DCS491 - Scissors DEWALT - Free user manual and instructions

USER MANUAL DCS491 DEWALT

Cordless Swivel Head Shears

English (original instructions) 1

Definitions: Safety Alert Symbols and Words

This instruction manual uses the following safety alert symbols and words to alert you to hazardous situations and your risk of personal injury or property damage.

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.
(### without word) Indicates a safety related message.

NOTICE: Indicates a practice not related to personal injury which, if not avoided, may result in property damage.

Fig. A 3 1 4 5 6 8 2 7 DCS491, DCS494

DCS496

1 Trigger switch/variable speed switch
2 Swivel head shear
3 On/Lock-off control button
4 Hex wrench
5 Battery pack
6 Battery release buttons
7 Rotating collar
8 Collar release button

WARNING! Read all safety warnings and all

instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

WARNING: To reduce the risk of injury, read the instruction manual.

If you have any questions or comments about this or any DEWALT tool, call us toll free at: 1-800-4-DEWALT (1-800-433-9258).

English

GENERAL POWER TOOL SAFETY WARNINGS

WARNING! Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE

The term "power tool" in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

1) Work Area Safety

a) Keep work area clean and well lit. Cluttered or 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.
f) If operating a power tool in a damp location is unavoidable, use a ground fault circuit interrupter (GFCI) protected supply. Use of a GFCI 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 personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.
c) Prevent unintentional starting. Ensure the switch is in the off position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.
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 jewelry. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelry 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 dust collection 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 and/or the battery pack from the power tool 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 tool's 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, taking

English

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) 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.
b) Use power tools only with specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire.
c) 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.
d) 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 Specific Safety Instructions for Shears

• Hold power tool by insulated gripping surfaces, when performing an operation where the cutting accessory may contact hidden wiring. Cutting accessory contacting a "live" wire may make exposed metal parts of the power tool "live" and could give the operator an electric shock.
• Cut material at or below rated capacity. Remember, material thickness increases as gauge number deceases (14 gauge is thicker than 16 gauge). 14 gauge thickness is .075" (1.9 mm); 16 gauge is .060" (1.5 mm).
  • NEVER have any part of your body near the blades. Serious personal injury may result.
• Keep hands away from cutting area. A moment of inattention while operating power tools may result in serious personal injury.
  • ALWAYS wear gloves when handling sheet metal. The edges are sharp and can cause serious personal injury.
• Firmly secure the piece of metal to be cut to prevent movement during cutting.
  • ALWAYS start tool before engaging material to be cut.
• ALWAYS use tool with curl deflector.

• If possible, cut material so scrap curl is to the right. This direction will move curl down and out of the way.

• Use shears upright. If tool is upside down, metal curl may turn toward you.

• DO NOT use the shear with any kind of accessory or attachment.
  • Always wear safety shoes to protect your feet from sharp metal debris on the floor.
• Keep all screws tight. Check periodically for loosening.
• Do not place anything into the motor housing openings.
• Clean out your tool often, especially after heavy use. Dust and grit containing metal particles often accumulate on interior surfaces and could create an electric shock hazard.
• Stay clear of end pieces that may fall after being cut off. Contact with a sharp edge could result in personal injury.

Additional Safety Information

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, sanding, grinding, drilling, and other construction activities contains chemicals known to the State of California 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.

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 disperse 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 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.

English

CAUTION: When not in use, place tool on its side can be 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.

• Air vents often cover moving parts and should be avoided. Loose clothes, jewelry or long hair can be caught in moving parts.

The label on your tool may include the following symbols. The symbols and their definitions are as follows:

V....volts

Hz......hertz

min......minutes

or DC.....direct current

Class I Construction (grounded)

.../min.....per minute

BPM.....beats per minute

Construction (double insulated)

n_0 no load speed

n ......rated speed

earthing terminal

⚠️......safety alert symbol

△......visible radiation

......wearrespiratory protection

weareye

protection

O....wearhearing protection

BATTERIES AND CHARGERS

The battery pack is not fully charged out of the carton. Before using the battery pack and charger, read the safety instructions below and then follow charging procedures outlined. When ordering replacement battery packs, be sure to include the catalog number and voltage. Your tool uses a DEWALT charger. Be sure to read all safety instructions before using your charger. Consult the chart at the end of this manual for compatibility of chargers and battery packs.

READ ALL INSTRUCTIONS

Important Safety Instructions for All Battery Packs

WARNING: Read all safety warnings and all instructions for the battery pack, charger and power tool. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

• Do not charge or use the battery pack in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Inserting or removing the battery pack from the charger may ignite the dust or fumes.
• NEVER force the battery pack into the charger. DO NOT modify the battery pack in any way to fit into a non-compatible charger as battery pack may rupture causing serious personal injury. Consult

the chart at the end of this manual for compatibility of batteries and chargers.

• Charge the battery packs only in designated DrWALT 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 104 °F (40 °C) (such as outside sheds or metal buildings in summer). For best life store battery packs in a cool, dry location.

NOTE: Do not store the battery packs in a tool with the trigger switch locked on. Never tape the trigger switch in the ON position.

• 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.
• 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 persist, seek medical attention.

WARNING: Burn hazard. Battery liquid may be flammable if exposed to spark or flame.

WARNING: Fire hazard. Never attempt to open the battery pack for any reason. If the battery pack case is cracked or damaged, do not insert into the charger. Do not crush, drop or damage the 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 (e.g., pierced with a nail, hit with a hammer, stepped on). Damaged battery packs should be returned to the service center for recycling.

Transportation

WARNING: Fire hazard. Do not store or carry the battery pack so that metal objects can contact exposed battery terminals. For example, do

not place the battery pack 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 in carry-on baggage UNLESS they are properly protected from short circuits. So when transporting individual battery packs, make sure that the battery terminals are protected and well insulated from materials that could contact them and cause a short circuit.

English

Fuel Gauge Battery Packs (Fig. B)

Some DEWALT battery packs include a fuel gauge which consists of three green LED lights that indicate the level of charge remaining in the battery pack.

The fuel gauge is an indication of approximate levels of charge remaining in the battery pack according to the following indicators:

75–100% charged

51–74% charged

< 50% charged

Pack needs to be charged

To actuate the fuel gauge, press and hold the fuel gauge button 9. A combination of the three green LED lights will illuminate designating the level of charge left. When the level of charge in the battery is below the usable limit, the fuel gauge will not illuminate and the battery will need to be recharged.

Fig. B 9

NOTE: The fuel gauge is only an indication of the charge left on the battery pack. It does not indicate tool functionality and is subject to variation based on product components, temperature and end-user application.

For more information regarding fuel gauge battery packs, please contact call 1-800-4-DEWALT (1-800-433-9258) or visit our website www.dewalt.com.

The RBRC® Seal

The RBRC® (Rechargeable Battery Recycling Corporation) Seal on the nickel cadmium, nickel metal hydride or lithium-ion batteries (or battery packs) indicates that the costs to recycle these batteries

(or battery packs) at the end of their useful life have already been paid by DrWALT. In some areas, it is illegal to place spent nickel cadmium, nickel metal hydride or lithium-ion batteries in the trash or municipal solid waste stream and the Call 2 Recycle® program provides an environmentally conscious alternative.

Call 2 Recycle, Inc., in cooperation with DeWALT and other battery users, has established the program in the United States and Canada to facilitate the collection of spent nickel cadmium, nickel metal hydride or lithium-ion batteries. Help protect our environment and conserve natural resources by returning the spent nickel cadmium, nickel metal hydride or lithium-ion batteries 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 Call 2 Recycle, Inc.

RBRC ^™ is a registered trademark of the Rechargeable Battery Recycling Corporation.

Important Safety Instructions for All Battery Chargers

WARNING: Read all safety warnings and all instructions for the battery pack, charger and power tool. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

• 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 the charger to rain or snow.
• Pull by the plug rather than the cord when disconnecting the charger. This will reduce the risk of damage to the electric plug and cord.
• Make sure that the 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.
• When operating a charger outdoors, always provide a dry location and use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
• 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. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. When using more than one extension to make up the total length, be sure each individual extension contains at least the minimum wire size. The following table shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The lower the gauge number, the heavier the cord.

ENGLISH

Minimum Gauge for Cord Sets

Volts		Total Length of Cord in Feet (meters)
120 V 25 (7.6)		50 (15.2) 100 (30.5) 150 (45.7)
240 V 50 (15.2)		100 (30.5) 200 (61.0) 300 (91.4)
Ampere Rating		American Wire Gauge
More Than	Not More Than
0 6 18	16 16 14
6 10 18	16 14 12
10 12 16	16 14 12
12 16 14	12 Not Recommended

• Do not place any object on top of the 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 operate the charger with a damaged cord or plug.
• Do not operate the 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 the 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.
• 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 120V household electrical power. Do not attempt to use it on any other voltage. This does not apply to the vehicular charger.

WARNING: Shock hazard. Do not allow any liquid to go inside the charger. Electric shock may result.

WARNING: Burn hazard. Do not submerge the battery pack in any liquid or allow any liquid to enter the battery pack. 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: Burn hazard. To reduce the risk of injury, discharge only DeWALT rechargeable battery packs. Other types of batteries may overheat and burst resulting in personal injury and property damage.

NOTICE: Under certain conditions, with the charger plugged into the power supply, the charger can be shorted by foreign material. Foreign materials of a conductive nature, such as, but not limited to, grinding dust, metal chips, steel wool, aluminum foil or any buildup of metallic particles should be kept away from the charger cavities. Always unplug the charger from the power supply when there is no

battery pack in the cavity. Unplug the charger before attempting to clean.

Charging a Battery (Fig. C)

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

Fig. C 5

1. Insert the battery pack 5 into the charger, making sure the battery pack is fully seated in the charger. The red (charging) light will blink continuously indicating that the charging process has started.
2. The completion of charge will be indicated by the red light remaining ON continuously. The battery pack is fully charged and may be used at this time or left in the charger. To remove the battery pack from the charger, push the battery release button 6 on the battery pack.

NOTE: To ensure maximum performance and life of lithium-ion battery packs, charge the battery pack fully before first use.

Charger Operation

Refer to the indicators below for the charge status of the battery pack.

DCB101
Charging	— — — — —
Fully Charged	—
Hot/Cold Pack Delay	— • — • — •
Problem Pack or Charger	• • • • • • • • •

DCB107, DCB112, DCB113, DCB115, DCB118, DCB132 Charging Fully Charged Hot/Cold Pack Delay*

* DCB107, DCB112, DCB113, DCB115, DCB118, DCB132: The red light will continue to blink, but a yellow indicator light will be illuminated during this operation. Once the battery pack has reached an appropriate temperature, the yellow light will turn off and the charger will resume the charging procedure.

The compatible charger(s) will not charge a faulty battery pack. The charger will indicate faulty battery pack by refusing to light or by displaying a problem pack or charger blink pattern.

NOTE: This could also mean a problem with a charger. If the charger indicates a problem, take the charger and battery pack to be tested at an authorized service center.

Hot/Cold Pack Delay

When the charger detects a battery pack that is too hot or too cold, it automatically starts a Hot/Cold Pack Delay, suspending charging until the battery pack has reached an appropriate temperature. The charger then automatically switches to the pack charging mode. This feature ensures maximum battery pack life.

A cold battery pack will charge at a slower rate than a warm battery pack. The battery pack will charge at that slower rate throughout the entire charging cycle and will not return to maximum charge rate even if the battery pack warms.

The DCB118 charger is equipped with an internal fan designed to cool the battery pack. The fan will turn on automatically when the battery pack needs to be cooled.

Never operate the charger if the fan does not operate properly or if ventilation slots are blocked. Do not permit foreign objects to enter the interior of the charger.

Lithium-Ion Battery Packs Only

Li-Ion tools are designed with an Electronic Protection System that will protect the battery pack against overloading, overheating or deep discharge.

The tool will automatically turn off if the Electronic Protection System engages. If this occurs, place the lithium-ion battery pack on the charger until it is fully charged.

Wall Mounting

DCB107, DCB112, DCB113, DCB115, DCB118, DCB132

These chargers are designed to be wall mountable or to sit upright on a table or work surface. If wall mounting, locate the charger within reach of an electrical outlet, and away from a corner or other obstructions which may impede air flow. Use the back of the charger as a template for the location of the mounting screws on the wall. Mount the charger securely using drywall screws (purchased separately) at least 1" (25.4 mm) long, with a screw head diameter of 0.28–0.35" (7–9 mm), screwed into wood to an optimal depth leaving approximately 7/32" (5.5 mm) of the screw exposed. Align the slots on the back of the charger with the exposed screws and fully engage them in the slots.

Charger Cleaning Instructions

WARNING: Shock hazard. Disconnect the charger from the AC outlet before cleaning. Dirt and grease may be removed from the exterior of the charger using a cloth or soft non-metallic brush. Do not use water or any cleaning solutions.

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 +104 °F (+40 °C). This is important and will prevent serious 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 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.

1. If the battery pack does not charge properly:

a. Check operation of 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 the 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.

1. 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 effect on the battery pack.

2. Foreign materials of a conductive nature such as, but not limited to, grinding dust, metal chips, 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 the charger before attempting to clean.

3. Do not freeze or immerse the charger in water or any other liquid.

Storage Recommendations

1. The best storage place is one that is cool and dry, away from direct sunlight and excess heat or cold.
2. For long storage, it is recommended to store a fully charged battery pack in a cool dry place out of the charger for optimal results.

NOTE: Battery packs should not be stored completely depleted of charge. The battery pack will need to be recharged before use.

SAVE THESE INSTRUCTIONS FOR FUTURE USE

COMPONENTS (FIG. A)

WARNING: Never modify the power tool or any part of it. Damage or personal injury could result.

Refer to Figure A at the beginning of this manual for a complete list of components.

INTENDED USE

These shears are designed for professional shearing applications.

DO NOT use under wet conditions or in presence of flammable liquids or gases.

These shears are professional power tools. DO NOT let children come into contact with the tool. Supervision is required when inexperienced operators use this tool.

ENGLISH

ASSEMBLY AND ADJUSTMENTS

WARNING: To reduce the risk of serious personal injury, turn unit off and remove the battery pack before making any adjustments or removing/installing attachments or accessories. An accidental start-up can cause injury.

Remove and Replace Parts (Fig. A, D, E) DCS491, DCS494

To remove shear head from motor, loosen three cap screws ⑨ using the hex wrench ④ provided. Remove shear head ② 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 7 from shear housing 10. Be careful not to lose rear spacer bushing when removing middle cap screw. Remove center blade 11 from housing by tapping blade gently towards the rear. The side knives 12 and side spacers 13 will now drop out of the housing.

Fig. D

Fig. D 10 4 9 15 16 14

To remove eccentric bearing assembly from shaft, use an appropriate wrench to loosen eccentric nut 14 by turning counterclockwise.

To install eccentric bearing assembly onto shaft, make sure the large, thin washer 15 is first inserted over shaft. Screw eccentric bearing assembly onto shaft and tighten with appropriate wrench. Lubricate bearing 16 with a good grade of bearing grease.

Fig. E 11 12 13

To install cutter blades into shear housing, place the side knives 12 and side spacers 13 into position in the shear housing 10. 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.

Remove and Replace Parts (Fig. A, F-H) DCS496

To remove shear head from motor, loosen the two back cap screws 9 using the hex wrench 4 provided. Remove shear head 2 from the body by pulling head firmly forward (Fig. F). Slight twisting action may be required if head does not slide off easily.

Fig. F 13 2 4

To remove cutter blades from the shear head, completely loosen the two cap screws 9 closest to the collar and remove shear head from motor unit. Loosen the tensioning screw 17 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.

Fig. G 9 17 9

To replace blades, place lower jaw 18 onto two pins 20. Apply a thin layer of grease from the packet (included) around the pin and on the top side of the blade. Place upper jaw 19 onto pin. Apply the rest of the grease provided onto the eccentric 13 on the output shaft of the motor unit and into the area behind the upper moving blade in the shear head.

Install replacement washer 21, cone side up, over the pin on top of the moving blade. Place top half of head back 22 onto bottom half 23, making sure to align the pin to the hole. Reinstall all three cap screws 7 and nuts 24, but DO NOT tighten completely.

Fig. H

Fig. H 19 21 20 24 18 22 23 9

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 17 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.

Swivel Head (Fig. I, J)

To better accommodate safe cutting at any angle, the shear head can be easily and quickly repositioned.

1. Press and hold the collar release button 8.
2. Rotate the head and collar 7 to desired position.
3. Release the collar release button 8.

NOTE: Continue rotating the head until it clicks into the nearest locking detent posotion.

Fig. I 7 8

DCS491, DCS494

To adjust the curl of waste material, the left side knife has elongated holes. Adjustment may be necessary after changing blades or material being cut. Loosen cap screws and tap side knife either forward or backward so that curl of waste does not hit shear housing or work material while cutting.

Fig. J 9

OPERATION

WARNING: To reduce the risk of serious personal injury, turn unit off and remove the battery pack before making any adjustments or removing/installing attachments or accessories. An accidental start-up can cause injury.

Installing and Removing the Battery Pack (Fig. K)

NOTE: For best results, make sure your battery pack is fully charged.

To install the battery pack 5 into the tool handle, align the battery pack with the rails inside the tool's handle and slide it into the handle until the battery pack is firmly seated in the tool and ensure that it does not disengage.

To remove the battery pack from the tool, press the release button 6 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.

Fig. K

Technical diagram of a mechanical assembly with labeled parts 5 and 6

English

Proper Hand Position (Fig. L)

WARNING: To reduce the risk of serious personal injury, ALWAYS use proper hand position as shown.

WARNING: To reduce the risk of serious personal injury, ALWAYS hold securely in anticipation of a sudden reaction.

For proper hand position refer to figure L.

Illustration of a hand using a tool to adjust or install a mechanical component (no text or symbols visible)

Variable Speed Switch (Fig. M)

To turn the tool ON, squeeze the trigger switch 1. 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.

Fig. M 3 1

On/Lock-Off Control Button (Fig. M)

An On/Lock-Off control button 3 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 M. 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.

Shearing (Fig. N)

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 a metal. The edges are sharp and can cause serious personal injury.

DCS491, DCS494

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. 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.

Technical line drawing showing two mechanical joint configurations (no text or symbols)

DCS496

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.

MAINTENANCE

WARNING: To reduce the risk of serious personal injury, turn unit off and remove the battery pack before making any adjustments or removing/installing attachments or accessories. An accidental start-up can cause injury.

Cleaning

WARNING: Blow dirt and dust out of all air vents with clean, dry air at least once a week. To minimize the risk of eye injury, always wear ANSI Z87.1 approved eye protection when performing this.

WARNING: Never use solvents or other harsh chemicals for cleaning the non-metallic parts of the tool. These chemicals may weaken the plastic materials used in these parts. Use a cloth dampened only with water and mild soap. Never let any liquid get inside the tool; never immerse any part of the tool into a liquid.

Accessories

WARNING: Since accessories, other than those offered by DeWALT, have not been tested with this product, use of such accessories with this tool could be hazardous. To reduce the risk of injury, only DeWALT recommended accessories should be used with this product.

Recommended accessories for use with your tool are available at extra cost from your local dealer or authorized service center. If you need assistance in locating any accessory, please contact DEWALT Industrial Tool Co., 701 East Joppa Road, Towson, MD 21286, call 1-800-4-DEWALT (1-800-433-9258) or visit our website: www.dewalt.com.

Repairs

The charger and battery pack are not serviceable.

WARNING: To assure product SAFETY and REELABILITY, repairs, maintenance and adjustment (including brush inspection and replacement) should be performed by a DrWALT factory service center or a DrWALT authorized service center. Always use identical replacement parts.

Register Online

Thank you for your purchase. Register your product now for:

• WARRAnTY sERViCE: Registering your product will help you obtain more efficient warranty service in case there is a problem with your product.
• COnFiRMATiOn OF OWnERshiP: In case of an insurance loss, such as fire, flood or theft, your registration of ownership will serve as your proof of purchase.
• FOR YOUR SAFETY: Registering your product will allow us to contact you in the unlikely event a safety notification is required under the Federal Consumer Safety Act.

Register online at www.dewalt.com/register.

Three Year Limited Warranty

DeWALT will repair, without charge, any defects due to faulty materials or workmanship for three years from the date of purchase. This warranty does not cover part failure due to normal wear or tool abuse. For further detail of warranty coverage and warranty repair information, visit www.dewalt.com or call 1-800-4-DeWALT (1-800-433-9258). This warranty does not apply to accessories or damage caused where repairs have been made or attempted by others. This warranty gives you specific legal rights and you may have other rights which vary in certain states or provinces.

In addition to the warranty, DEWALT tools are covered by our:

1 YEAR FREE sERViCE

DeWALT will maintain the tool and replace worn parts caused by normal use, for free, any time during the first year after purchase.

2 YEARs FREE sSERVICE On DEWAIT BATTERY PACKs

DC9071, DC9091, DC9096, DC9182, DC9280, DC9360, DCB120, DCB127, DCB201, DCB203, DCB203BT, DCB207, DCB361

3 YEARs FREE sSERVICE On DEWAIT BATTERY PACKs

DCB200, DCB204, DCB204BT, DCB205, DCB606

NOTE: Battery warranty voided if the battery pack is tampered with in any way. DEWALT is not responsible for any injury caused by tampering and may prosecute warranty fraud to the fullest extent permitted by law.

90 DAY MOnEY BACK gUARAnTEE

If you are not completely satisfied with the performance of yourDeWALT Power Tool, Laser, or Nailer for any reason, you can return it within 90 days from the date of purchase with a receipt for a full refund – no questions asked.

IATin AMERiCA: This warranty does not apply to products sold in Latin America. For products sold in Latin America, see country specific warranty information contained in the packaging, call the local company or see website for warranty information.

FREE WARning IABEI REPIACEMENT: If your warning labels become illegible or are missing, call 1-800-4-DEWALT (1-800-433-9258) for a free replacement.

DCSXXX CORDLESS SHEAR SER. WARNING TO REDUCE THE RISK OF INJURY, USER MUST READ INSTRUCTION MANUAL KEEP AWAY FROM BLADES, USE ONLY WITH DWALL TATTERBLES, ALWAYS USE PROPER EYE AND RESPIRATORY PROTECTION. DWALL INDUSTRIAL TOOL CO., LTDSON, MD 212W USA FOR SERVICE INFORMATION, CALL 1-AM-4-DEWALL www.DEWALL.com

USE: 120 Wh Shipping: 3 x 40 Wh

(if there is no assembly, this section may be Ajustements)

Technical diagram of a mechanical assembly with labeled parts 5 and 6

Illustration of hands using a tool to adjust or install a mechanical component, no text or symbols present

Pure mechanical diagram showing a lever and pivot point without any text or symbols

Simple line drawing of a mechanical component or tool with no text or symbols

DCS496

DC9071, DC9091, DC9096, DC9280, DC9360, DC9180, DCB120, DCB127, DCB201, DCB203, DCB203BT, DCB207

COnTRAT D'EnTRETiEn gRATUiT DE TROis Ans sur IEs BIOC-PiES DeWALT

DCB200, DCB204, DCB204BT, DCB205

USE: 120 Wh Shipping: 3 x 40 Wh

Technical diagram of a mechanical assembly with labeled parts 5 and 6

Illustration of hands using a tool to adjust or install a mechanical component (no text or symbols visible)

Simple line drawing of a mechanical component or tool with no visible text, numbers, or symbols.

Pure technical line drawing of a mechanical component without any text, numbers, or symbols

DCS496

Eje Central Lázaro Cárdenas No. 18 - Local (55) 5588 9377 D, Col. Obrera

ESPAÑOL

MERIDA, YUC

Calle 63 #459-A - Col. Centro [phone]

MONTERREY, N.L.

Av. Francisco I. Madero 831 Poniente - Col. (818) 375 23 13 Centro

PUEBLA, PUE

17 Norte #205 - Col. Centro [phone]

QUERETARO, QRO

Av. San Roque 274 - Col. San Gregorio (442) 2 17 63 14

SAN LUIS POTOSI, SLP

DC9071, DC9091, DC9096, DC9280, DC9360, DC9180, DCB120, DCB127, DCB201, DCB203, DCB203BT, DCB207

EsPAÑOI

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DEWALT BATTERY AND CHARGER SYSTEMS

Chargers/Charge Time (Minutes)

*BT - Bluetooth® NOTE: The Bluetooth® word mark and logos are registered trademarks owned by the Bluetooth®, SIG, Inc. and any use of such marks by DeWALT is under license. Other trademarks and trade names are those of their respective owners.
**Battery Datecode 201536 or later.

"X" Indicates that the battery pack is not compatible with that specific charger. All charge times are approximate. Actual charge time may vary. Read the instruction manual for more specific information.