Operation; Maintenance - DeWalt DC520KA Instruction Manual

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 mate-
rials 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 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 other-
wise subjected to damage or stress.
• Do not use an extension cord unless it is absolutely necessary. Use of improper exten-
sion 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 minimum wire size.
Recommended Minimum Wire Size for Extension Cords
Total Length of Cord
25 ft. 50 ft. 75 ft. 100 ft.
7.6 m 15.2 m 22.9 m 30.5 m 38.1 m 45.7 m
Wire Size AWG
18 18 16 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 charg-
er 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, 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 household electrical power (120
Volts). 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. 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 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 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 12.0, 14.4, or 18.0 Volt D
D WALT 1 Hour Chargers, 15 Minute Chargers or Vehicular 12 volt charger. Be sure to read all
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safety instructions before using your charger. Consult the chart on the back cover of this manu-
al for compatibility of chargers and battery packs.
Charging Procedure (Fig. 1)
DANGER: Electrocution hazard. 120 volts are present at charging terminals. Do not probe with
conductive objects.
1. Plug the charger into an appropriate outlet before inserting battery pack.
2. Insert the battery pack into the charger, as shown in Figure 1, making sure the pack is fully
seated in charger. The red (charging) light will blink continuously indicating that the charg-
ing 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. 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:
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, 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.
WALT rechargeable
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125 ft. 150 ft. 175 ft.
53.3 m
14 14 12
WALT Charger. Your battery can be charged in
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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.

OPERATION

Installing and Removing the Battery Pack
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
WALT recharge-
snap into place as shown in Figure 3.
To remove the battery pack from the tool, press the release buttons 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.
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 SECTION OF THIS
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.
Variable Speed Switch
To turn the tool "ON", squeeze the trigger switch. To turn the tool "OFF" release the trigger. Your
tool is equipped with a variable speed switch which 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, driving in metals or plastics, driving
screws, or in any application requiring high torque. Higher speeds are better for driving in wood,
wood compositions and for using abrasive and polishing accessories. For maximum tool life,
use variable speed only for starting holes or fasteners.
Forward/Reverse Control Button
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, as shown in Figure 4. To select reverse, depress the
forward/reverse control button on the left side of the tool. The center position of the control but-
ton locks the tool in the "OFF" position. When changing the position of the forward/reverse con-
trol button, be sure the trigger is released.
Dead Spindle Action
All D WALT screwdrivers provide a "dead" front spindle to permit fasteners to be located in the
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driving accessory. Clutches are held apart by light spring pressure, permitting the drilling clutch
to rotate without turning the driven clutch and accessory. When sufficient forward pressure is
applied to the unit, the clutches engage and rotate the spindle and accessories.
Accessory Assembly
The 1/4" hex drive ball lock chuck is used on all depth sensitive and drywall screwdrivers.
Assemble accessories by engaging the hex spindle and tapping lightly on the accessory until it
snaps into place. Usually pliers are required to remove the accessory by pulling forward.
Depth Adustment
1. Rotate adjustment collar (Fig. 5). Clockwise rotation will provide deeper seating of screws.
2. Test drive a fastener in scrap material to determine if fastener is correctly seating. Further
adjustment may be necessary.
3. To increase depth, turn adjustment collar so that end of bit extends further from end of
locator.
4. To decrease depth, turn adjustment collar so that end of bit is closer to the end of locator.
D WALT screwdrivers have very fine depth settings; each "click" is .007". One complete revo-
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lution of the locator collar equals .083" change in depth setting.
Changing Bit Holder
1. Press release buttons and remove collar from clutch housing.
2. Pull bit holder straight out with pliers if it is difficult to remove.
3. Push new bit holder into spindle until ball lock snaps in groove in bit holder shank.
4. Align ribs on inside of depth locator with grooves in clutch housing before snapping into
place.
5. Depth locator is removable by unscrewing dust seal.
Changing Bit Tip
1. Press release buttons and remove collar from clutch housing. (Fig. 6)
2. Use pliers to remove worn bit and install new bit tip.
Operation: Depth Sensitive Units
1. Install bit tip in bit holder or install nutsetter.
2. Adjust depth locator.
3. Check for correct rotation, start screwdriver and place screw on bit.
4. Contact work surface, applying forward pressure to drive screw until depth locator contacts
the work surface. Screwdriver will ratchet automatically, disengaging bit from screw.
5. This depth sensitive screwdriver is suitable for driving drywall screws when operated in high
speed, and deck screws when operated in low speed.
FOR DEPTH SENSITIVE POSITIVE CLUTCHES PLEASE REMEMBER:
• The bit will not turn until pressure is applied to the unit. Push to engage.
• The high/low speed gear shifter is designed to be used when the unit is not running.
• If the unit appears to be working, but the bit will not turn, check to make sure that the
high/low speed gear shifter is pushed fully to either setting.
• Use recommended speed range; high speed for light duty applications and low speed for
heavy duty applications.
• Trigger switch will not depress unless tool is in either forward or reverse position.
• The tool is shipped with a drywall nosepiece installed. A nutsetter nosepiece is included as
an accessory.
Tips For Driving Screws Into Decks
(Switch unit to low speed)
• Select proper length deck screws to ensure complete anchoring into the wood.
• Before driving deck screws, check that there is no gap between the boards to be fastened
together.
• Although the screwdriver will drive drywall screws into decks, we recommend screws specif-
ically designed for deck assembly. Other fasteners may not drive as well or hold as satis-
factorily.
• When using the screwdriver for the first time to drive screws into pressure-treated lumber,
practice driving some screws in scrap material to get a "feel" and to adjust for proper seat-
ing depth. It will be significantly easier to guide and control the screw if 1/8" pilot holes are
pre-drilled. This pre-drilling is recommended at the board ends to avoid splitting the lumber.
• Once a screw has started driving, do not stop the screwdriver until the screw is seated. Keep
firm pressure on the screwdriver. Because of the high driving torque required in pressure-
treated wood, the head of the deck screw may strip if the screwdriver user fails to maintain
steady pressure on the bit.
• More pressure can be applied to the bit if the screwdriver is gripped by sliding the thumb
and index finger along the side of the tool near the top. Actuate the trigger with middle fin-
ger and/or fourth finger. D
driver to allow for a comfortable grip.
• Avoid driving screws through knots. Screws are difficult to start into knots. If a knot can't be
avoided, first drill a pilot hole equal in diameter to the body diameter of the deck screw.
• Keep a few additional bits on hand before starting any job.
Intalling and Changing Nutsetters and Locators
1. Select nutsetter size desired.
2. One locator is supplied (a 9/16" ID for 3/8" and 5/16" nutsetters).
3. Drop nutsetter into nose of locator and wrap the end of nutsetter until ball lock snaps in
groove in nutsetter shank.
4. To change the nutsetter or locator, pull forward on adustment collar and remove from clutch
housing.
5. Pull nutsetter straight out with pliers if it is difficult to remove.
6. Assemble nutsetter as shown in Figure 7.
7. Reassemble adjustment collar. Align ribs on inside of depth locator with grooves in clutch
housing.
Depth Adjustment on Depth Sensitive Units for Drill
Point Screws
1. For washer head screws: Rotate adjustment collar until end of nutsetter is flush with end of
locator.
2. For large washer head and sealer screws: adjust as above until nutsetter is recessed
approximately 1/16" into the locator.
3. Test drive a fastener in scrap material to determine if seating is correct.
4. Readjust if necessary.

MAINTENANCE

Cleaning
CAUTION: Blow dirt and dust out of all air vents with dry air at least once a week. Wear safe-
ty glasses when performing this. 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. Do not use gasoline, turpentine,
lacquer or paint thinner, dry cleaning fluids or similar products. Never let any liquid get inside the
tool; never immerse any part of the tool into a liquid.
WALT has designed recesses along the top sides of your screw-
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