that metal objects can contact exposed battery terminals. For example, do not place battery in aprons, pockets, tool boxes, product kit boxes, drawers, etc., with loose nails, screws, keys, etc. without battery cap. Transporting batteries can possibly cause fires if the battery terminals inadvertently come in contact with conductive materials such as keys, coins, hand tools and the like. The US Department of Transportation Hazardous Material Regulations (HMR) actually prohibit transporting batteries in commerce or on airplanes (i.e., packed in suitcases and carry-on luggage) UNLESS they are properly protected from short circuits. So when transporting individual batteries, make sure that the battery terminals are protected and well insulated from materials that could contact them and cause a short circuit. SPECIFIC SAFETY INSTRUCTIONS FOR NICKEL CADMIUM (NiCd) OR NICKEL METAL HYDRIDE (NiMH) • Do not incinerate the battery pack even if it is severely damaged or is completely worn out. The battery pack can explode in a fire. • A small leakage of liquid from the battery pack cells may occur under extreme usage or temperature conditions. This does not indicate a failure. However, if the outer seal is broken: a. and the battery liquid gets on your skin, immediately wash with soap and water for several minutes. b. and the battery liquid gets into your eyes, flush them with clean water for a minimum of 10 minutes and seek immediate medical attention. (Medical note: The liquid is 25-35% solution of potassium hydroxide.) Important Safety Instructions for All Battery Packs When ordering replacement battery packs, be sure to include catalog number and voltage. Consult the chart at the end of this manual for compatibility of chargers and battery packs. The battery pack is not fully charged out of the carton. Before using the battery pack and charger, read the safety instructions below. Then follow charging procedures outlined. READ ALL INSTRUCTIONS • Do not charge or use battery in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Inserting or removing the battery from the charger may ignite the dust or fumes. • Never force battery pack into charger. Do not modify battery pack in any way to fit into a non-compatible charger as battery pack may rupture causing serious personal injury. Consult the chart at the end of this manual for compatibility of batteries and chargers. • Charge the battery packs only in DEWALT chargers. • DO NOT splash or immerse in water or other liquids. • Do not store or use the tool and battery pack in locations where the temperature may reach or exceed 40˚C (105°F) (such as outside sheds or metal buildings in summer). 4 SPECIFIC SAFETY INSTRUCTIONS FOR LITHIUM ION (LI-ION) • Do not incinerate the battery pack even if it is severely damaged or is completely worn out. The battery pack can explode in a fire. Toxic fumes and materials are created when lithium ion battery packs are burned. • If battery contents come into contact with the skin, immediately wash area with mild soap and water. If battery liquid gets into the eye, rinse water over the open eye for 15 minutes or until irritation ceases. If medical attention is needed, the battery electrolyte is composed of a mixture of liquid organic carbonates and lithium salts. • Contents of opened battery cells may cause respiratory irritation. Provide fresh air. If symptoms persists, seek medical attention. WARNING: Burn hazard. Battery liquid may be flammable if exposed to spark or flame. • Before using charger, read all instructions and cautionary markings on charger, battery pack, and product using battery pack. DANGER: Electrocution hazard. 240 volts are present at charging terminals. Do not probe with conductive objects. Electric shock or electrocution may result. 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 DEWALT rechargeable 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 battery pack are specifically designed to work together. • These chargers are not intended for any uses other than charging DEWALT 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. The RBRC™ Seal The RBRC™ (Rechargeable Battery Recycling Corporation) Seal on the nickel cadmium, nickel metal hydride or lithium ion batteries (or battery packs) indicate that the costs to recycle these batteries (or battery packs) at the end of their useful life have already been paid by DEWALT. In some areas, it is illegal to place spent nickel cadmium, nickel metal hydride or lithium ion batteries in the trash or municipal solid waste stream and the RBRC program provides an environmentally conscious alternative. RBRC™ in cooperation with DEWALT and other battery users, has established programs in the United States and Canada to facilitate the collection of spent nickel cadmium, nickel metal hydride or lithium ion batteries. Help protect our environment and conserve natural resources by returning the spent nickel cadmium and nickel cadmium, nickel metal hydride or lithium ion batteries to an authorized DEWALT service center or to your local retailer for recycling. You may also contact your local recycling center for information on where to drop off the spent battery. RBRC™ is a registered trademark of the Rechargeable Battery Recycling Corporation. Important Safety Instructions for all Battery Chargers SAVE THESE INSTRUCTIONS: This manual contains important safety and operating instructions for battery chargers. 5 • 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. • 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 240V household electrical power. Do not attempt to use it on any other voltage. This does not apply to the vehicular charger. 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 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 DEWALT 7.2, 9.6, 12, 14.4, 18 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. FIG. 1 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. Charging Procedure (Fig. 1) DANGER: Electrocution hazard. 240 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. 6 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. 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 Important Charging Notes 1. Longest life and best performance can be obtained if the battery pack is charged when the air temperature is between 18°- 24°C (65°F and 75°F). DO NOT charge the battery pack in an air temperature below +4.5°C (+40°F), or above +40.5°C (+105°F). 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 18°- 24°C (65°F - 75°F). 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. 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. 7 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. 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. INTENDED USE These heavy-duty impact wrench/drivers are designed for professional impact screwdriving applications. The impact function makes this tool particularly useful for driving fasteners in wood, metal and concrete. DO NOT use under wet conditions or in presence of flammable liquids or gases. These heavy-duty impact wrench/drivers are professional power tools. DO NOT let children come into contact with the tool. Supervision is required when inexperienced operators use this tool. OPERATION Storage Recommendations 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. 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. Installing and Removing the Battery Pack (Fig. 2) SAVE THESE INSTRUCTIONS FOR FUTURE USE FIG. 2 NOTE: Make sure your battery pack is fully charged. 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 H snap into place. To remove the battery pack from the tool, press the release buttons (H) and firmly pull the battery pack out of the tool handle. Insert it into the charger as described in the charger section of this manual. Motor Voltage decrease of more than 10% will cause loss of power and overheating. All DEWALT tools are factory tested; if this tool does not operate, check your battery pack. COMPONENTS WARNING: Never modify the power tool or any part of it. Damage or personal injury could result. A. Trigger switch F. Detent pin B. Rocker switch (DW059-XE) G. Anvil C. Forward/reverse button H. Battery release buttons D. Sleeve I. Worklight E. 6.35 mm (1/4") hex quick-release chuck Switch DW059-XE (FIG. 3) Pressing the BOTTOM part of the rocker switch (B) runs the tool in forward (right hand thread) direction. Pressing the TOP of the switch reverses motor direction. This allows “rocking” fasteners to break them loose. 8 Forward/Reverse Control Button (Fig. 3) FIG. 3 A forward/reverse control button (C) 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. D E I C A B Worklight (Fig. 3) There is a worklight (I) located just above the trigger switch (A). The worklight will be activated when the trigger switch is squeezed. NOTE: The worklight is for lighting the immediate work surface and is not intended to be used as a flashlight. Quick-Release Chuck (Fig. 4) H DW059 DC825-XE, DC827-XE, DC835-XE, DC845-XE NOTE: The chuck accepts 6.35 mm (1/4") hex accessories only. Place the switch in the locked off (center) position or remove battery pack before changing accessories. To install an accessory, pull the chuck collar (D) away from the front of the tool, insert the accessory and release the collar. The accessory is locked in place. To remove an accessory, pull the chuck collar away from the front of the tool. Remove the accessory and release the collar. Variable Speed Trigger Switch (Fig. 3) To turn the tool on, squeeze the trigger switch (A). 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 more you squeeze the trigger, the faster the tool will operate. Use lower speeds for starting holes without a center punch, drilling in metals or plastics, or driving screws. For maximum tool life, use variable 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. FIG. 4 FIG. 5 E G D F 9 Anvil With Detent Pin (Fig. 5) • Bolt Size: Larger bolt diameters generally require higher fastening torque. Fastening torque will also vary according to length, grade, and torque coefficient. • Bolt: Ensure that all threads are free of rust and other debris to allow proper fastening torque • Material: The type of material and surface finish of the material will affect fastening torque. • Fastening Time: Longer fastening time results in increased fastening torque. Using a longer fastening time than recommended could cause the fasteners to be overstressed, stripped or damaged. DC820-XE, DC830-XE, DW059-XE Place the switch in the locked off (center) position or remove battery pack before changing accessories. To install a socket on the anvil, align the hole in the side of the socket with the detent pin (F) on the anvil (G). Press the socket on until the detent pin engages in the hole. Depression of detent pin may be necessary to aid installation of socket. CAUTION: Use only impact sockets. Non-impact sockets may break and cause a hazardous condition. Inspect socket prior to use to ensure that it contains no cracks. To remove a socket, depress the detent pin through the hole and pull the socket off. MAINTENANCE Usage 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. Your impact tool generates the following output torque: Cat # Ft.-Lbs. In.-Lbs. Nm DC820-XE 145 1740 195 DC825-XE 111 1330 150 DC827-XE 111 1330 150 DC830-XE 135 1620 180 DC835-XE 103 1240 140 DC845-XE 96 1150 130 DW059-XE 300 3600 405 CAUTION: Ensure fastener and/or system will withstand the level of torque generated by the tool. Excessive torque may cause breakage and possible personal injury. 1. Place the socket on the fastener head. Keep the tool pointed straight at the fastener. 2. Press rocker switch to start operation. Always check torque with a torque wrench, as the fastening torque is affected by many factors including the following: • Voltage: Low voltage, due to a nearly discharged battery, will reduce fastening torque. • Socket size: Failure to use the correct socket size will cause a reduction in fastening torque. 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 DEWALT, have not been tested with this product, use of such accessories with this tool could be hazardous. To reduce the risk of injury, only DEWALT, recommended accessories should be used with this product. 10 sound mechanical and/or electrical condition. Normal wear parts are not covered in this service. Carbon brushes worn more then 50% will be replaced. NOTE: Three Year Warranty is not applicable to items deemed as consumables. Radial arm saws are covered by a one (1) year warranty only. DEWALT Reserves the right to review its warranty policy prior to launch of any new business development products. 30 DAY NO SATISFACTION GUARANTEE If you are dissatisfied with any DEWALT power tool, laser or nailer, for any reason, simply return it to the point of purchase with your sales receipt within 30 days for a replacement unit or a full refund. FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are missing, call (AUS) 1800 654 155 or (NZ) 09 259 1111 for a free replacement. 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 DEWALT Industrial Tool Co., 20 Fletcher Road, Mooroolbark, VIC 3138 Australia or call 1800 654 155 or (NZ) 09 259 1111. CAUTION: Use only impact sockets. Non-impact sockets may break and cause a hazardous condition. Inspect sockets prior to use to ensure that it contains no cracks. Repairs The charger is not serviceable. There are no serviceable parts inside the charger. To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including brush inspection and replacement) should be performed by certified service centers or other qualified service organizations, always using identical replacement parts. Guarantee Applicable to hand held Power Tools, Lasers and Nailers. 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. Please return the complete unit, transportation prepaid, to any DEWALT Service Centre, or any authorised service station. For warranty repair information, call (AUS) 1800 654 155 or (NZ) 09 259 1111. This warranty does not apply to • Accessories • Damage caused where repairs have been made or attempted by others. • Damage due to misuse, neglect, wear and tear, alteration or modification. This warranty gives you specific legal rights and you may have other rights under the provisions of the Consumer Guarantee Act 1993 (New Zealand only), Trade Practices Act 1974 and State Legislation (Australia only). In addition to the warranty, DEWALT tools are covered by our: FREE ONE YEAR SERVICE CONTRACT DEWALT will also maintain the tool for free at any time during the first year of purchase. This includes labour, parts and lubrication required to restore the product to 11 DEWALT BATTERY AND CHARGER SYSTEMS Battery Output Nominal Chargers/Charge Time 240 Volts 12 Volts Cat. Number Voltage Amp Hour 97014 98014 DW9106 DW9107 DW9108 DW9115 DW9116 DW9117 DW9118 DE9116 DE9118 DW911 DC011 DW0245 DE2046 DE9000 DC9310 DC9036 DE0240-XJ DW0242 DW0240 DC9096 DC9180 DW9096 DE9095-XJ DC9091 DC9144 DE9091-XJ DW9091 DC9071 DE9071-XJ DE9074-XJ DW9050 DW9071 DW9072 DW9063 DW9062 DW9061 DW9048 DW9057 DW9046 36 24 24 24 18 18 18 18 14.4 14.4 14.4 14.4 12 12 12 12 12 12 9.6 9.6 9.6 9.6 7.2 7.2 X 2.0 2.0 1.7 2.4 X 2.4 2.0 2.4 X 2.0 1.7 2.4 2.0 1.25 1.3 1.7 1.2 1.25 1.3 1.7 1.3 1.25 1.3 X X X X X X X X 60 X 45 45 60 60 45 40 60 45 45 45 60 40 45 40 X X X X X X X X 60 X 45 45 60 60 45 40 60 45 45 45 60 40 45 40 X X X X X X X X 60 X 45 45 60 60 45 40 60 45 45 45 60 40 45 40 X X X X X X X X 60 X 45 45 60 45 30 X 45 30 30 30 45 X 30 X X X X X 60 X 60 60 60 X 45 45 60 45 30 X 45 30 30 30 45 X 30 X X X X X X X X X 15 X 15 15 15 15 15 15 15 15 15 15 15 15 15 15 X X X X 60 X 60 60 60 X 45 45 60 45 30 X 45 30 30 30 45 X 30 X X X X X 20 X 20 20 15 X 15 15 15 15 12 X 15 12 12 12 15 X 12 X X X X X X X X X 60 X 90 90 60 90 60 X 90 60 60 60 90 X 60 X X X X X 60 X 60 60 60 X 45 45 60 45 30 X 45 30 30 30 45 X 30 X X X X X X X X X 60 X 90 90 60 90 60 X 90 60 60 60 90 X 60 X X X X X 60 X 60 60 60 X 45 45 60 45 30 X 45 30 30 30 45 X 30 X X X X X 60 X 60 60 60 X 45 45 60 45 30 X 45 30 30 30 45 X 30 X X 60 60 60 X X X X X X X X X X X X X X X X X X X X X 60 60 60 X X X X X X X X X X X X X X X X X X X X 60 X X X X X X X X X X X X X X X X X X X X X X X X X X X 60 60 60 60 60 60 45 45 60 45 30 X 45 30 30 30 45 X 30 X DW9109 DC9319 X X X X 60 X 60 60 60 X 45 45 60 45 30 X 45 30 30 30 45 X 30 X X X X X 60 60 60 60 60 60 45 45 60 45 30 X 45 30 30 30 45 X 30 X X Indicates that the battery pack is not compatible with that specific charger. All charge times are approximate. Actual charge time may vary. Read the instruction manual for more specific information. The battery voltage is nominal, it can measure above or below depending on the state of charge. DEWALT Industrial Tool Co., 20 Fletcher Road, Mooroolbark, VIC 3138 Australia (03 8720 5100) • 5 Te Apunga Place, Mt Wellington, New Zealand (09 259 1111) (NOV07) Form No. 652829-00 DC820-XE, DC825-XE, DC827-XE, DC830-XE, DC835-XE, DC845-XE, DW059-XE Copyright © 2007 DEWALT The following are trademarks for one or more DEWALT power tools: the yellow and black color scheme; the “D” shaped air intake grill; the array of pyramids on the handgrip; the kit box configuration; and the array of lozenge-shaped humps on the surface of the tool.