Instruction manual

ManualsBrandsDeWalt ManualsPower ToolDC495

• The charger is designed to operate on standard household electrical power (120

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 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

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 DEWALT Charger. Your battery can be charged in

DEWALT 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. 2)

DANGER: Electrocution hazard. 120 volts are present at charging terminals. Do not probe with

conductive objects.

1. Plug the charger into an appropriate outlet before inserting battery pack.

2. Insert the battery pack into the charger, as shown in Figure 2, making sure the pack is fully

seated in charger. The red (charging) light will blink continuously indicating that the charging

process has started.

3. The completion of charge will be indicated by the red light remaining ON continuously. The

pack is fully charged and may be used at this time or left in the charger.

Indicator Light Operation

Charge Indicators

Some chargers are designed to detect certain problems that can arise with battery packs.

Problems are indicated by the red light flashing at a fast rate. If this occurs, re-insert battery pack

into the charger. If the problem persists, try a different battery pack to determine if the charger is

OK. If the new pack charges correctly, then the original pack is defective and should be returned

to a service center or other collection site for recycling. If the new battery pack elicits the same

trouble indication as the original, have the charger tested at an authorized service center.

HOT/COLD PACK DELAY

Some chargers have a Hot/Cold Pack Delay feature: when the charger detects a battery that is

hot, it automatically starts a Hot Pack Delay, suspending charging until the battery has cooled.

After the battery has cooled, the charger automatically switches to the Pack Charging mode.

This feature ensures maximum battery life. The red light flashes long, then short while in the

Hot Pack Delay mode.

PROBLEM POWER LINE

Some chargers have a Problem Power Line indicator. When the charger is used with some

portable power sources such as generators or sources that convert DC to AC, the charger may

temporarily suspend operation, flashing the red light with two fast blinks followed by a

pause. This indicates the power source is out of limits.

LEAVING THE BATTERY PACK IN THE CHARGER

The charger and battery pack can be left connected with the red light glowing indefinitely. The

charger will keep the battery pack fresh and fully charged.

NOTE: A battery pack will slowly lose its charge when kept out of the charger. If the battery pack

has not been kept on maintenance charge, it may need to be recharged before use. A battery

pack may also slowly lose its charge if left in a charger that is not plugged into an appropriate

AC source.

WEAK BATTERY PACKS: Chargers can also detect a weak battery. 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. To facilitate the cooling of the battery pack after

use, avoid placing the charger or battery pack in a warm environment such as in a metal

shed, or an uninsulated trailer.

3. If the battery pack does not charge properly:

a. Check current at receptacle by plugging in a lamp or other appliance

b. Check to see if receptacle is connected to a light switch which turns power off when you

turn out the lights.

c. Move charger and battery pack to a location where the surrounding air temperature is

approximately 65°F - 75°F (18°- 24°C).

d. If charging problems persist, take the tool, battery pack and charger to your local service

center.

4. The battery pack should be recharged when it fails to produce sufficient power on jobs which

were easily done previously. DO NOT CONTINUE to use under these conditions. Follow the

charging procedure. You may also charge a partially used pack whenever you desire with

no adverse affect on the battery pack.

5. Under certain conditions, with the charger plugged into the power supply, the exposed

charging contacts inside the charger can be shorted by foreign material. Foreign materials

of a conductive nature such as, but not limited to, 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.

COMPONENTS (Fig. 1)

A. Trigger switch/variable speed switch

B. Swivel head shear

C. On/Lock-off control button

D. Hex wrench

E. Battery pack

F. Battery release buttons

Variable Speed Switch (Fig. 1)

To turn the tool ON, squeeze the trigger switch (A). To turn the tool OFF release the trigger.

Your tool is equipped with a variable speed switch which enables you to select the best speed

for a particular application. The farther you squeeze the trigger, the faster the tool will operate.

Use lower speeds for cutting tight curves or following precise guideline. Higher speeds are

better for gradual curves and straight line cuts. For maximum tool life, use lower speeds only

for short periods of time.

On/Lock-Off Control Button (Fig. 1, 4)

An On/Lock control button (C) serves as a lock-off button. To select the ON position, release

the trigger switch and depress the control button on the right side of the tool, as shown in

Figure 4. To select Locked/Off, depress the control button on the left side of the tool. When

changing the position of the control button, be sure the trigger is released.

Installing and Removing the Battery Pack (Fig. 3)

NOTE: Make sure your battery pack is fully charged.

WARNING: To prevent inadvertant operation, lock trigger switch before removing or installing

battery.

To install the battery pack into the tool handle, align the base of the tool with the notch

inside the tool’s handle and slide the battery pack firmly into the handle until you hear the lock

snap into place.

To remove the battery pack from the tool, press the release buttons (F) and firmly pull

the battery pack out of the tool handle. Insert it into the charger as described in the charger

manual.

OPERATION

WARNING: Cut Hazard. NEVER have any part of your body near the blades. Serious

personal injury may occur.

WARNING: Cut Hazard. To reduce the risk of serious personal injury, DO NOT use the

shear with any kind of accessory or attachment.

WARNING: Cut Hazard. Wear gloves when handling sheet metal. The edges are sharp and

can cause serious personal injury.

DC490, DW940, DW941

For accurate work, always clamp or anchor the material to be cut. Line up one edge of the tool’s

middle blade with the cutting line and advance blades into the material without forced effort or

unnecessary pressure. A little practice will enable you to determine what forward pressure gives

you the smoothest cutting. It is important to keep the lower surfaces of the side blades flat on

the material being cut (Fig. 12). When cutting curves, do not tilt the tool; keep the side blades

flat and level.The head of the shear will swivel to afford better access to the material. For best

cutting efficiency, keep blades sharp.

FIG. 2

DW940,

DW941

FIG. 3

DC490

DC495

FIG. 6

LOCKED

VERROUILLÉ

BLOQUEADO

SOUS

TENSION

ENCENDIDO

FIG. 5

FIG. 4

DW940, DW941 DC490, DC495

FIG. 1

DC495

For best results, always clamp or anchor the material to be cut. Position the shear so that the

material is between the two jaws. It is best to practice using the tool on scrap material in order

to determine the best pressure and angle at which to hold the tool for the application. When not

cutting from the edge of the material, drilling a starter hole should ease positioning of the shear.

Wear gloves when handling sheet metal. The edges are sharp and can cause injury.

Disassembly and Assembly

WARNING: Turn unit off and disconnect battery pack before installing and removing

accessories, before adjusting or when making repairs. To prevent inadvertant operation,

lock the trigger switch when the tool is not in use and when storing the tool.

DC490, DW940, DW941 (FIG. 1, 5, 6)

To remove shear head from motor, loosen three cap screws (G) using the hex wrench (D)

provided. Remove shear head (B) by pulling head firmly forward. Slight twisting action may be

required if head does not slide off easily.

To remove cutter blades from shear head, remove three cap screws (G) from shear housing

(H). Be careful not to lose rear spacer bushing when removing middle cap screw. Remove

center blade (I) from housing by tapping blade gently towards the rear. The side knives (J) and

side spacers (K) will now drop out of the housing.

To remove eccentric bearing assembly from shaft, use an appropriate wrench to loosen

eccentric nut (L) by turning counterclockwise.

To install eccentric bearing assembly onto shaft, make sure the large, thin washer (M) is first

inserted over shaft. Screw eccentric bearing assembly onto shaft and tighten with appropriate

wrench. Lubricate bearing (N) with a good grade of bearing grease.

To install cutter blades into shear housing, place the side knives (J) and side spacers (K) into

position in the shear housing (H). Insert center cap screw through side knife and side spacer with

rear spacer bushing between them. Start cap screw into thread just enough to hold blades in

place. DO NOT TIGHTEN. Insert spacer bushing into hole in center blade and lubricate. Install

center blade into shear housing by tapping blade gently forward using a drift pin to line up hole

in center blade with forward holes in housing. Insert and tighten forward cap screw making sure

spacer bushing in center blade stays in position. Apply good grade of bearing grease to clevis

or yoke in center blade where it rides on the eccentric bearing assembly. Insert rear cap screw

into shear housing but do not completely tighten.

To install shear head assembly onto drive motor, make sure all cap screws are loosened

about 3 or 4 complete turns. Place shear head onto unit and alternately tighten cap screws

snugly to lock head assembly in place. It may be necessary to gently tap the shear head into

place if it does not readily slip onto the nose of the power unit.

DC495 (FIG. 1, 7–10)

To remove shear head from motor, loosen the two back cap screws (G) using the hex wrench

(D) provided. Remove shear head (B) from the body by pulling head firmly forward (Fig. 7). Slight

twisting action may be required if head does not slide off easily.

To remove cutter blades from the shear head, completely loosen the two back cap screws

and remove shear head from motor unit. Loosen the tensioning screw (O) 1/2 turn. Completely

loosen all three cap screws and remove head assembly. Turn assembly over and remove top

half of head and then remove the blades.

To replace blades, place lower jaw (P) onto two pins (R). Apply a thin layer of grease from the

packet (included) around the pin and on the top side of the blade. Place upper jaw (Q) onto pin.

Apply the rest of the grease provided onto the eccentric (L) on the output shaft of the motor unit

and into the area behind the upper moving blade in the shear head.

Install replacement washer (S), cone side up, over the pin on top of the moving blade. Place top

half of head back (T) onto bottom half (U), making sure to align the pin to the hole. Reinstall all

three cap screws (G) and nuts (V), but DO NOT tighten completely.

Slide shear head back onto motor unit, making sure that the eccentric engages the moving

blade. Once the head is on the motor unit and aligned, tighten all three screws and follow

adjustment procedure below.

To ensure proper blade tension, tighten tensioning screw (O) by turning clockwise to seat

the blades. Next, loosen tensioning screw by turning counterclockwise slightly to allow blade

movement.

NOTE: The tensioning screw should be adjusted to correspond to material thickness.

Adjustment (Fig. 11, 12)

SWIVEL HEAD

WARNING: Turn unit off and disconnect battery pack before installing and removing

accessories, before adjusting or when making repairs. To prevent inadvertant operation,

lock the trigger switch when the tool is not in use and when storing the tool.