DeWalt DCL040, DCL040E1 Manual

Introduction

You have chosen a DeWALT tool. Years of experience, thorough product development and innovation make DeWALT one of the most reliable partners for professional power tool users.

Package Contents

The package contains:
1 LED worklight
1 Li‑Ion battery pack (C1, D1, L1, M1, E1, P1, H1, S1, T1, X1, Y1 models)
2 Li‑Ion battery packs (C2, D2, L2, M2, E2, P2, H2, S2, T2, X2, Y2 models)
3 Li‑Ion battery packs (C3, D3, L3, M3, E3, P3, H3, S3, T3, X3, Y3 models) 1 I nstruction manual
NOTE: Battery packs, chargers and kitboxes are not included with N models. Battery packs and chargers are not included with NT models. B models include Bluetooth® battery packs.
NOTE: The Bluetooth® word mark and logos are registered trademarks owned by the Bluetooth®, SIG, Inc. and any use of such marks by DeWALT is under license. Other trademarks and trade names are those of their respective owners.

• Check for damage to the tool, parts or accessories which may have occurred during transport.

Take the time to thoroughly read and understand this manual prior to operation.CB606,DCB609,DCB612,DCB615. Refer to Technical Data for more information. Markings on Tool The following pictograms are shown on the tool:

	Read instruction manual before use.
	Visible radiation. Do not stare into light.
	Do not stare at operating lamp. May be harmful to eyes.

Date Code Position (Fig. B)
The date code , which also includesthe year of manufacture, is printed into the housing.
Example:
2022 XX XX
Year and week of Manufacture

Description

Never modify the power tool or any part of it. Damage or personal injury could result.

1. Switch
2. Loop hook
3. Pivoting head
4. Battery pack
5. Battery release button
6. Belt hook (optional accessory)
7. Belt hook screw

Intended Use
These worklights are professional tools.
DO nOT use under wet conditions or in the presence of flammable liquids or gases.
DO nOT let children come into contact with the tool.
Supervision is required when inexperienced operators use this tool.

• Young children and the infirm. This appliance is not intended for use by young children or infirm persons without supervision.
• This product is not intended for use by persons (including children) suffering from diminished physical, sensory or mental abilities; lack of experience, knowledge or skills unless they are supervised by a person responsible for their safety. Children should never be left alone with this product.

ASSEMBLY AND ADJUSTMENTS

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. An accidental start-up can cause injury.

Use only DeWALT battery packs and chargers.
Inserting and Removing the Battery Pack from the Tool (Fig. B)
NOTE: Make sure your battery pack is fully charged.

To Install the Battery Pack into the Tool Handle

1. Align the battery pack with the rails inside the tool's handle (Fig. B).
2. Slide it into the handle until the battery pack is firmly seated in the tool and ensure that you hear the lock snap into place.

To Remove the Battery Pack from the Tool

1. Press the release button and firmly pull the battery pack out of the tool handle.
2. Insert battery pack into the charger as described in the charger section of this manual.

Fuel Gauge Battery Packs (Fig. B)
Some DeWALT battery packs include a fuel gauge which consists of three green LED lights that indicate the level of charge remaining in the battery pack.
To actuate the fuel gauge, press and hold the fuel gauge button . A combination of the three green LED lights will illuminate designating the level of charge left. When the level of charge in the battery is below the usable limit, the fuel gauge will not illuminate and the battery will need to be recharged.
NOTE: The fuel gauge is only an indication of the charge left on the battery pack. It does not indicate tool functionality and is subject to variation based on product components, temperature and end‑user application.

Fitting the Warning Label
The safety warnings on the label shown on the laser must be formulated in the language of the user.
For that purpose, a separate sheet of self‑adhesive labels has been supplied with the tool.

Check that the safety warnings on the label have been formulated in your language.
The warnings should read as follows:
RISK GROUP 2

POSSIBLY HAZARDOUS OPTICAL RADIATION EMITTED FROM THIS PRODUCT.

• If the warnings are in a foreign language, proceed as follows:
  • Remove the required label from the sheet.
  • Carefully place the label over the existing label.
  • Press the label in place.

OPERATION

Instructions for Use

Always observe the safety instructions and applicable regulations.

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. An accidental start-up can cause injury.

Switch (Fig. A)
To turn the light on, press the switch . To turn it off, press the switch again.

Pivoting Head (Fig. C)
The pivoting head rotates to provide light in the range of ‑10 ° to 100 °.

Carrying and Suspending the Light (Fig. A, D)

When the worklight hangs by the belt hook or loop hook, do not shake the light or the object from which it hangs. Do not hang the worklight from any electrical wires or anything that is not secure. Personal injury or property damage may occur.

Only use the belt hook or the loop hook for hanging the LED worklight. The belt hook and loop hook are not intended to support additional weight. Do not attach or hang anything additional to the light or risk of breakage may occur.

Do not use the belt hook or loop hook to reach with or to support your weight in any situation.

Loop Hook (Fig. D)
The light may be carried or hung by the loop hook . When not in use, the loop may be folded down.

Belt Hook (Optional Accessory) (Fig. A)

To reduce the risk of serious personal injury, ensure the screw holding the belt hook is secure.

When attaching or replacing the belt hook , use only the screw that is provided. Be sure to securely tighten screw.
The belt hook can be attached to either side of the light using only the screw provided, to accommodate left‑ or right‑handed users. If the hook is not desired at all, it can be removed from the light.
To move the belt hook, remove the screw that holds the belt hook in place, then reassemble on the opposite side. Be sure to securely tighten screw.

MAINTENANCE

Your power tool has been designed to operate over a long period of time with a minimum of maintenance. Continuous satisfactory operation depends upon proper tool care and regular cleaning.

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. An accidental start-up can cause injury.
The charger and battery pack are not serviceable.

Lubrication

Your power tool requires no additional lubrication.

Cleaning


Blow dirt and dust out of the main housing with dry air as often as dirt is seen collecting in and around the air vents. Wear approved eye protection and approved dust mask when performing this procedure.

Never use solvents or other harsh chemicals for cleaning the non-metallic parts of the tool. These chemicals may weaken the 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.

Optional Accessories

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.
Consult your dealer for further information on the appropriate accessories.

Dust Extraction System (Fig. J)
The use of a dust extraction system is recommended to reduce potentially harmful airborne dust and to prolong tool and accessory life.
Consult your dealer for further information on suitable dust extraction systems.

Rechargeable Battery Pack
This long life battery pack must be recharged when it fails to produce sufficient power on jobs which were easily done before. At the end of its technical life, discard it with due care for our environment:

• Run the battery pack down completely, then remove it from the tool.
• Li‑Ion cells are recyclable. Take them to your dealer or a local recycling station. The collected battery packs will be recycled or disposed of properly.
  SDS plus® and SDS max® are registered trade marks of Robert Bosch GmbH

AFTER SERVICE AND REPAIR

DEWALT service centers are staffed with trained personnel to provide customers with efficient and reliable product service. We do not take any responsibility when you have repaired in unauthorized service center. You can refer to the leaflet of CONTACT CENTER LOCATOR in product package and contact us through hotline, website or social media to find the nearest DEWALT service center around you.

IMPORTANT SAFETY INSTRUCTIONS

When using the worklight, basic precautions should always be followed, including the following:

1. Read all the instructions before using the worklight.
2. DO NOT stare directly into the light source.
3. DO NOT use optical instruments to look directly into the light source.
4. DO NOT point the light into other people's eyes.
5. To reduce the risk of injury, close supervision is necessary when a worklight is used near children.
6. Turn the worklight off when not in use and before servicing or cleaning.
7. Do not operate any worklight after it malfunctions or is dropped or damaged in any manner. Return worklight to the nearest authorised service facility for examination, repair, or electrical or mechanical adjustment.
8. To reduce the risk of electrical shock, do not put worklight in water or other liquids. Do not place or store worklight where it can fall or be pulled into a tub or sink.

1. Battery Tool Use and Care
   1. 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.
   2. Use power tools only with specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire.
   3. 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.
   4. 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.
   5. Do not use a battery pack or tool that is damaged or modified. Damaged or modified batteries may exhibit unpredictable behaviour resulting in fire, explosion or risk of injury.
   6. Do not expose a battery pack or tool to fire or excessive temperature. Exposure to fire or temperature above 130°C may cause explosion.
   7. Follow all charging instructions and do not charge the battery pack or tool outside the temperature range specified in the instructions. Charging improperly or at temperatures outside the specified range may damage the battery and increase the risk of fire.
2. Service
   1. 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.
   2. Never service damaged battery packs. Service of battery packs should only be performed by the manufacturer or authorized service providers.

SAVE THESE INSTRUCTIONS

Specific Safety Rules for Worklights

Fire hazard. Do not operate worklight or charger near flammable liquids or in gaseous or explosive atmospheres. Internal sparks may ignite fumes causing personal injury.

• Do not expose light or charger to wet or damp areas. Do not expose light or charger to rain or snow.
• Do not wash worklight or charger with water or allow water to get inside light or charger. Do not submerge light in water at any time.
• While worklight is in use, do not cover with cloth or other flammable materials due to increased risk of fire.
• Store the worklight indoors when not in use.
• Do not contact hot parts.
• To reduce the risk of injury, only DeWALT recommended accessories should be used with this product.
  
  Do not place the worklight in a position which may cause anyone to intentionally or unintentionally stare into the light. Serious eye injury could result.
  
  This worklight is in excess of the Exempt Group (acc. EN62471) and the viewer related risk due to retinal blue light is dependent upon how the users use the worklight. A Safety Hazard Distance of more than 2 m should be kept.
  
  When not in use, place worklight 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.

Residual Risks

• The following risks are inherent to the use of this appliance:
  • impaired vision when looking directly into light
  • burns from touching a hot surface

Chargers
DeWALT chargers require no adjustment and are designed to be as easy as possible to operate.

Electrical Safety
The electric motor has been designed for one voltage only. Always check that the battery pack voltage corresponds to the voltage on the rating plate. Also make sure that the voltage of your charger corresponds to that of your mains. Your DeWALT charger is double insulated in accordance withIEC60335; therefore no earth wire is required.

If the supply cord is damaged, it must be replaced only by DeWALT or an authorised service organisation.

Using an Extension Cable
An extension cord should not be used unless absolutely necessary. Use an approved extension cable suitable for the power input of your charger (see Technical Data). The minimum conductor size is 1 mm²; the maximum length is 30 m.
When using a cable reel, always unwind the cable completely.

Important Safety Instructions for All Battery Chargers
SAVE THESE INSTRUCTIONS: This manual contains important safety and operating instructions for compatible battery chargers (refer to Technical Data).

• Before using charger, read all instructions and cautionary markings on charger, battery pack, and product using battery pack.
  
  Shock hazard. Do not allow any liquid to get inside charger. Electric shock may result.
  
  We recommend the use of a residual current device with a residual current rating of 30mA or less.
  
  Burn hazard. To reduce the risk of injury, charge only DeWALT rechargeable batteries. Other types of batteries may burst causing personal injury and damage.
  
  Children should be supervised to ensure that they do not play with the appliance.
  NOTICE: 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.
• 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.
• 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 authorised service centre.
• Do not disassemble charger; take it to an authorised service centre when service or repair is required. Incorrect reassembly may result in a risk of electric shock, electrocution or fire.
• In case of damaged power supply cord, the supply cord must be replaced immediately by the manufacturer, its service agent or similar qualified person to prevent any hazard.
• 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 two chargers together.
• The charger is designed to operate on standard 220240V household electrical power. Do not attempt to use it on any other voltage. This does not apply to the vehicular charger.

Charging a Battery (Fig. B)

1. Plug the charger into an appropriate outlet before inserting battery pack.
2. Insert the battery pack into the charger, making sure the battery pack is fully seated in the charger. The red (charging) light will blink repeatedly indicating that the charging process has started.
3. The completion of charge will be indicated by the red light remaining ON continuously. The battery pack is fully charged and may be used at this time or left in the charger. To remove the battery pack from the charger, push the battery release button on the battery pack.

NOTE: To ensure maximum performance and life of lithium‑ion battery packs, charge the battery pack fully before first use.

Charger Operation
Refer to the indicators below for the charge status of the battery pack.

Charge Indicators

* The red light will continue to blink, but a yellow indicator light will be illuminated during this operation. Once the battery pack has reached an appropriate temperature, the yellow light will turn off and the charger will resume the charging procedure.
The compatible charger(s) will not charge a faulty battery pack.
The charger will indicate faulty battery by refusing to light.
NOTE: This could also mean a problem with a charger.
If the charger indicates a problem, take the charger and battery pack to be tested at an authorised service centre.

Hot/Cold Pack Delay
When the charger detects a battery pack that is too hot or too cold, it automatically starts a Hot/Cold Pack Delay, suspending charging until the battery pack has reached an appropriate temperature. The charger then automatically switches to the pack charging mode. This feature ensures maximum battery pack life.
A cold battery pack will charge at a slower rate than a warm battery pack. The battery pack will charge at that slower rate throughout the entire charging cycle and will not return to maximum charge rate even if the battery pack warms.
The DCB118 charger is equipped with an internal fan designed to cool the battery pack. The fan will turn on automatically when the battery pack needs to be cooled. Never operate the charger if the fan does not operate properly or if ventilation slots are blocked. Do not permit foreign objects to enter the interior of the charger.

Electronic Protection system
XR Li‑Ion tools are designed with an Electronic Protection System that will protect the battery pack against overloading, overheating or deep discharge.
The tool will automatically turn off if the Electronic Protection System engages. If this occurs, place the lithium‑ion battery pack on the charger until it is fully charged.

Wall Mounting
These chargers are designed to be wall mountable or to sit upright on a table or work surface. If wall mounting, locate the charger within reach of an electrical outlet, and away from a corner or other obstructions which may impede air flow. Use the back of the charger as a template for the location of the mounting screws on the wall. Mount the charger securely using drywall screws (purchased separately) at least 25.4 mm long with a screw head diameter of 7–9 mm, screwed into wood to an optimal depth leaving approximately 5.5 mm of the screw exposed. Align the slots on the back of the charger with the exposed screws and fully engage them in the slots.

Charger Cleaning Instructions

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. Never let any liquid get inside the tool; never immerse any part of the tool into a liquid.

Battery Packs

Important Safety Instructions for All Battery Packs
When ordering replacement battery packs, be sure to include catalogue number and voltage.
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.
• 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 fall below 4 ˚C (34 ˚F) (such as outside sheds or metal buildings in winter), or reach or exceed 40 ˚C (104 ˚F) (such as outside sheds or metal buildings in summer).
• 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.
  
  Burn hazard. Battery liquid may be flammable if exposed to spark or flame.
  
  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 centre for recycling.
  
  Fire hazard. Do not store or carry the battery pack so that metal objects can contact exposed battery terminals. For example, do not place the battery pack in aprons, pockets, tool boxes, product kit boxes, drawers, etc., with loose nails, screws, keys, etc.
  
  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.

Transportation

Fire hazard. Transporting batteries can possibly cause fire if the battery terminals inadvertently come in contact with conductive materials. When transporting batteries, make sure that the battery terminals are protected and well insulated from materials that could contact them and cause a short circuit.
NOTE: Lithium-ion batteries should not be put in checked baggage.
DeWALT batteries comply with all applicable shipping regulations as prescribed by industry and legal standards which include UN Recommendations on the Transport of Dangerous Goods; International Air Transport Association (IATA) Dangerous Goods Regulations, International Maritime Dangerous Goods (IMDG) Regulations, and the European Agreement Concerning The International Carriage of Dangerous Goods by Road (ADR). Lithium‑ion cells and batteries have been tested to section 38.3 of the UN Recommendations on the Transport of Dangerous Goods Manual of Tests and Criteria. In most instances, shipping a D e WALT battery pack will be excepted from being classified as a fully regulated Class 9 Hazardous Material. In general, only shipments containing a lithium‑ion battery with an energy rating greater than 100 Watt Hours (Wh) will require being shipped as fully regulated Class 9. All lithium‑ion batteries have the Watt Hour rating marked on the pack. Furthermore, due to regulation complexities, D does not recommend air shipping lithium‑ion battery packs alone regardless of Watt Hour rating. Shipments of tools with batteries (combo kits) can be air shipped as excepted if the Watt Hour rating of the battery pack is no greater than 100 Wh. Regardless of whether a shipment is considered excepted or fully regulated, it is the shipper's responsibility to consult the latest regulations for packaging, labeling/marking and documentation requirements. The information provided in this section of the manual is provided in good faith and believed to be accurate at the time the document was created. However, no warranty, expressed or implied, is given. It is the buyer's responsibility to ensure that its activities comply with the applicable regulations.

Transporting the FlEXVOlT^TM Battery
The DeWALT FLEXVOLT^TM battery has two modes: Use and Transport.

Use Mode: When the FLEXVOLT^TM battery stands alone or is in a DeWALT 18V (20V Max) product, it will operate as an 18V (20V Max) battery. When the FLEXVOLT^TM battery is in a 54V (60V Max) or a 108V (120V Max) (two 54V (60V Max) batteries) product, it will operate as a 54V (60V Max) battery.
Transport Mode: When the cap is attached to the FLEXVOLT^TM battery, the battery is in Transport mode. Keep the cap for shipping.
When in Transport mode, strings of cells are electrically disconnected within the pack resulting in 3 batteries with a lower Watt hour (Wh) rating as compared to 1 battery with a higher Watt hour rating. This increased quantity of 3 batteries with the lower Watt hour rating can exempt the pack from certain shipping regulations that are imposed upon the higher Watt hour batteries. For example, the Transport Wh rating might indicate 3 x 36 Wh, meaning 3 batteries of 36 Wh each. The Use Wh rating might indicate 108 Wh (1 battery implied).

Storage Recommendations

1. The best storage place is one that is cool and dry away from direct sunlight and excess heat or cold. For optimum battery performance and life, store battery packs at room temperature when not in use.
2. For long storage, it is recommended to store a fully charged battery pack in a cool, dry place out of the charger for optimal results.
   NOTE: Battery packs should not be stored completely depleted of charge. The battery pack will need to be recharged before use.

Labels on Charger and Battery Pack
In addition to the pictographs used in this manual, the labels on the charger and the battery pack may show the following pictographs:

	Read instruction manual before use.
	See Technical Data for charging time.
	Do not probe with conductive objects.
	Do not charge damaged battery packs.
	Do not expose to water.
	Have defective cords replaced immediately
	Charge only between 4 ˚C and 40 ˚C.
	Only for indoor use.
	Charge De WALT battery packs only with designated De WALT chargers. Charging battery packs other than the designated De WALT batteries with a De WALT charger may make them burst or lead to other dangerous situations.
	Do not incinerate the battery pack.
	USE (without transport cap). Example: Wh rating indicates 108 Wh (1 battery with 108 Wh).
	TRANSPORT (with built‑in transport cap). Example: Wh rating indicates 3 x 36 Wh (3 batteries of 36 Wh).

Battery Type
The following tools operate on a 18(20 Max) volt battery pack:
DCL040
These battery packs may be used: DCB180, DCB181, DCB182,
DCB183, DCB184, DCB203, DCB204, DCB205, DCB208, DCB186,
DCB187, DCB189, DCB240, DCBP034, DCBP520, DCB546, DCB547, DCB548, DCB549, DCB606, DCB609, DCB612, DCB615. Refer to Technical Data for more information.