dewalt® industrial tools

DEWALT® INDUSTRIAL TOOLS
USA SERVICE OPERATIONS
TECHNICAL SERVICES DEPARTMENT
SERVICE BULLETIN
SUBJECT: CHARGER REWORK
UNIT: DW9116 1-HOUR NiCd BATTERY CHARGER
DATE CODE RANGE: 9927EM – 0031EM
OTHER REFERENCES: SB 5955
SB NO.
06019
PAGE 1 OF 4
ISSUED: 31-Aug-2000
REISSUED: 7-Sep-2000
Written By: Don Stancavitch
DW9116 Battery Chargers are being recalled for repair because, under certain circumstances, an
internal part can come loose and protrude through the charger case, which may create the
possibility of an electric shock hazard. If the charger is marked with a yellow or green dot sticker
near the date code, it has already been reworked.
Rework Instructions:
1. Charger must be reworked at a grounded workstation by a grounded technician – See Service
Bulletin 5955 for further information.
2. Do not plug charger into power supply during this rework.
3. Remove 4 housing screws from charger (T-15 Torx Bit - Tamper Resistant - Grainger Stock No.
5F524).
4. Remove top cover from charger leaving PC board in base.
5. Ensure that clip is fully seated in brass heat sink slots. If clip is missing, charger must be
replaced rather than reworked.
CLIP
PO Box 564, 626 Hanover Pike, Hampstead, MD 21074
6. Insert Wire Tie (149138-05) into slot at end of clip that sticks up above back of heat sink –
some clips are assembled opposite to that shown below (note 7) and wire tie will have to be
inserted into other slot. Order 1 of 149138-05 to receive 100 wire ties. Supplier of wire tie is
Gardner Bender (Wire Tie No. 46-308). DO NOT USE ANY OTHER WIRE TIE! Position wire
tie head as shown.
7. Loop and zip the Wire Tie as shown. Cut tail to ¼” from the head.
End of clip that
sticks up above
heat sink
8. Make sure cordset is routed properly, replace top cover, and reinstall screws (4.4 – 6.2 in-lb).
Do not over-tighten screws – over-tightening will strip the thread in the plastic housing. If
threads are accidentally stripped, charger must be scrapped.
9. Charger Test – Test must be performed using DW9096 Battery. Test will not work if battery is
too hot. If battery becomes hot during test, it likely needs to be discharged using 18V tool and
then allowed to cool.
•
Plug charger into test panel
PO Box 564, 626 Hanover Pike, Hampstead, MD 21074
•
Charger LED should blink once
•
Insert DW9096 Battery into charger – Current will go up, down, then up again. Should be
between 0.75 and 1.0 Amp. Current may pulsate once per second but this is normal.
Charger LED will blink slowly.
•
Press tune-up button – it should click.
•
If charger operates as described, it passes – if not, it must be replaced.
10. After rework is complete, place ¾” Dia. Yellow
Label 429958-00 (Avery No. AVE-T5462) on
underside of charger near date code to indicate
charger has been reworked. Order 1 of 429958-00
to receive 1000 labels.
Remainder of bulletin applies only to USA company-owned service centers.
Point-Of-Sale Processing:
™ Select
1 Orders
™ Select
2 Repair
™ Enter Account (Customer) # 506125 which will bring up:
DW9116 - REWORK
701 E Joppa Road
TWM005 / ATTN J. Saltysiak
Towson, MD 21286
™ Enter Customer
Name and Address in Ship To field
™ Enter Customer
Phone Number in PO Field (Field 12)
™ Select
1 Repair Type
™ Complete N
™ Enter Catalog Number DW9116RC
™ Enter Type 1
™ Enter Charger Date Code
™ Enter $2.00 ($3.00 if done on overtime) in Field 8 - Guar. Cost (This must be done for all repairs)
PO Box 564, 626 Hanover Pike, Hampstead, MD 21074
Multiple chargers from the same customer
™ Enter number of chargers (Field 6) – maximum of 40 per workorder
™ Enter total for number of chargers times $2.00 or $3.00 for overtime (Field 8 – Guar. Cost)
™ Leave date codes blank.
This process will generate one work order showing quantity entered to be worked on.
Rework Processing
™ Charge $2.00 per charger for labor ($3.00 if done on overtime)
™ Do not input wire tie P/N 149138-05 on workorder (account number to write off wire ties will be provided)
Transportation Costs
Transportation costs to our location are generally the responsibility of the customer. Use the most economical
shipping method possible for chargers that must be shipped back to the customer and include that charge on
the invoice mentioned above. For inter-company shipments, record transportation charge on Transportation
Recovery Form (SAP account number 2222600-1508006001).
Tender Process
™ Charge rework to Account (Customer) # 506125
™ DO NOT PROCESS ANY TRANSACTIONS TO THIS ACCOUNT (CUSTOMER)
NUMBER OTHER THAN VALID CHARGER REWORK ACTIVITY!
Authorized Service Center Involvement
Professional authorized service centers will be provided with a recall form that they will submit to Hampstead where
their reimbursement check will be initiated.
Consumer Assistance Toll-Free Telephone Number:
A toll-free number (888-388-3273) will be provided for customers who have questions about this recall.
PO Box 564, 626 Hanover Pike, Hampstead, MD 21074