DC9180

Product Service Plan

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The purpose of this document is to:

1. Determine if a DC9180, battery is OK or Failed

2. Provide suggestions for potential digital communication failures• The Nano battery uses digital communication to “talk” with the

charger. Ensuring proper terminal engagement is essential to the function of the system.

• This procedure suggests what key areas of the digital communication system may be failed.

Step #1

• Place pack in good charger for 5 minutes (note only 90 seconds is needed to remove the pack from sleep mode, but 5 minutes ensures the pack has enough charge to perform the following tests)

• Observe charger light blink pattern

PASS Let Pack cool for up to 1 hr at room temp

• Normal Blink Pattern after 5 minutes.

– see charger label for blink patterns• Hot/cold pack delay blink pattern

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Step #2

• Place pack in good charger for 5 minutes (note only 90 seconds is needed to remove the pack from sleep mode, but 5 minutes ensures the pack has enough charge to perform the following tests)

• Observe charger light blink pattern

PASS Move to digital communication Check

• Normal Blink Pattern after 5 minutes.

– see charger label for blink patterns• Problem Blink Pattern at any time

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PASS FAIL

1. Tool operates in full speed in a consistent manner.

1. Failure to run in full speed. Inconsistent operation.

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Step #3

• Place pack in known good high drain tool such as a drill, recip or circ saw.

• Observe full speed operation

PASS FAIL

1. Tool runs each time the trigger is actuated.

1. The tool shuts off randomly and may or may not come back on.

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Step #4

• Place pack in known good high drain drill such as the DC925, DC927.

• Cycle the trigger 20 times as fast as possible.

If the battery shows a problem blink during Step #1…

Perform the following tests to confirm that the battery is communicating with the charger and

accepting charge

Digital Communication Check

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Digital communication check #1

• Inspect the terminals of the battery to ensure good METAL contact is exposed. Damaged, painted, or worn terminals may interfere with the communication to the charger and result is a problem mode blink.

PASS FAIL

1. Terminals are in good condition1. Worn, broken, painted or damaged

terminals

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Digital communication check #2PART A

• Ensure the charger terminals are not broken or damaged. This can be done by looking into the well of the charger and ensuring the openings of the terminals match the openings in the plastic.

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Digital communication check #2PART B

1. After ensuring the charger terminals are not damaged, place the battery in the charger. Ensure the battery is fully pressed into the well of the charger. Charge for 90 seconds.

PASS FAIL

1. Terminals are in good condition2. Pack is fully seated in the

charger and charges for 90 Seconds

1. Bent or broken terminals2. Pack is fully seated in the charger

and shows a problem mode blink anytime within 90 seconds.

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Battery not fully seated

Nano Terminal layout

PositiveNegative and

Digital communication

Digital communication

Note: The voltage at the terminals can not be used to accurately measure the state of charge of the battery nor if the battery is defective. The electronics withinthe pack alone as well as the interaction between the electronics in the pack and the meter being used to measure the voltage may cause erroneous readings.

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