DeWalt DW9109 Instruction Mamual

D WALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286
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(JUL04-CD-1) Form No. 626596-00
The following are trademarks for one or more D
"D" shaped air intake grill; the array of pyramids on the handgrip; the kit box configuration; and the array of
lozenge-shaped humps on the surface of the tool.

Important Safety Instructions

• This manual contains important safety and operating instructions for your vehicle charger
DW9109.
• Before using charger, read all instructions and cautionary markings on (1) charger, (2) battery
pack, and (3) product using battery pack.
DANGER: If the battery pack is cracked or damaged, do not insert into charger. Danger of
electric shock or electrocution.
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.
CAUTION: To reduce risk of injury, charge only D
types of batteries may burst, causing personal injury and damage.
• Do not expose charger to rain or snow.
• Use of an attachment not recommended or sold by D
tric shock or injury to persons.
• To reduce risk of damage to electric plug and cord, pull by plug rather than cord when dis-
connecting charger from 12 volt outlet.
• Make sure cord is located so that it will not be stepped on, tripped over or otherwise subjected
to damage or stress.
• The charger plug has an integral overload protector (fuse). If a cordset or plug failure occurs,
a replacement cordset must be used. This part is available from D
centers at extra cost. DO NOT operate the charger without proper overload protection (fuse).
Refer to Special Installation instructions for wiring information in vehicles without a cigarette
lighter socket.
• The charger is designed to operate from a 12 volt negative ground vehicle battery system.
DO NOT attempt to use it with any other voltage system.
• Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged
in any way; take it to a D WALT certified service center.
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• Do not disassemble charger; take it to a qualified D
vice or repair is required. Incorrect reassembly may result in a risk of electrical shock or fire.
• DO NOT store the charger and battery pack in locations where the temperature may reach
or exceed 105° (40°C) (such as outside sheds, or metal buildings in summer.)
• Do not charge battery pack when it or air temperature is BELOW +40°F (+4°C) or ABOVE
+105°F (+40°C).
SAVE THESE INSTRUCTIONS
Important Charging Notes
1. To prevent excessive discharge of the vehicle battery, DO NOT CHARGE MORE THAN
TWO BATTERY PACKS WITHOUT OPERATING THE VEHICLE.
2. Disconnect charger from cigarette lighter socket when not in use to prevent vehicle
battery from discharging.
3. 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.
4. The charger and battery pack may become warm to touch while charging. This is a normal
condition, and does not indicate a problem.
5. If the battery pack does not charge properly:
a. Ensure the cigarette lighter operates when pushed in the socket.
b. Ensure the cigarette lighter operates when the vehicle's ignition switch is in the
"Accessory" position.
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 or send the tool, battery pack and charger to your local
service center.
DW9109 Copyright © 2003, 2004 D
WALT power tools: the yellow and black color scheme; the
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WALT type rechargeable batteries. Other
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WALT may result in a risk of fire, elec-
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WALT certified service
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WALT certified service center when ser-
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6. 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.
7. 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.
8. Under severely hot conditions and when the battery pack is needed back in service quick-
ly, forced cooling of the battery is required. To force cool, place the pack in the airstream
from an electric fan or in a cool location.
9. Do not freeze or immerse charger in water or any other liquid.
10. 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.
11. For optimum performance, leave the battery pack in the charger for eight hours or more
once every 10 to 20 recharges. This balances the cells, keeps the battery pack at peak per-
formance and extends the usable life of the battery pack.
NOTE: Battery storage and carrying caps are provided for use whenever the battery
is out of the tool or charger. Remove cap before placing battery in charger or tool.
WARNING: 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.
without battery cap. 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 transporting 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
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
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
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 WALT service center or to your local retailer for recycling. You may also contact your
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local recycling center for information on where to drop off the spent battery.
Battery Packs
The DW9109 charger is designed to charge D
18 volts in about 60 minutes. 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 charg-
er and it will automatically charge the pack.
When ordering D
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voltage.

Charging Procedure

1. Unwrap cord and plug in the charger.
2. Place the battery pack in the charger as shown in Figure 1.
3. The indicator light will start to blink. Refer to "INDICATOR LIGHT OPERATION" below.
4. In about 1 hour (for an XR or XR+ battery) or about 45 minutes (for a standard battery) the
WALT
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indicator light will stop blinking and remain continuously on. Fast charging is complete and
your battery pack is ready for use.
5. The indicator light will remain on for an additional 16 hours while the charger maintains your
battery pack in a fully charged condition.
6. After 16 hours, the charger will shut off automatically to reduce the amount of energy
drained from the vehicle's battery.
7. The indicator light may stay on momentarily after the battery pack is removed from the
charger. ALWAYS wait for the indicator light to go out before inserting another pack.
To prevent excessive discharge of the vehicle battery, Do not charge more than two bat-
tery packs without operating the vehicle.
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 condition.
The charger will then go on to charge the battery to the highest capacity possible.
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 to
20 charge/discharge cycles or whenever the pack no longer delivers the same amount of work.
To use the automatic tune-up mode, simply place the battery pack in the charger and leave it for
at least eight 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
WALT and other battery users, has established programs in the
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WALT battery packs with voltage from 7.2 up to
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WALT replacement battery packs, be sure to include catalog number and
WALT. In
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