DeWalt DC415-XE User manual

DC415-XE
HEAVY-DUTY 36V CORDLESS FINISHING GRINDER
INSTRUCTION MANUAL

1
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. Inserting
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 recommended 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.

3
• 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 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
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 DEWALT.
• The label on your tool may include the following symbols. The symbols and their
definitions are as follows:
V ................. volts A ...............amperes
Hz ............... her tz W ..............watts
min ............. minutes ...........alternating current
.......... direct current no..............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.

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RBRC™ in cooperation with DEWALT and other battery users, has established
programs in the United States to facilitate the collection of spent lithium ion batteries.
Help protect our environment and conserve natural resources by returning the spent
lithium ion battery to an authorized DEWALT 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.
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.
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.
WARNING: Shock hazard. Do not allow any liquid to get inside charger.
CAUTION: Burn hazard. To reduce the risk of injury, charge only DEWALT 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 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.
• 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.
MINIMUM GAGE FOR CORD SETS
For Cable length (m): 7.5 15 25 30 45 60
Use Cable with minimum rating (Amperes)
Tool Amperes
0 - 3.4 7.5 7.5 7.5 7.5 7.5 7.5
3.5 - 5.0 7.5 7.5 7.5 7.5 10 15
5.1 - 7.0 10 10 10 10 15 15
7.1 - 12.0 15 15 15 15 20 20
12.1 - 20.0 20 20 20 20 25 –
• 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 mount charger on wall or permanently affix charger to any surface. The
charger is intended to use on a flat, stable surface (i.e., table top, bench top).
• 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.

6
• 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.
Do not attempt to use it on any other voltage.
SAVE THESE INSTRUCTIONS
Charger
Your battery pack requires a 1 hour DEWALT charger. Be sure to read all safety
instructions before using your charger. Consult the chart on the back of this
manual for compatibility of chargers and battery packs.
Charging Procedure
1. Plug the charger into an appropriate outlet before
inserting the battery pack.
2. Insert the battery pack into the charger. The
charger is equipped with a three-light fuel gauge
that will blink according to the state of charge of
the battery pack.
3. The completion of charge is indicated by the three red lights remaining ON
continuously. The pack is fully charged and may be used at this time or left on
the charger.
0% - 33% 1st light blinks
33% - 66% 1st light on, 2nd light blinks
66% - 99% 1st, 2nd lights on, 3rd light blinks
100% 1st, 2nd, 3rd lights on
Charger Diagnostics
This charger is designed to detect certain problems that can arise with the battery
packs or the charger. Problems are indicated by the three red lights flashing together
in different patterns.
PROBLEM POWERLINE
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. The
three red lights will flash together with two fast blinks followed by a pause. This
indicates that the power souce is out of limits.
BAD BATTERY
The charger can detect a weak or damaged battery. The three red lights will flash
together with rapid blinking. The battery will no longer charge and should be returned
to a service center or a collection site for recycling.
BAD CHARGER
The charger will detect if it is not functioning properly. The three red lights will flash
together with one fast blink followed by a long blink. The charger will no longer work
and should be returned to an authorized service center or replaced.
LEAVING THE BATTERY IN THE CHARGER
The charger and battery pack can be left connected with the red lights glowing
indefinitely. The charger will keep the battery pack fresh and fully charged. This
charger features an automatic tune-up mode which equals or balances the individual
cells in the battery pack to allow it to function at peak capacity. Battery packs should
be tuned up weekly or whenever the battery no longer delivers the same amount of
work. To use the automatic tune-up mode, place the battery pack in the charger and
leave it for at least 8 hours.
Important Charging Notes
1. Longest life and best performance can be obtained if the battery pack is charged
when the air temperature is between 18°- 24°C (65°F and 75°F). DO NOT charge
the battery pack in an air temperature below +4.5°C (+40°F), or above +40.5°C
(+105°F). 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.

7
c. Move charger and battery pack to a location where the surrounding air
temperature is approximately 18°- 24°C (65°F - 75°F).
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. 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: Shock hazard. Do not allow any liquid to get inside charger.
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. 1)
NOTE: Make sure your battery pack is fully charged.
WARNING: To reduce the risk of serious personal injury, make certain the lock-
off button (B), as shown under Components, is engaged to prevent switch
actuation before removing or installing battery.
FIG. 1
J
To install the battery pack into the tool handle, align the base of the tool with the
rails 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 button (J) 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.
COMPONENTS (FIG. 2, 3)
A. Trigger switch F. Anti-lockup backing flange
B. Lock-Off Button G. Threaded clamp nut
C. Spindle lock button H. Guard (Type 1, Type 27)
D. Side handle I. Battery pack
E. Abrasive wheel J. Battery release button
FIG. 2
D
E
C
B
AJ
H
I

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be serviced and re-assembled by a DEWALT 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
2.08 Nm (18 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 pages 9 and 10 for information on choosing the correct
accessories.
WARNING: 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 14 x 2 mm
hub. Every unthreaded accessory must have a 22.2 mm (7/8") arbor hole. If it does not,
it may have been designed for a circular saw. Use only the accessories shown on pages
9 and 10 of this manual. Accessory ratings must always be above tool speed as shown
on tool nameplate.
MOUNTING GUARD
MOUNTING AND REMOVING GUARD
WARNING: To reduce the risk of serious personal injury, turn tool off and and remove
battery pack before making any adjustments or removing/installing attachments or
accessories.
CAUTION: Guards must be used with all grinding wheels, cutting wheels, sanding flap
discs, wire brushes, and wire wheels.
The tool may be used without a guard only when sanding with conventional sanding
discs. DEWALT model DC415 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.
G
F
K
FIG. 3
F
ASSEMBLY AND ADJUSTMENTS
D
ATTACHING SIDE HANDLE
The side handle (D) 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
WARNING: To reduce the risk of serious personal
injury, turn tool off and and remove battery pack
before making any adjustments or removing/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 6.35 mm (1/4"), the tool must