DeWalt DC415-XE Instruction Manual

DC415-XE

HEAVY-DUTY 36V CORDLESS FINISHING GRINDER

INSTRUCTION MANUAL

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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.

General Safety Rules

WARNING! Read all instructions. Failure to follow all instructions listed below
may result in electric shock, fire and/or serious injury. The term “power tool” in all
of the warnings listed below refers to your mains operated (corded) power tool or
battery operated (cordless) power tool.

SAVE THESE INSTRUCTIONS

1. WORK AREA
a. Keep work area clean and well lit. Cluttered and 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.

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.

b. Use safety equipment. Always wear eye protection. Safety equipment such

as dust mask, non-skid safety shoes, hard hat, or hearing protection used for
appropriate conditions will reduce personal injuries.

c. Avoid accidental starting. Ensure the switch is in the off position before

plugging in. Carrying power tools with your finger on the switch or plugging

in power tools that have the switch on invites accidents.

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.

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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 these

devices 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 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 tools
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 and in the manner intended for the particular type of power tool,
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. Ensure the switch is in the off position before inserting battery pack. Inser ting

the battery pack into power tools that have the switch on invites accidents.

b. 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.

c. Use power tools only with specifically designated battery packs. Use of any

other battery packs may create a risk of injury and fire.

d. 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.

e. 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.

Additional Safety Instructions

• Check that the grinding wheel backing flange has a yellow rubber ring (K)
installed, see Figure 3. Replace rubber ring if missing, damaged or worn. See
page 9 for details regarding proper accessory installation.

WARNING: The grinding wheel or accessory may loosen during coast-down of the
tool when shut off if rubber ring is missing or damaged. If grinding wheel or accessory
loosens, it may dismount from the machine and may cause serious personal injury.

• Always use proper guard with grinding wheel. A guard protects operator from

broken wheel fragments and wheel contact.

• Accessories must be rated for at least the speed recom mended on the tool

warning label. Wheels and other accessories running over their rated speed can

fly apart and cause injury. Accessory ratings must always be above tool speed
as shown on tool nameplate.

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• 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.

• Do not use Type 11 (flaring cup) wheels on this tool. Using inappropriate
accessories can result in injury.

• Before using, inspect recommended accessory for cracks or flaws. If such a
crack or flaw is evident, discard the accessory. The accessory should also
be inspected whenever you think the tool may have been dropped. Flaws may

cause wheel breakage.

• Do not use circular saw blades or any other toothed blades with this tool.

Serious injury may result.

• When starting the tool with a new or replacement wheel, or a new or
replacement wire brush installed, hold the tool in a well protected area and
let it run for one minute. If the wheel has an undetected crack or flaw, it should

burst in less than one minute. If the wire brush has loose wires, they will be
detected. Never start the tool with a person in line with the wheel. This includes
the operator.

• Avoid bouncing the wheel or giving it rough treatment. If this occurs, stop the tool
and inspect the wheel for cracks or flaws.

• Direct sparks away from operator, bystanders or flammable materials. Sparks
may be produced while using a sander or grinder. Sparks may cause burns or
start fires.

• Always use side handle. Tighten the handle securely. The side handle should
always be used to maintain control of the tool at all times.

• Clean out your tool often, especially after heavy use. Dust and grit containing
metal particles often accumulate on interior surfaces and could create a hazard.

• 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.

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.

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.

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• 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.

• 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).

WARNING: 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). Damaged battery packs should be returned to service center for recycling.

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. 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 transpor ting individual batteries, make sure
that the battery terminals are protected and well insulated from materials that could
contact them and cause a short circuit.

The RBRC™ Seal

TThe RBRC™ (Rechargeable Battery Recycling Corporation) Seal
on the lithium ion battery (or battery pack) indicates that the costs
to recycle the battery (or battery pack) at the end of its useful life
have already been paid by D

EWALT.

• 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

min ............. minutes

...........alternating current

.......... direct current

n

o ..............no load speed

.............. Class I Construction .............earthing terminal

................... (grounded) .............safety alert symbol

...............Class II Construction …/min .......revolutions per minute

................... (double insulated) BPM ..........beats per minute

Introduction

The DC9000-XE charger is designed to charge DEWALT battery packs in approximately
1 hour. This charger requires no adjustment and is designed to be as easy as possible
to operate. Simply place your battery pack into the receptacle of a plugged in charger
and it will automatically charge the pack.

Important Safety Instruction for Battery Packs

WARNING: For safe operation, read this manual and manuals originally supplied with
tool before using the charger.
When ordering replacement battery packs, be sure to include catalog number and
voltage. Consult the chart on the last page 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 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.

• 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.