The RBRC™ Seal
The RBRC™ (Rechargeable Battery Recycling Corporation) Seal on the nickel-cadmium 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
E
WALT. In some areas, it is illegal to place spent nickel-cadmium batteries in the
trash or municipal solid waste stream and the RBRC program provides an environmentally conscious
alternative.
RBRC™ in cooperation with D
E
WALT and other battery users, has established programs in the United States to facilitate
the collection of spent nickel-cadmium batteries. Help protect our environment and conserve natural resources by
returning the spent nickel-cadmium battery to an authorized D
E
WALT service center or to your local retailer for recycling.
You may also contact your local recycling center for information on where to drop off the spent battery.
RBRC™ is a registered trademark of the
Rechargeable Battery Recycling Corporation
.
Important Safety Instructions for Battery Chargers
SAVE THESE INSTRUCTIONS: This manual contains important safety instructions for battery chargers.
• Before using charger, read all instructions and cautionary markings on charger, battery pack, and product using
battery pack.
DANGER:
240 volts are present at charging terminals. Do not probe with conductive objects. Electric shock or electro-
cution may result.
WARNING:
Do not allow any liquid to get inside charger. Electric shock may result.
CAUTION:
To reduce the risk of injury, charge only D
E
WALT nickel cadmium rechargeable 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 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 D
E
WALT 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.
•
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.
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 ventila-
tion 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, 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 (240 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 indi-
cates 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 maintenance 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
E
WALT Charger. Your battery can be charged in D
E
WALT 1 Hour Chargers, 15
Minute Chargers or Vehicular 12 volt charger. Be sure to read all safety instructions before using your charger. Consult the
chart on the back cover of this manual for compatibility of chargers and battery packs.
Charging Procedure (Fig. 1)
1. Plug the charger into an appropriate outlet.
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.
CAUTION:
240 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
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, reinsert 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 bat-
tery 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.
PACK CHARGING...................
FULLY CHARGED...................
HOT/COLD PACK DELAY........
REPLACE PACK......................
PROBLEM POWER LINE........
FIG. 1
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 condition. 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 normal condition, and does not
indicate a problem.
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.
6. Do not freeze or immerse charger in water or any other liquid.
WARNING:
Don't allow any liquid to get inside charger. Electric shock may result. To facilitate the cooling of the bat-
tery pack after use, avoid placing the charger or battery pack in a warm environment such as in a metal shed, or an unin-
sulated trailer.
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.
Installing and Removing the Battery Pack (Fig. 2)
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 and slide the battery pack firmly into
the handle until you hear the lock snap into place.
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 manual.
COMPONENTS (FIG. 3)
A. Trigger Switch
F. Abrasive Wheel
B. Lock-Off Button
G. Unthreaded Backing Flange (not shown)
C. Spindle Lock Button
H. Threaded Clamp Nut (not shown)
D. Spindle (not shown)
I. Guard (Type 1, Type 27)
E. Side Handle
J. Battery
ASSEMBLY AND ADJUSTMENTS
Attaching Side Handle
The side handle can be fitted to either side of the gear case in the threaded holes. Before
using the tool, check that the handle is tightened securely.
To improve user comfort, the gear case will rotate 90˚ for cutting operations.
Rotating the Gear Case
CAUTION:
Turn off tool and remove battery before making any adjustments or removing
or installing attachments or accessories.
1. Remove the four corner screws attaching the gear case to motor housing.
2. Without separating the gear case from motor housing, rotate the gear case head to
desired position.
NOTE:
If the gear case and motor housing become separated by more than 3.31mm (1/8"),
the tool must be serviced and reassembled by a D
E
WALT service center. Failure to have the
tool serviced may cause brush, motor and bearing failure.
3. Re-install screws to attach the gear case to the motor housing. Tighten screws to 88.96 NM (20 in-lbs.) torque.
Overtightening could cause screws to strip.
ACCESSORIES
It is important to choose the correct guards, backing pads and flanges to use with grinder accessories. See page 3 for
information on choosing the correct accessories.
CAUTION:
Accessories must be rated for at least the speed recommended on the tool warning label. Wheels and other
accessories running over their rated accessory speed may fly apart and cause injury. Threaded accessories must have a
14mm x 2 (5/8"-11) hub. Every unthreaded accessory must have a 22mm (7/8") arbor hole. If it does not, it may have
been designed for a circular saw. Use only the accessories shown on page 3 of this manual. Accessory ratings must
always be above tool speed as shown on tool nameplate.
Mounting Guard
MOUNTING AND REMOVING GUARD
CAUTION: Turn off tool and remove battery before making any adjustments or removing or installing attachments
or accessories.
CAUTION: Guards must be used with all grinding wheels, sanding flap discs, wire brushes, and wire wheels.
The
tool may be used without a guard only when sanding with conventional sanding discs. D
E
WALT
model DC410 is provided with a guard intended for use with depressed center wheels (Type
27) and hubbed grinding wheels (Type 27). The same guard is designed for use with sanding
flap discs (Type 27 and 29) and wire cup brushes. Grinding and cutting with wheels other than
Type 27 and 29 require different accessory guards included with tool. A Type 1 guard is
provided for use with a Type 1 wheel. Mounting instructions for these accessory guards are
included in the accessory package.
1. Open the guard latch (J), and align the arrow on the guard (K) with the arrow on the
hub (L). This will align the lugs on the guard with the slots on the gear case cover.
2. Push the guard down until the guard lugs engage and rotate freely in the groove on the gear
case hub.
3. With the guard latch open, rotate the guard (I) into the desired working position. The guard
body should be positioned between the spindle and the operator to provide maximum oper-
ator protection.
4. Close the guard latch to secure the guard on the gear case. You should not be able to
rotate the guard by hand when the latch is closed. Do not operate the grinder with a
loose guard or the clamp lever in open position.
5. To remove the guard, open the guard latch, rotate the guard so that the arrows are
aligned and pull up on the guard.
NOTE:
The guard is pre-adjusted to the diameter of the gear case hub at the factory. If, after
a period of time, the guard becomes loose, tighten the adjusting screw (M) with clamp lever
in the closed position with guard installed on the tool.
CAUTION:
Do not tighten the adjusting screw with the clamp lever in the open position. Undetectable damage to the
guard or the mounting hub may result.
CAUTION:
If the guard cannot be tightened by the adjusting clamp, do not use the tool and take the tool and guard to
a service center to repair or replace the guard.
NOTE:
Edge grinding and cutting can be performed with Type 27 wheels designed and specified for this purpose; 6.35mm
(1/4") thick wheels are designed for surface grinding while 3.31mm (1/8") wheels are designed for edge grinding. Cutting
can also be performed by using a Type 1 wheel and a Type 1 guard.
M
I
J
L
K
FIG. 3
E
F
C
B
A
J
I
FIG. 2
