Recommended Minimum Wire Size for Extension Cords
Total Length of Cord
25 ft.
50 ft.
75 ft.
100 ft.
125 ft.
150 ft.
175 ft.
7.6 m
15.2 m
22.9 m
30.5 m
38.1 m
45.7 m
53.3 m
Wire Size AWG
18
18
16
16
14
14
12
•
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 120V household electrical power. 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. 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 D
E
WALT 7.2, 9.6, 12, 14.4, or 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.
Charging Procedure
DANGER: Electrocution hazard. 120 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.
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
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 pack. Such batteries are
still usable but should not be expected to perform as much work. The charger will indicate to
replace battery pack.
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 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 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, grinding dust, metal chips, 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.
Storage Recommendations
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.
SAVE THESE INSTRUCTIONS FOR FUTURE USE
COMPONENTS (Fig. 1–4)
A. Plunger rod release trigger
G. Plunger rod
B. Trigger switch
H. Plunger
C. Trigger switch lock-off
I. Release buttons
D. Battery pack
J. Cartridge holder
E. Variable speed dial
K. Poker
F. Plunger rod handle
L. Sausage holder
Electronic Force Control
The tool is designed to dispense a wide range of adhesive and caulk, and to detect when
material is not dispensing or dispensing slowly. In certain cases, the tool may not dispense
material properly due to solidified adhesive, puncture holes, frozen materials and the like. Always
follow the manufacturer’s recommendations regarding solidified adhesive, puncture holes, frozen
materials, etc. to reduce the risk of damaging the tube or casing.
Remove the battery pack and replace material tube/casing following the manufacturer’s
instructions and the instructions under To Insert Material. Take the tool to a D
E
WALT service
center if the tool continues to shut down.
Electronic Auto-reverse
This tool has an auto-reverse feature that reverses the plunger in certain situations depending
on material used and speed of tool.
ASSEMBLY
The DC545, DC546 and the DC547 cordless adhesive guns come fully assembled.
The DC545 accepts 10 oz., 300-310 ml. or 1/10th gallon cartridges. The DC546 accepts 29 oz.
or quart cartridges. The DC547 accepts 10 oz./300 ml., or 20 oz./600 ml. sausage packs.
OPERATION
Installing and Removing the Battery Pack
NOTE: Make sure your battery pack is fully charged.
CAUTION: To prevent inadvertant operation, lock trigger switch before removing or installing
battery.
To install the battery pack into the tool handle, align the base of the tool with the notch inside
the tool’s handle and slide the battery pack firmly into the handle until you hear the lock snap
into place (Fig. 2).
To remove the battery pack from the tool, press the release buttons (I) 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.
Trigger Switch (Fig. 1)
To turn the tool on, squeeze the trigger switch (B). To turn the tool off, release the trigger
switch. Your tool is equipped with a trigger switch lock-off (C) to safeguard against inadvertent
release of material.
Trigger Switch Lock-off (Fig. 1)
WARNING: To reduce the risk of personal injury, turn unit off and disconnect battery
pack before installing and removing accessories, before adjusting or when making
repairs. To prevent inadvertant operation, lock the trigger switch when the tool is not in use and
when storing the tool.
1. To lock the trigger switch, push trigger switch lock-off (C) up. The tool will not operate with
the switch in the locked position.
2. To unlock the trigger switch, push the trigger switch lock-off down.
Variable Speed Dial (Fig. 1)
1. Turn the variable speed dial (E) to an appropriate speed for your application. Turn the
dial counterclockwise for minimum flow of caulk or adhesive. Turn the dial clockwise for
maximum flow of caulk or adhesive.
2. Press the trigger switch (B) to start the flow of material.
3. Release trigger switch to stop the flow of material.
Rotating Cartridge Holder
The cartridge holder rotates 360˚ to apply material at any angle.
Plunger Rod Handle (Fig. 1)
WARNING: To reduce the risk of personal injury, turn unit off and disconnect battery
pack before installing and removing accessories, before adjusting or when making
repairs. To prevent inadvertant operation, lock the trigger switch when the tool is not in use and
when storing the tool.
WARNING: To reduce the risk of serious personal injury, DO NOT use the plunger rod
handle as a hook to suspend objects from.
The plunger rod handle may be used to suspend tool from a stable location when not in use or
for storage.
To Adjust Plunger Rod (Fig. 1)
1. To manually adjust plunger rod (G), press and hold the plunger rod release trigger (A).
2. Push or pull plunger rod handle (F) to desirable position.
3. Release plunger rod release trigger.
To Insert Material
NOTE: Material left in the cartridge/sausage holder may dry if left unattended. Follow
manufacturer’s recommendations when using caulk or adhesive material.
CARTRIDGE HOLDER (FIG. 3)
1. Ensure that the proper cartridge holder is installed properly.
2. Use the trigger switch lock-off (C) to lock trigger switch (A).
3. Trim nozzle end of the caulk/adhesive tube (Fig. 5). Small openings require more force to
push the material possibly affecting battery life.
4. Break inner seal of caulking tube or adhesive material using the poker (K) located on the
under side of the cartridge holder.
CAUTION: If the inner seal is not broken, material could be forced out through the rear of the
tube and damage the tool.
CAUTION: Keep plunger rod, cartridge holder and cartridge clean of all material. Retracting a
plunger rod that is covered with dried material may damage the internal parts of the tool and
cause misalignment of tube.
5. Securely hold the tool, press plunger rod release trigger (A) to declutch and free the plunger
rod (G). Using the plunger rod handle (F), pull the plunger rod (G) back to allow the caulk/
adhesive tube to fit inside the cartridge holder.
6. Insert caulk/adhesive tube.
7. Press and hold plunger rod release trigger (A) while pushing the plunger rod handle (F)
forward until the plunger (H) is against the tube.
8. Release the plunger rod release trigger.
9. Rotate cartridge holder to desired angle.
SAUSAGE HOLDER (FIG. 4)
1. Unscrew nozzle cap (M) and remove nozzle (N).
2. Press and hold plunger rod release trigger (A). Using the plunger rod handle (F), pull plunger
rod (G) back to allow the caulk/adhesive casing to fit inside the sausage holder (L).
3. Insert sausage pack into sausage holder and cut casing (closest end to the nozzle) according
to manufacturer’s instructions.
IMPORTANT: Insert sausage pack into sausage holder and cut casing (closest end to the
nozzle) according to manufacturer’s instructions. This sausage holder is designed to be
used only WITH sausage packs. DO NOT remove caulk/adhesive material from the casing.
NEVER dip the nozzle tip into any type of material.
4. With nozzle tip facing away from tool, screw nozzle cap back onto sausage holder.
5. Trim tip of nozzle cap for appropriate application (Fig. 5).
To Change Holders
WARNING: To reduce the risk of personal injury, turn unit off and disconnect battery
pack before installing and removing accessories, before adjusting or when making
repairs. To prevent inadvertant operation, lock the trigger switch when the tool is not in use and
when storing the tool.
FIG. 1
I
D
FIG. 2
L
N
M
FIG. 4
FIG. 3
K
J
FIG. 5
D
F
G
E
B
A
C
H
I
10 OZ./29 OZ. CARTRIDGE HOLDER
PORTE-CARTOUCHE DE 300 ML / 857 ML (10 OZ. / 29 OZ.)
SOSTENEDOR DEL CARTUCHO DE 300 ML / 857 ML (10 OZ. / 29 OZ).
FIG. 6
FIG. 7
S
J
R
Q
G
O
P
N
L
Q
R
U
T
G
W
V
X
600 ML SAUSAGE HOLDER
PORTE-BÂTON DE 600 ML
SOSTENEDOR DEL POMO DE 600 ML
M
