Equalizer Express 360 SR1418360 User manual

© 2008 Equalizer Industries, Inc.
Revision 10/24/08
COVERS
ALL
EXPRESS
MODELS
®

EQUALIZER® EXPRESS® SERIAL NUMBER
KEEP THIS FOR YOUR RECORDS
All Equalizer®Express®tools are warranted for one year to be free of
factory defects. Warranty does not apply to abuse, misuse, or normal
wear and tear.We will repair or replace, at our option, any defective part.
Tools are repaired and sent back the same day they are received.
If you feel your tool is covered under warranty,
the entire tool, including all blades, must be returned to:
EQUALIZER INDUSTRIES, INC.
2611 OAKMONT DRIVE
ROUND ROCK, TEXAS 78665
If you want a tool repaired, but are not seeking to
have it repaired under warranty we require that you return the
complete tool including the blades.
Equalizer Industries, Inc., reserves the right to refuse to repair, at
our expense, any tool which has not been properly maintained as
specified in the Users Guide. Particularly important are the following:
1. KEEP THE BLADES SHARP!!!!! This is the one thing most technicians WILL
NOT do and it WILL damage the tool.
2. Use a cutting lubricant. If you are using the short cut method (not
recommended by anyone anymore) use only clean water as a cutting
lubricant.
3. DO NOT HIT THE PINCHWELD.THIS WILL DESTROY THE DRIVE
MECHANISM OF YOUR TOOL.
If you have any questions about your tool, call us toll free at
800.334.1334 or fax us at 512.388.4188
EXPRESS
®Table Of Contents
Equalizer®Express®Blades & Sheath..........................................4-7
SR1418360 • SR1428360 Equalizer®Express® 360...................... 8
120-Volt Powered
LDT204 • LDK205 Equalizer®Express® StingRayTM...................13
120-Volt Powered
DTE1000 • DTA1007 Equalizer®Express® XRP............................18
18-Volt Battery Powered
Equalizer®Express®18-Volt Battery & Charger .........................22
Equalizer®Express®XRP .............................................................. 24-26
Anti-Vibration pad installation
EBD838 • Equalizer®Express® Big Dawg™....................................28
36-Volt Battery Powered
Equalizer®Express®36-Volt Battery & Charger .........................33
Equalizer®Express® Big Dawg™................................................ 36-39
Battery Clip installation
SP1416 • Equalizer®Express®...........................................................40
Air Powered - Pneumatic
Parts Diagrams All Models ....................................................... 45-57
© 2008 Equalizer Industries, Inc.
All content including photographic or illustrated images and text descriptions that are displayed
within this guide are the sole property of Equalizer Industries, Inc.
Any reproduction is prohibited without the express written consent of Equalizer Industries, Inc.

CAUTION!
Keep your blades sharp! This is crucial for effective cutting action and tool
longevity. A dull blade will destroy the drive mechanism in your Equalizer®
Express®. Sharpen the blade between each removal with an Express®Blade
Sharpener (Equalizer®Part # SFE329). Be careful to maintain the original
sharpening angle. Every ten removals, re-sharpen the blade on a bench grinder
(Equalizer®Part # TGO431 shown). Keeping a sharp blade will help the tool cut
faster, will reduce vibration, increase the life of the tool and reduce fatigue for the
user. Most tool damage is caused because the blade has not been kept sharp.
Equalizer®does not warranty tools when the blade has not been kept sharp.
Do your part to prolong the life of this tool and keep the blade sharp!
Every ten removals
4
Between each removal
About Equalizer®Express®Blades...
The same blades are used on all models of the Equalizer®Express®.The blade
is very thin and flexible, allowing for curved cutting angles. It is sharpened on
three sides and on a single plane.The blade must be properly oriented (flat
side rides against the glass). When properly oriented the blade’s sharpening
design causes the blade to cut along the bottom surface of the glass, thereby
protecting headliners and mouldings from damage.
Discard the blade when it has been sharpened down to the line that says - DO
NOT SHARPEN BELOW THIS LINE.Using a blade that has been sharpened below
this line will eliminate the flexibility of the blade and damage the tool.The blade is
extremely sharp and can cut even when the tool is not in operation!
Blades • Sheath
5
BFE1400 • Standard Wide Blade
3" Wide, 10" Long
BFE1401 • Standard Narrow Blade
1-1/2" Wide, 10" Long
Equalizer®Express®Blades
The BFE1400 is the most used size and is
perfect for slicing through wide bands of
urethane.The BFE1401 and LBE1403 blades
are perfect for removing glass that is not
broken. Their narrow (1-1/2" wide) blade is
more flexible, which puts less stress on the
glass.
LBE1402 • Long Wide Blade
3" Wide, 12" Long
RLE1404 • Long Reach Blade
3" Wide, 14" Long
Side view of Spacer Blade.
BFE1420 • Finger Blade
10" Long
BFS1421 • Spacer Blade
1-1/2" Wide, 10" Long
BFS1422 • Spacer Blade
3" Wide, 10" Long
LBE1403 • Long Narrow Blade
1-1/2" Wide, 12" Long
On some vehicles, the urethane is far below
the glass, but there is a limited amount of
vertical space inside the vehicle. For
this, you will need one of the 12” blades
(LBE1402 or LBE1403). They perform the
same function as the BFE1400 and BFE1401,
but are 2” longer. On other vehicles,
specifically the Windstar, Transport,
Camaro, and Caravan, the urethane is very
deep below the dash.This is also true on the
Century Class Freightliners and some motor
homes. For those vehicles you
should keep one of the 14”
blades (RLE1404) in your tool box.
For side-to-side cutting and around very
radical curves in the glass, and in vehicles that
have corners with a sharper-than-90° angle.
The round tip of the BFE1420 will reach up
into the corner and cut the urethane.
Some vehicles such as Ford Windstar, Econoline,
Explorer, Ranger, newer Chevy/GMC and Mazda
pickups have a moulding with a piece of metal
inside and many encapsulated glasses have a
very dense encapsulation material that make
it difficult to cut.The BFS1421 and BFS1422
are designed to hold the blade below the
moulding and prevent the blade from cutting
into the encapsulation. A permanently attached,
self-lubricating nylon spacer lets the blade
move easily back and forth while holding the
blade under the lower lip of the moulding or
encapsulation.

6
The sheath is the unique, patented idea that allows the Equalizer® Express®to use
a flexible blade and still have the strength to cut the toughest urethane. Express®
Blades come in longer and shorter sizes, but there is only one size sheath and it
fits all Equalizer® Express® tools.
THE SHEATH...
The sheath provides
protection for the
dash and interior
vehicle parts. Since the
cutting is done by the
end of the blade, the
sheath remains free of contaminants. No cleaning is necessary. To keep the sheath
cool we recommend that you periodically apply a light film of high heat grease to
the blade part that is inside the sheath.
Equalizer®Express® Sheath
ES1406
You can cause damage to blades (as shown above) by forcing the tool to cut
faster rather than letting it cut at it’s own pace. Damage can also be caused by
not using a cutting lubricant such as Equalizer® Cutting Lubricant (Part # ECL784)
or water, and by hitting metal clips, rivets, and the pinchweld. Damaged blades
can cause excess vibration making your tool harder to control. When you have a
damaged blade (as shown above), resharpen to maintain a sharp straight edge.
BEFORE YOU BEGIN...
Spray the entire cutting area
and blade with plenty of water.
Lubrication is vital for maximum
cutting ease. Failure to use water
increases cutting friction and will
cause tool damage. Periodically spray
the blade with water.
RUST PREVENTION
To prevent rust caused by water droplets, place a few drops of oil into the
sheath every day and allow it to run down into the blade holder.
7
Worn out sheaths must be replaced. If not replaced, the blade
will not flex properly which will result in damage to your tool.

8
120-Volt Electric
Users Guide
SR1418360 • SR1428360
9
Changing the Sheath
Voltage ........................................................120 volts
Amps .................................................................13
Watts ..............................................................1560
Strokes Per Minute ...............................................0-3,000
The Equalizer®Express® 360 120-Volt
tool is a multipurpose auto glass
removal tool, designed primarily for
inside use on bonded auto glass
parts. It may be used outside on
A-pillars for windshields of some
vehicle models, and on all broken
tempered parts. The blade shaft is enclosed in a sheath which protects inte-
rior car parts. Most of the cutting is accomplished on the end of the blade,
therefore the operator utilizes upper torso muscles, making the tool easy
to operate and ergonomically friendly.The Equalizer®Express®360 120-Volt
tool’s specific blade stroke length and dynamic two-way cutting power slices
through the toughest urethane adhesive with ease.
Changing The Blade
Warning: Before changing a blade
the tool should be disconnected
from the power source.
To put a blade in the tool, the blade
latch must be rotated 90°.You can
rotate the blade latch with your
finger, fingernail, or a straight screwdriver. Put a blade into the tool until it
stops. Push in lightly on the blade and rotate the blade latch until the blade
drops into place. Release the blade latch and it will rotate back in the oppo-
site direction locking the blade in place.
Warning: The proper way to hold the tool is to hold the front part by the
rubber boot. Do not hold the tool by the aluminum foot assembly as this
may result in your fingers being pinched by the moving blade holder.
The sheath is not adjustable! The four top screws are secured in
place with Loctite®to prevent loosening from vibration, and are
not meant to be removed unless you are replacing the sheath.
Please be aware that some force may be required to remove these
screws. If difficulty is encountered, to prevent stripping of the screws we
recommend warming the sheath retainer with a heat gun or other warming
device and follow these steps:
1. Loosen the screws with a 3/16” hex wrench.
2. Make note of the built-in sheath stop located at the back of the sheath
holder. This is very important! (Continued...)

10
3. Remove the old sheath.
4. Insert the new sheath until it touches the stop, but do not insert the
sheath past the stop!
One of the great features of the Equalizer®Express®360 is the ability to
rotate the handle so you can get into confined or awkward spaces.To
rotate the handle, pull the release latch back and twist the front barrel.The
handle will rotate and lock in 45° increments. Because of it's unique design,
it can be swiveled 360˚ around (without turning it backwards) to get back
to the standard configuration.
Oscillating Reciprocating
When set to reciprocating the blade will move in a straight back and forth
direction. When set to oscillating the blade moves back and forth and
as it reaches the end of it's stroke it moves up slightly as it reciprocates.
Besides the in and out thrusting this gives some sideways cutting ability
to the blade.
11
Start cutting from the inside top
center of the glass. Cut toward
the A-pillars and down the side
to the bottom corner of the glass
( On some models you can cut
the sides from the outside of the
vehicle). Keep the blade properly
orientated and flat against the
glass. Reverse and cut from the
top center of the glass toward the other A-pillar. Relax and let the tool do
the work.
After both sides are cut, insert two PUMPER™s (Equalizer®LB779) to
increase the cutting angle, thereby improving cutting ease. For an even
greater cutting angle, slightly deflate the PUMPER™s then fold in half
and re-insert.
The plunge cut
The angle cut
Figure 1 Pumper™ can be folded in half
to increase distance of outward
pressure.
After the top and sides are loose, cut the bottom of the glass loose by starting at the
center and cutting toward the sides (fig. 1). A Pumper™(Equalizer®LB779) can make
this process easier. On some vehicles the angle of the corner will not allow you to cut
all the way into the corner. On these vehicles you can plunge cut down from the top
to completely release the corners (fig. 2).
Figure 2

12
General Safety Information
1. Always wear safety glasses and safety gloves when using the
Equalizer®Express®360 120-Volt tool.
2. Do not activate Equalizer®tools until they are in the cutting position.
Disengage the tool and let it stop before taking it out of the urethane.
3. The blade is sharp and can cut even when the tool is not running.
4. Do not force the tool. Put light forward pressure on the tool. Let it
do the work.
5. Consider your work environment. Do not use or expose power tools
to rain or damp weather.
6. Unplug from electric source before servicing and when changing
accessories.
7. Stay Alert!! Watch what you are doing. Use common sense.
2611 Oakmont Drive
Round Rock,Texas 78665
Telephone: [phone]
Toll Free USA & Canada: 800.334.1334
FAX: [phone]
Email: [e-mail]
Web: www.equalizer.com
FOR MORE INFORMATION ABOUT THIS TOOL
PLEASE CONTACT...
13
120-Volt Electric
User Guide
LDT204 • Standard Kit
LDK205 • Deluxe Kit

14
CAUTION
Discard the blade when it has been sharpened down to the line that says
- DO NOT SHARPEN BELOW THIS LINE. Using a blade that has been
sharpened below this line will eliminate the flexibility of the blade and
damage the tool. The blade is extremely sharp and can cut even when
the tool is not in operation!
Tool Description
The Equalizer®Express®StingRay™has an ergonomic design for ease of use. The
plunger floats on a series of ball bearings and the blade is driven by a floating pin
bearing system. This allows more of the power of the StingRay™to be applied directly
to the blade. The low profile of the handle gives you clearance no matter which
direction you are cutting. A rotating speed control gives a wide range of speeds from
500 to 3200 strokes per minute. It has a quick blade release that allows you to change
the blade without any tools.
The Blade
The blade is very thin and flexible about 1/2" behind the line that says Do Not
Sharpen Below This Line. If you sharpen below that line the blade will not flex
properly and that will damage the sheath and can damage the drive unit of the tool.
It is sharpened on three sides and on a single plane. The blade must be properly
orientated (flat side rides against the glass). When properly orientated the blade’s
sharpening design causes the blade to cut along the bottom surface of the glass,
thereby protecting headliners and mouldings from damage.
The blade is thin in this area so it will
flex to fit the contour of the glass.
Voltage...................................................................... 120 volts
Amps...................................................................................... 7
Watts................................................................................ 840
Strokes Per Minute ...............................................500 - 3200
15
Removing & Replacing The Blade
Warning: Before changing a blade the tool
should be disconnected from the power source.
To put a blade in the tool, the blade latch must be rotated approximately 45°. You
can rotate the blade latch with your finger, fingernail, or a straight screwdriver. Put
a blade into the tool until it stops. Push in lightly on the blade and rotate the blade
latch until the blade drops into place. Release the blade latch and it will rotate back in
the opposite direction locking the blade in place.
The Sheath
The sheath provides protection for the dash and interior vehicle parts. Since the
cutting is done by the end of the blade, the sheath remains free of contaminants and
no cleaning is necessary. To keep the sheath cool we recommend that you periodically
apply a light film of high heat grease (part #4237) to the blade part that is inside the
sheath.
Warning: The proper way to hold the
tool is to hold the the rubber boot behind
the flared rubber part. This flared part
prevents your hand from slippng forward.
Failure to follow these directions may
result in your fingers being pinched by
the moving blade holder.

16
Proper Use Of Your Equalizer®
Express®StingRay™
Begin the cutting process by spraying
the entire cutting area and blade with
cutting lubricant. Lubrication is vital
for maximum cutting ease. Failure to
use cutting lubricant increases cutting
friction and will cause tool damage.
Periodically during cutting, spray the
blade with cutting lubricant. In the
absence of cutting lubricant you can use
water.
Rust Prevention:
To prevent rust caused by water droplets, every day place a few drops
of oil into the sheath and allow it to run down into the blade holder.
Start cutting from the inside top center of the glass. Cut toward the A-pillars and
down the side to the bottom corner of the glass ( On some models you can cut
the sides from the outside of the vehicle). Keep the blade properly orientated
and flat against the glass. Reverse and cut from the top center of the glass toward
the other A-pillar. Relax and let the tool do the work.
After both sides are cut, insert two PUMPER™s (Equalizer®LB779) to
increase the cutting angle, thereby improving cutting ease. For an even greater
cutting angle, slightly deflate the PUMPER™s then fold in half, re-insert and
reinflate.
17
After the top and sides are loose, cut the bottom of the glass loose by starting at the center and
cutting toward the sides (fig. 1). A Pumper™(Equalizer®LB779) can make this process easier. On
some vehicles the angle of the corner will not allow you to cut all the way into the corner. On these
vehicles you can plunge cut down from the top to completely release the corners (fig. 2).
The plunge cut
The angle cut
Figure 1
Pumper™ can be folded in half
to increase distance of outward
pressure.
Figure 2
Between each removal
Every ten removals
SFE329
Blade Sharpening
A sharp blade is crucial for effective cutting action and tool longevity. A dull blade will
destroy the drive mechanism in your Equalizer®Express® Stingray™ 120-Volt.
Keep the blade sharp! Sharpen the blade between each removal with blade sharpener
SFE329. Be careful to maintain the original sharpening angle. Every ten removals,
re-sharpen the blade on a bench grinder. Keeping a sharp blade will help the tool cut
faster and prolong the life of the tool. A sharp blade will reduce vibration, minimizing
the fatigue of the operator. Most tool damage is caused because the blade has not
been kept sharp. We will not warranty tools when the blade has not been kept
sharp!

18
There are several off-the-shelf batteries that will fit the
Equalizer®Express® XRP.This tool’s battery is a DeWalt
DW9096XR+ and it feeds electricity to the motor and
runs it backwards so it will stop quickly. Other batteries
will feed too much electricity into the switch and can
cause the drive mechanism to unwind. Some do not
send enough and can cause the switch to be destroyed.The threads are
clockwise and when too much counter-clockwise force is applied the threads
can unscrew, freeze the tool and cause permanent damage. Use only DeWalt
DW9096XR+ batteries.
18-Volt Battery Powered
Users Guide
DTE1000 • DTA1007
Important Information
19
The Equalizer®Express®XRP
18-Volt cordless tool is a
multipurpose auto glass
removal tool, designed
primarily for inside use on
bonded auto glass parts. It may be used outside on A-pillars for windshields
of some vehicle models, and on all broken tempered parts. The blade shaft is
enclosed in a sheath which protects interior car parts. Most of the cutting is
accomplished on the end of the blade, therefore the operator utilizes upper
torso muscles, making the tool easy to operate and ergonomically friendly.
The Equalizer®Express®XRP 18-Volt cordless tool’s specific blade stroke
length and dynamic two-way cutting power slices through the toughest
urethane adhesive with ease.
The blade is installed by lifting the quick connect lever, fully inserting the
shaft of the blade into the sheath, and pressing the quick connect lever back
down.
Changing the Blade
The sheath is not adjustable! The four top screws are secured in place
with Loctite®to prevent loosening from vibration, and are not meant to be
removed unless you are replacing the sheath. Please be aware that some
force may be required to remove these screws. If difficulty is encountered, to
prevent stripping of the screws we recommend warming the sheath retainer
with a heat gun or other warming device. 1. Loosen the screws with a 3/16”
hex wrench (A). 2. Make note of the built-in sheath stops located at the back
of the sheath holder (B).This is very important! 3. Remove the old sheath
(C). 4. Insert the new sheath until it touches the stops but do not insert the
sheath past the sheath stops (D, E). (Continued...)
Changing the Sheath
Voltage .........................................................18 volts
Battery ..................................................... DW9096XR+
Strokes Per Minute ...............................................0-2,800

20
Top view of open
holder
G
Assure gap is even
on both sides.
C
Use a drop of red
Loctite®in each hole.
Loosen screws with
3/16” hex wrench.
Insert new sheath
until it hits stops.
UNDERSIDE view of hold-
er and sheath stops
D
B
Sheath stops
Remove old sheath.
E
F
ES1406
A
5. Place a drop of red Loctite®in each screw hole to secure the screws and
keep them from loosening from vibration (F). 6. Reassemble the sheath
holder; be sure to install all four screws so the gap is the same width on both
sides of the sheath retainer (G). CAUTION! Forcing sheath past the stops or
overtightening the top screws will damage your tool. Tools presented for
repair with stops destroyed or removed will not be repaired under warranty.
21
Start cutting from the inside
top center of the glass and cut
toward the A-pillars. Keep the
blade properly orientated and
flat against the glass. Reverse
and cut from the top center
of the glass toward the other
A-pillar. Relax and let the tool
do the work.
Next, from the inside (or
outside on some vehicle
models), cut the sides
from top to bottom.
After both sides are cut,
insert two PUMPER™s
(Equalizer®LB779) to
increase the cutting angle,
thereby improving cutting ease. For an even greater cutting angle, slightly
deflate the PUMPER™s then fold in half & re-insert.
The plunge cut The angle cut
After the sides are loose,cut the bottom of the glass loose, utilizing one or a
combination of two cutting methods.
Figure 1. The plunge cut. Cut straight down, move over three inches and repeat
this process until finished cutting.
Figure 2. The angle cut. Turn the tool at roughly a 45-degree angle and cut
along the bottom until finished.
Figure 1 Pumper™ LB779
Use one on each side.
Figure 2 Pumper™ can be folded in
half to increase distance of
outward pressure.

22
Important Instructions For Your Equalizer®
Express® 18-Volt Battery & Charger
Battery Use and Care
Take care when loading the battery into the tool. DO NOT slam the battery
into the Equalizer®Express®tool. Gently press the battery into the tool until
you hear it “click” into place. Depending on cutting conditions and operator
skill, a fully charged battery should remove about three windshields.
The batteries are the most sensitive part of the Equalizer® Express®tool.
Please, carefully read these detailed instructions about proper battery
charging and care.
Fig. 2
Fig. 1
Charging Procedure
1. Plug the charger into an appropriate power outlet.
2. Insert the battery pack into the charger, as shown in Fig.1 and Fig.2, making sure
the pack is fully seated in the charger.The red (charging) light will blink continously,
indicating that the charging process has started.
3. The battery pack will be fully charged in about 1 hour.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.
DW9116 - 120-Volt AC Charger
The DW9116 battery charger is designed to use standard
household 120 volt AC 60 Hz power.The use of other power
sources like,but not limited to,those that convert DC to AC is
not recommended and will destroy the internal circuitry of the
DW9116 charger. If you do not use standard household 120-Volt
AC,60 Hz power then only use an inverter.
DW9109 - 12-Volt Automotive Charger
The DW9109 battery charger is designed to plug into the
cigarette lighter or power point of a vehicle and use 12-Volt
DC power.Do not use AC power.The use of any other power
source,such as a device to convert AC to DC power,is not
recommended and may cause serious damage to the circuitry
of the DW9109 charger.
Anti-Vibration Devices
Your Equalizer®Express®18-Volt is equipped with two anti-vibration
devices; anti-vibration pads and an anti-vibration strap. These devices
reduce vibration to the battery by securing it to the tool.
Failure to use either anti-vibration
device will void your warranty!
23
Tune-Up Procedure
At the end of every two weeks, completely discharge your battery. Batteries
can develop a memory which will shorten the working time they can be
used.The tune-up procedure will eliminate the memory build-up.
1. Hold or tie down the trigger & let the tool run until it stops.
2. Wait 20 minutes then repeat (tool will only run a short time the second
time).
3. Allow the battery to cool completely, then recharge.
Important Safety Instructions About the Battery and Chargers
When using the Equalizer®Express®there are basic safety precautions
that should be followed to reduce risk of fire, electric shock and personal
injury, including the following:
•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.
•A small leakage of liquid from the battery pack cells may occur under
extreme usage or temperature conditions. This does not indicate a failure.
However, if the outer seal is broken and this leakage gets on your skin...
A. Wash quickly with soap and water.
B. Neutralize with mild acid such as lemon juice or vinegar.
C. If battery liquid gets into your eyes, flush them with clean water for a
minimum of 10 minutes and seek immediate medical attention.
(Medical Note:The liquid is a 25%-30% solution of potassium hydroxide.)
•Never attempt to open the battery pack for any reason. If the plastic
housing of the battery pack breaks or cracks, immediately discontinue use
and do not recharge.
•Do not carry extra, charged battery packs in aprons, pockets, or tool
boxes along with other metal objects. Battery pack could be short circuited,
causing damage to the battery pack and possibly causing severe burn or
fire.

24
How to Install 18-Volt
Battery with
Anti-Vibration Pads
25
Step 1:
Insert Battery as
shown
Step 2:
Lock Right Side in
as shown
How to Install 18-Volt Battery with Anti-Vibration Pads

26
Step 3:
Lock Left Side
in as shown
Step 4:
Pull Velcro Strap
tight around
battery.
How to Install 18-Volt Battery with Anti-Vibration Pads
27
General Safety Information
1. Always wear safety glasses and safety gloves when using the
Equalizer®Express®XRP 18-Volt Tool.
2. Do not activate Equalizer®tools until they are in the cutting position.
Disengage the tool and let it stop before taking it out of the urethane.
3. The blade is sharp and can cut even when the tool is not running.
4. Do not force the tool. Put light forward pressure on the tool. Let it
do the work.
5. Consider your work environment. Do not use or expose power tools
to rain or damp weather.
6. Unplug from electric source before servicing and when changing
accessories.
7. Stay Alert!! Watch what you are doing. Use common sense.
2611 Oakmont Drive
Round Rock,Texas 78665
Telephone: [phone]
Toll Free USA & Canada: 800.334.1334
FAX: [phone]
Email: [e-mail]
Web: www.equalizer.com
FOR MORE INFORMATION ABOUT THIS TOOL
PLEASE CONTACT...

28
36-Volt Battery Powered
Users Guide • EBD838
The Equalizer®Express®36-Volt cordless tool is a multipurpose auto glass
removal tool. Designed primarily for inside use on bonded auto glass parts,
but it may be used outside on A-pillars for windshields of some vehicle models,
and on all broken tempered parts. The blade shaft is enclosed in a sheath
which protects interior car parts. Most of the cutting is accomplished on the
end of the blade, therefore the operator utilizes upper torso muscles, making
the tool easy to operate and ergonomically friendly.The Equalizer®Express®
36-Volt cordless tool’s specific blade stroke length and dynamic two-way
cutting power slices through the toughest urethane adhesive with ease.
Voltage .........................................................36 volts
Battery ..........................................................DC9360
Strokes Per Minute ...............................................0-3,200
The Blade
The sheath is not adjustable! The four top screws are secured in place
with Loctite®to prevent loosening from vibration, and are not meant to be
removed unless you are replacing the sheath. Please be aware that some
force may be required to remove these screws. If difficulty is encountered,
to prevent stripping of the screws we recommend warming the sheath
retainer with a heat gun or other warming device. 1. Loosen the screws
with a 3/16” hex wrench (A). 2. Make note of the built-in sheath stops locat-
ed at the back of the sheath holder (B).This is very important! 3. Remove
the old sheath (C). 4. Insert the new sheath until it touches the stops but
do not insert the sheath past the sheath stops (D,E). (Continued...)
Changing the Sheath
The blade is very thin and flexible about 1/2" behind the line that says Do Not
Sharpen Below This Line. If you sharpen below that line the blade will not flex
properly which will damage the sheath and possibly damage the drive unit
of the tool.The blade is sharpened on three sides and on a single plane. It
must be properly orientated (flat side rides against the glass).When properly
orientated the blade’s sharpening design causes the blade to cut along the
bottom surface of the glass, thereby protecting headliners and mouldings
from damage.
29

Top view of open
holder
G
Assure gap is even
on both sides.
C
Use a drop of red
Loctite®in each hole.
Loosen screws with
3/16” hex wrench.
Insert new sheath
until it hits stops.
UNDERSIDE view of hold-
er and sheath stops
D
B
Sheath stops
Remove old sheath.
E
F
ES1406
A
5. Place a drop of red Loctite®in each screw hole to secure the screws and
keep them from loosening from vibration (F). 6. Reassemble the sheath
holder; be sure to install all four screws so the gap is the same width on both
sides of the sheath retainer (G). CAUTION! Forcing sheath past the stops or
overtightening the top screws will damage your tool. Tools presented for
repair with stops destroyed or removed will not be repaired under warranty.
30
Start cutting from the inside
top center of the glass and cut
toward the A-pillars. Keep the
blade properly orientated and
flat against the glass. Reverse
and cut from the top center
of the glass toward the other
A-pillar. Relax and let the tool
do the work.
Next, from the inside (or
outside on some vehicle
models), cut the sides
from top to bottom.
After both sides are cut,
insert two PUMPER™s
(Equalizer®LB779) to
increase the cutting angle,
thereby improving cutting ease. For an even greater cutting angle, slightly
deflate the PUMPER™s then fold in half & re-insert.
The plunge cut The angle cut
After the sides are loose,cut the bottom of the glass loose, utilizing one or a
combination of two cutting methods.
Figure 1. The plunge cut. Cut straight down, move over three inches and repeat
this process until finished cutting.
Figure 2. The angle cut. Turn the tool at roughly a 45-degree angle and cut
along the bottom until finished.
Figure 1 Pumper™ LB779
Use one on each side.
Figure 2 Pumper™ can be folded in
half to increase distance of
outward pressure.
31

32
General Safety Information
1. Always wear safety glasses and safety gloves when using the
Equalizer®Express®XRP 18-Volt Tool.
2. Do not activate Equalizer®tools until they are in the cutting position.
Disengage the tool and let it stop before taking it out of the urethane.
3. The blade is sharp and can cut even when the tool is not running.
4. Do not force the tool. Put light forward pressure on the tool. Let it
do the work.
5. Consider your work environment. Do not use or expose power tools
to rain or damp weather.
6. Unplug from electric source before servicing and when changing
accessories.
7. Stay Alert!! Watch what you are doing. Use common sense.
2611 Oakmont Drive
Round Rock,Texas 78665
Telephone: [phone]
Toll Free USA & Canada: 800.334.1334
FAX: [phone]
Email: [e-mail]
Web: www.equalizer.com
FOR MORE INFORMATION ABOUT THIS TOOL
PLEASE CONTACT...
33
Important Instructions For Your Equalizer®
Express® 36-Volt Battery & Charger
The DC9000 charger is designed to charge the EBD838 battery in
approximately 1 hour.This charger requires no adjustment and is
designed to be as easy as possible to operate. Simply plug in your charger,
place your battery pack into the receptacle, and it will automatically
charge the pack.
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.
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.
Charger Diagnostic
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.
DC9360 DC9000

34
PROBLEM POWERLINE
When the charger is used with some portable power sources such as
generators or inverters, 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 source 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 properly discarded or returned to Equalizer if you feel it is still
under warranty.
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 Equalizer for service or
replacement.
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 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 in for at least 8 hours.
Important Charging Notes
1.Longest life and best performance can be obtained if the battery pack
is between 65°F and 75°F (18° - 24°C). Do Not charge the battery pack in
anair temperature below +40°F (+4.5°C) or above +105°F (+40.5°C).This is
important and will prevent erious damage to the battery pack.
2.The charger and battery pack may become warm to the touch while
charging.This is a normal condition, and does not indicate a problem.To
facilitate the cooling of the charger or battery pack after use, avoid
placing them in a warm environment.
3.If the battery pack does not charge properly:
a. Check current at receptacle by plugging in another appliance that
you know works.
b. Check to see if receptacle is connected to a light switch which turns
power off when you turn the lights out. (continued...)
35
c. Move the charger and battery pack to
a location where surrounding air temperature
is approximately 65°F and 75°F (18° - 24°C).
d. If charging problems persist, send the tool,
battery pack and charger back to Equalizer for
evaluation.
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 affects 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, pack it
properly and return it to Equalizer.
Important: 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.
If battery contents come into contact with the skin, immediately wash the area
with a mild soap and water. If the battery liquid gets into the eyes, 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.

36
How to Install
Battery Clip for
Equalizer®
Big Dawg™
37
Step 1: Remove screws to release handle.
Step 2: Place clip on handle.
How to Install Battery Clip for Equalizer® Big Dawg™

38
Step 3: Slide the clip all the way down on the handle.
Step 4: Close the handle.
How to Install Battery Clip for Equalizer® Big Dawg™
39
Step 5:
Finished Big DawgTM with battery clip.
How to Install Battery Clip for Equalizer® Big Dawg™