Operation; Maintenance - DeWalt DC500 Instruction Manual

• These chargers are not intended for any uses other than charging D
able 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 dam-
age to electric plug and cord.
• Make sure that cord is located so that it will not be stepped on, tripped over, or oth-
erwise 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.
• 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. When using more than one extension
to make up the total length, be sure each individual extension contains at least the mini-
mum wire size.
Recommended Minimum Wire Size for Extension Cords
Total Length of Cord
25 ft. 50 ft. 75 ft. 100 ft. 125 ft.
7.6 m 15.2 m 22.9 m 30.5 m 38.1 m
Wire Size AWG
18 18 16 16 14
• 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 — have them replaced immediately.
• 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, electro-
cution 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 household electrical power (120
Volts). Do not attempt to use it on any other voltage. This does not apply to the vehic-
ular charger.
SAVE THESE INSTRUCTIONS
FOR FUTURE USE
Battery Performance
Some chargers have a Tune-Up™ feature that optimizes battery pack performance. Your
charger may provide automatic Tune-Up™ mode or manual (i.e., push button) Tune-Up™
mode. For information on this feature, please see the appropriate section below. Because bat-
teries slowly lose their charge when they are not on the charger, the best place to keep your
battery pack is on the charger at all times.
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. Whenever 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 indi-
vidual 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 transition to a main-
tenance charge; the indicator light shuts off when the automatic Tune-Up™ Mode is
complete.
USING THE MANUAL TUNE-UP™ MODE
The manual Tune-Up™ mode equalizes or balances the individual cells in the battery pack
allowing it to function at peak capacity. This mode takes up to 8 hours to complete. 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.
1. To tune up your battery pack, place the battery in the charger as usual. The red light will
blink continuously indicating that the charge cycle has started.
2. Press the Tune-Up™ Mode button any time after the charge cycle has started. The red
light will stop blinking momentarily, blink quickly 3 times, and then resume blinking contin-
uously. The charger is now tuning up the cells in your battery.
3. When the Tune-Up™ mode cycle is complete, the light will stay on continuously. The pack
is fully charged and may be used at this time or left in the charger.
4. If you select Tune-Up™ Mode and then change your mind, remove the battery from the
charger. After 5 seconds, insert the battery into the charger. The normal charge cycle will
begin.
Charging Procedure
1. Plug the charger into an appropriate outlet.
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.
CAUTION: 120 volts present at charging terminals. Do not probe with conductive objects.
Danger of electric shock or electrocution. Keep battery door closed and latched at all times .
Indicator Light Operation
PACK CHARGING...................
FULLY CHARGED...................
HOT/COLD PACK DELAY........
REPLACE PACK......................
PROBLEM POWER LINE........
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 author-
ized 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. 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 condi-
tion. 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 nor-
mal 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:
WALT recharge- a. Check current at receptacle by plugging in a lamp or other appliance
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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 or send 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 materi-
als 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 charg-
er before attempting to clean.
150 ft. 175 ft.
6. Do not freeze or immerse charger in water or any other liquid.
45.7 m 53.3 m
WARNING: 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
14 12
the battery pack breaks or cracks, return to a service center for recycling.

OPERATION

The vacuum is designed to operate on a 12.0, 14.4, or 18 V D
AC input. Battery pack and charger sold separately. The vacuum will automatically switch
between AC and DC modes.
The vacuum is designed to perform as a wet/dry unit with no component changes required
when changing from wet to dry, or dry to wet pick up. This vacuum is for household use.
It is recommended that the tank be emptied of any dry contents prior to being used for wet
pick up to facilitate tank cleaning.
Installing and Removing the Battery Pack (Fig. 1)
NOTE: Make sure your battery pack is fully charged.
To install the battery pack, open rear door (A) of the vacuum as shown. Make sure the bat-
tery pack is fully seated, close the rear door and fasten the latch (B).
To remove the battery pack, open the rear door, remove battery and insert the battery into
the charger as described in the charger section of the manual.
Vacuum Cleaning (Fig. 2)
1 Attach the appropriate accessory to the hose (C).
2. Insert D
wall outlet.
3. To turn machine on, press the I/O (on/off) button (D).
TO EMPTY TANK
1. Turn machine off and remove the battery pack or unplug power cord from the wall outlet.
2. Unlatch side latches (J) and remove power head from the tank.
3. Empty contents of tank into suitable container. A drain (E) is located at the bottom rear of
the tank for emptying liquid into a floor drain.
4. Clean or change filters. See Filter section of this manual.
5. Inspect machine for damage by foreign objects. Contact the nearest D
service center for replacement of damaged or missing parts.
6. Replace power head onto the tank and latch securely.
AUTOMATIC VACUUM SHUTOFF
The vacuum is equipped with an Automatic Vacuum Shutoff that functions when the tank is full
of water. The sound of the motor changes and the suction stops when the tank is full.
To continue use:
1. Turn machine off and remove the battery pack or unplug power cord from the wall outlet.
2. Remove the power head from the tank and empty the tank.
3. Replace power head onto the tank and latch securely.
NOTE: The machine must be used in the upright position at all times to prevent unwanted actu-
ation of the Automatic Vacuum Shutoff. If unwanted actuation should happen, turn off the motor
and wait until the motor stops turning. Turn the motor on again and suction will be restored.
Filter (Fig. 3)
A high efficiency wet/dry filter is included.
NOTE: Never operate without a filter in place. A clean filter is the most important factor in the
operation and efficiency of any vacuum. If the filter becomes clogged beyond cleaning, dam-
aged, or fails to operate properly, replace only with genuine D
TO CLEAN OR CHANGE THE FILTER
1. Turn machine off and remove the battery pack or unplug power cord from the wall outlet.
2. Unlatch the side latches and remove the power head from the tank. Twist the filter off the
power head.
3. Clean the filter by shaking off excess dust, tapping into a waste receptacle, then rinsing
under running water. Depending on the condition of the filter, a water wash is not always
required. Do not use a brush to clean filter.
4. Reinstall filter by twisting to secure onto power head.
5. Replace power head onto the tank and secure latches.
Blower (Fig. 2)
The blower function can be used to remove debris from behind small spaces, to dry a damp
floor, to blow grass clippings or leaves from an outside walk, patio, etc.
TO USE AS A BLOWER
1. Empty the tank following the instructions under the Vacuum Cleaning section of this
manual.
2. Twist the vacuum hose (C) to remove.
3. Insert the hose into the side exhaust port (F) and twist to secure.

MAINTENANCE

• Empty the vacuum often, especially when wet debris is in the canister.
• MAINTAIN TOOL WITH CARE. Keep fan area clean for best and safest performance.
• Do not attempt to repair the vacuum. To assure product safety and reliability, repairs,
maintenance, and adjustments should be performed by authorized D
centers.
Cord, Hose and Accessory Storage (Fig. 1)
When the vacuum is not in use, the cord should be coiled around the cord wrap (G) located
at the back of the vacuum. The hose can be placed in the holder (H) also located at the back
of the vacuum. The two accessories (crevice tool and wide nozzle) can be stored on board the
vacuum (I).
Lubrication
Never lubricate the vacuum motor. The motor bearings are permanently sealed. This vacuum
is intended for indoor use and for wet or dry pick up, but it is not intended to be exposed to rain.
Accessories
The DC500 includes a 1-1/4" hose, crevice tool, and wide nozzle.
A replacement filter is available at extra cost at your local D
Recommended accessories for use with your tool are available at extra cost from your local
dealer or authorized service center. If you need assistance in locating any accessory for your
tool, contact: D
CAUTION: The use of any other accessory not recommended for use with this vacuum
could be hazardous.
Repairs
To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including
brush inspection and replacement) should be performed by authorized service centers or
other qualified service personnel, always using identical replacement parts.
Three Year Limited Warranty
D WALT will repair, without charge, any defects due to faulty materials or workmanship for
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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
apply to accessories or damage caused where repairs have been made or attempted by oth-
ers. 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 time
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during the first year after purchase.
If you are not completely satisfied with the performance of your D
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.
FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are
missing, call 1-800-4-D
SAVE THESE INSTRUCTIONS
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WALT battery pack or plug cord into appropriate
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WALT replacement filters.
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WALT service center.
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WALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286.
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WALT (1-800-433-9258). This warranty does not
E
WALT tools are covered by our:
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1 YEAR FREE SERVICE
2 YEARS FREE SERVICE ON XRP ™ BATTERY PACKS
DC9096, DC9091 and DC9071
90 DAY MONEY BACK GUARANTEE
WALT for a free replacement.
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WALT battery pack, or 120 V
WALT authorized
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WALT service
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WALT Power Tool, Laser,
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