DEWALT DCD1623 2-Inch Cordless Magnetic Drill Press Instruction Manual

DEWALT DCD1623 2-Inch Cordless Magnetic Drill Press Instruction Manual

Components

1. ON/OFF switch
2. Magnet engagement lever
3. Forward/reverse switch
4. Speed selector
5. Gear selector
6. Feed handle
7. Feed handle hub
8. Feed handle release button
9. LED button
10. 3/4″ Weldon quick‑change chuck
11. 5/8″ Keyed chuck
12. Motor height adjustment lever
13. Magnetic coolant bottle bracket
14. Coolant bottle
15. Coolant tube
16. Coolant coupling connector
17. Coolant flow regulator
18. Coolant bottle cap
19. Connector nut
20. Magnetic base
21. Magnetic coolant bottle attachment point
22. Carry handle
23. Carry handle release button
24. Magnet engagement and E‑Clutch® indicator
25. Chip guard
26. Safety chain

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.

Intended Use

This heavy‑duty drill press is designed for professional drilling applications.
DO NOT use under wet conditions or in presence of flammable liquids or gases.

This drill press is a professional power tool. DO NOT let children come into contact with the tool. Supervision is required when inexperienced operators use this tool

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.

(Used 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.

GENERAL POWER TOOL SAFETY WARNINGS

WARNING: Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below 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 a 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.
   h) Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.

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 remove the battery pack, if detachable, 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 thepower tool. Power tools are dangerous in the hands of untrained users.
   e) Maintain power tools and accessories. 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 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.
   h) Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

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.
   e) Do not use a battery pack or tool that is damaged or modified. Damaged or modified batteries may exhibit unpredictable behavior resulting in fire, explosion or risk of injury.
   f) Do not expose a battery pack or tool to fire or excessive temperature. Exposure to fire or temperature above 265 °F (130 °C) may cause explosion.
   g) Follow all charging instructions and do not charge the battery pack or tool outside the temperature range specified in the instructions. Charging improperly or at temperatures outside the specified range may damage the battery and increase the risk of fire.

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.
   b) Never service damaged battery packs. Service of battery packs should only be performed by the manufacturer or authorized service providers.

Additional Safety Rules for a Drill Presses

• Always use the safety chain. Mounting can release. If mounting surface does not allow the use of the chain, then secure the unit by another means such as a clamp. Electrical power may fail or unit may accidentally disconnect.
• Use clamps or other practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control.
• Keep your fingers well out of the drill area.
• The magnetic base is suitable for use on steel with a thickness of at least 3/8″ (10 mm), with no visible air gap between the magnet bottom surface and the mounting surface. Coats of paint and surface irregularities will create an air gap. Keep the air gap to a minimum. Air gaps between the magnet and working surface weakens the magnetic holding strength.
• Always place the magnet base on a flat surface or straight pipe. Do not clamp the base on small or irregularly shaped objects.
• Always place the magnet base on a surface that is clear of shavings, chips, swarf and surface dirt.
• Keep the magnet clean and free of debris and swarf.
• Do not switch on the motor until the drill has been mounted and installed according to the instructions.
• Do not switch on the motor before having checked that the magnetic base has been tightened firmly to the mounting surface. Before switching on the motor, make sure the accessory has been mounted correctly.
• Always use the recommended speed for the accessories and the material.
• Do not use the machine on the same workpiece on which electric welders are being used.
• Use only an appropriate cutting fluid.
• Do not use liquid cutting fluids while drilling vertical surfaces or overhead. Dip the cutter in cutting paste or apply an appropriate spray for these applications.
• Do not pour cutting fluid into the reservoir while it is mounted on the drill. Do not allow cutting fluid to enter the drill motor.
• If battery comes in contact with cutting fluid wipe it off immediately. The cutting fluid used with this drill may compromise certain battery pack housings. It is highly recommended that battery packs with oil resistant housings (glass filled nylon, designated by a G suffix in the model number) be used.
• Always use the chip guard while drilling.

CAUTION: E xtremely powerful magnet. Keep away from pacemakers, defibrillators, medical equipment, computers, computer disks, cassette tapes, engine control modules, etc.
CAUTION: Do not use the magnet engagement lever or the feed handle to lift unit.
CAUTION: After switching power to the magnet off, the magnetic base will continue to adhere to the surface for a moment before releasing. A light blow with the hand will release the base.

Additional Safety Information

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

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, sawing, 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.

• 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 absorptionof harmful chemicals. Direct particles away from face and body.
• Use the appropriate dust extractor vacuum to remove the vast majority of static and airborne dust. Failure to remove static and airborne dust could contaminate the working environment or pose an increased health risk tothe operator and those in close proximity.
• Use clamps or other practical ways to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control and injury.
• Air vents often cover moving parts and should be avoided. Loose clothes, jewelry or long hair can be caught in moving parts.

CAUTION: When not in use, place tool where it will not cause a tripping or falling hazard.

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
• IPM: impacts per minute
• OPM: oscillations per minute
• RPM: revolutions per minute
• sfpm: surface feet per minute
• SPM: strokes per minute
• A: amperes
• W: watts
• Wh: watt hours
• Ah: amp hours
• or AC: alternating current
• or AC/DC: alternating or direct current
• : Class II Construction (double insulated)
• no: no load speed
• n: rated speed
• PSI: pounds per square inch
• : earthing terminal
• : safety alert symbol
• : visible radiation do not stare into the light
• : wear respiratory protection
• : wear eye protection
• : wear hearing protection
• : read all documentation
• : do not expose to rain
• : Strong magnet. People with cardiac pacemakers or other medical implant must stay clear of thisdrill.

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.

Important Safety Instructions for All Battery Packs

• WARNING: Read all safety warnings, instructions, and cautionary markings for the battery pack, charger and product. 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 DeWALT chargers.

• DO NOT splash or immerse in water or other liquids.

• DO NOT allow water or any liquid to enter battery pack.

• 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.

• Do not expose a battery pack or appliance to fire or excessive temperature. Exposure to fire or temperature above 265 °F (130 °C) may cause explosion.

• Follow all charging instructions and do not charge the battery pack or appliance outside of the temperature range specified in the instructions. Charging improperly or at temperatures outside of the specified range may damagethe battery and increase the risk of fire.

• 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.

• Battery liquid may be flammable if exposed to spark or flame.

• 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.

Storage Recommendations
The best storage place is one that is cool and dry, away from direct sunlight and excess heat or cold. Store the fully charged battery pack out of the charger.

Battery Pack Cleaning Instructions
Dirt and grease may be removed from the exterior of the battery pack using a cloth or soft non‑metallic brush. Do not use water or any cleaning solutions.

Fuel Gauge Battery Packs (Fig. B)

Some battery packs include a fuel gauge. When the fuel gauge button is pressed and held, the LED lights will indicate the approximate level of charge remaining. This does not indicate tool functionality and is subject to variation based on product components, temperature, and end‑user application.

Transportation

WARNING: Fire hazard. Do not store, carry, or transport 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, coins, hand tools, etc. 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.
NOTE: Li‑ion battery packs should not be put in checked baggage on airplanes and must be properly protected from short circuits if they are in carry‑on baggage.

Shipping the DeWALT FLEXVOLT® Battery Pack
The DeWALT FLEXVOLT® battery pack has a battery cap that should be used when shipping the battery pack.

Attach the cap to the battery pack to ready it for shipping. This converts the battery pack to three separate 20V batteries. The three batteries have the Watt hour rating labeled “Shipping” on the battery pack. If shipping without the cap or in a tool, the pack is one battery at the Watt hour rating labeled “Use”.

Example battery pack label:
USE: 120 Wh SHIPPING: 3 x 40 Wh

In this example, the battery pack is three batteries with 40 Watt hours each when using the cap. Otherwise, the battery pack is one battery with 120 Watt hours.

The RBRC® Seal

Please take your spent battery packs to an authorized DeWALT service center or to your local retailer for recycling. In some areas, it is illegal to place spent battery packs in the trash. You may also contact your local recycling center for information on where to drop off the spent battery pack. Do not place in curbside recycling. For more information visit www.call2recycle.org. or call the toll free number in the RBRC® Seal.
RBRC® is a registered trademark of Call 2 Recycle, Inc.

Important Safety Instructions for All

Battery Chargers

• WARNING: Read all safety warnings, instructions, and cautionary markings for the battery pack, charger and product. 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 a DeWALT charger. DeWALT chargers and battery packs are specifically designed to work together.
• These chargers are not intended for any uses other than charging DeWALT rechargeable battery packs. Charging other types of battery packs may cause them to overheat and burst, resulting in personal injury, property damage, fire, electric shock or electrocution.
• Do not expose the charger to rain or snow.
• Do not allow water or any liquid to enter charger.
• 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 heavier the cord and thus the greater its capacity. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. The following table shows the correct size to use depending on total length of all extension cords plugged together, and nameplate ampere rating. If in doubt, use the next heavier gauge.

Minimum Gauge for Cord Sets

• 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. Have them replaced immediately.
• 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.
• 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.
• 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 and ventilation slots.
• Always unplug the charger from the power supply when there is no battery pack in the cavity.

Charging a Battery (Fig. B, C)

1.  Plug the charger into an appropriate outlet.

2. Insert and fully seat battery pack 29 . The red charging light(s) will continuously blink while charging.

3. Charging is complete when the red charging light(s) remain(s) continuously ON. Battery pack can be left in charger or removed. Some chargers require the battery pack release button to be pressed for removal.
   WARNING: Only charge batteries in air temperature over 40 ° F (4.5 ° C) and below 104 ° F (+40 ° C).

4. Charger will not charge a faulty battery pack, which may be indicated by the charging light(s) staying OFF. Take charger and battery pack to an authorized service center if light(s) stay(s) OFF.
   NOTE: Refer to label near charging light(s) on charger for blink patterns. Older chargers may have additional information and/or may not have a yellow indicator light.
   NOTE: To remove the battery pack, some chargers require the battery pack release button to be pressed

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 may charge at a slower rate than a warm battery pack.
The hot/cold pack delay will be indicated by the red light(s) continuing to blink but with the yellow light continuously ON. Once the battery pack has reached an appropriate temperature, the yellow light will turn OFF and the charger will resume the charging procedure.

DCB118 and DCB1112 Chargers
The DCB118 and DCB1112 chargers are 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.

Electronic Protection System
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 and the battery pack will need to be recharged.

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 – 75 °F (18 °C–24 °C). DO NOT charge when the battery pack is 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.

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

4. You may charge a partially used pack whenever you desire with no adverse effect on the battery pack.

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.

Wall Mounting

Some DeWALT 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.

SAVE THESE INSTRUCTIONS FOR FUTURE USE

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.

Installing the Machine (Fig. A, H)

1. Assemble the feed handle.
2. Install the chip guard.
3. Fit the lubrication system as necessary.
4. This machine features a concave base making it possible to install on a solid surface, or a pipe with a diameter of no less than 4″ and a thickness of no less than 3/8″. Remove any particles that will obstruct full contact between the magnetic base 20 and the mounting surface.
5. Fit and tighten the safety chain 26

Assembling the Feed Handle (Fig. D)

The quick‑release feed handle can be mounted in one simple operation both to the left and the right of the machine.

1. Screw the handles 6 into the hub 7. Ensure that the handles are secure.
2. Keep the hub realease button 8 depressed while inserting the hub shaft into the hole 33.
3. Release the button.

Assemble the Chip Guard (Fig.E)

WARNING: Always use the chip guard.

1. Hold the chip guard 25 in front of the tool holder, aligning the slots in the chip guard with the holes in the machine.
2. Fit the wing bolts 39 (from the accessories bag) into the holes located in the front of the frame.

Lubrication System (Fig. A, F)

Filling the Coolant Bottle

WARNING: Do not pour cutting fluid into the bottle while mounted in the bracket. Do not allow cutting fluid to enter the drill motor. Electric shock may result.
WARNING: Do not allow cutting fluid to enter the battery port or come in contact with the battery pack.

NOTE: If battery comes in contact with cutting fluid wipe it off immediately. The cutting fluid used with this drill may compromise certain battery pack housings. It is highly recommended that battery packs with oil resistant housings (glass filled nylon, designated by a G suffix in the model number) be used.
NOTE: The lubrication system is designed for dispensing cutting fluids specifically intended for drilling. Other liquids may damage the system.

1. Turn the the flow regulator 17 counterclockwise to close.
2. Remove coolant bottle 14 from magnetic coolant bottle bracket 13.
3. Unscrew the cap 18.
4. Fill the container with cutting coolant diluted with water.
5. Screw the cap back on.
6. Place coolant bottle into magnetic coolant bottle bracket 13.

Fitting the Lubrication System (Fig. A, F)

WARNING: Do not use the lubrication system in vertical surfaces or overhead drilling applications. Only use the lubrication system for horizontal drilling applications, as shown in Figure A.

1. Place coolant bottle 14 into the magnetic coolant bottle bracket 13 , then slide the magnetic coolant bottle bracket onto the either side of the magnetic coolant bottle attachment point 21 .
2. Attach the coolant tube 15 to the coupling connector 16 on the gearbox.
   a. Unscrew the nut 19 by the wrench first, and place the nut through the end of the coolant tube 15 .
   b. Press the coolant tube onto the coupling connector 16 first, then use a wrench to tighten the nut.
   c. To remove, unscrew the nut and then pull the coolant tube from the coupling connector.
   NOTE: After the coolant tube has been removed, tighten the nut on the coupling connector to prevent losing it.

In order to use the lubrication system, the coolant bottle 14 must be filled with a sufficient amount of cutting fluid.

Lubrication in Horizontal Applications (Fig. F)

1. Adjust the fluid flow as required using the flow regulator 17 .
2. Add more cutting fluid if the shavings become blue.

Lubrication in Vertical and Overhead Applications
Dip the cutter in cutting paste or apply an appropriate spray.

Fitting the Safety Chain (Fig. H)

WARNING: Always use the safety chain.
WARNING: Never attach the safety chain through the carry handle.

Feed the provided safety chain 26 through the safety chain opening 28 of unit and around the workpiece and secure in place.

Inserting and Removing an Accessory (Fig. G)

The tool holder accepts annular cutters with a Weldon 3/4″ shank with two flats.

CAUTION: Laceration hazard. The cutter teeth are sharp.

1. Slide the pilot pin 42 through the hole in the center of the cutter shank.
2. Push up on the 3/4″ Weldon quick‑change chuck 10 .
3. Insert the cutter 43 with pilot pin and turn until the flat meets the locking pin. When the flat meets the locking pin the collar will snap down.
4. Check that the cutter is securely held in the arbor.
5. Lift the 3/4″ Weldon quick‑change chuck to release the cutter.

Three‑Jaw Chuck (Fig. G)

A 3‑jaw chuck 11 can be installed to fit the drill press for various bit sizes. Refer to Inserting and Removing an Accessory for installation instructions.

1. Place chuck key 27 in each of the three holes, and tighten in clockwise direction. It’s important to tighten chuck with all three holes to prevent slippage.
2. To release bit, turn chuck key counterclockwise in just one hole, then loosen the chuck by hand.

NOTE: It may be necessary to adjust the motor position when chuck is installed. Please refer to Adjusting the Motor Height for instructions.

Refer to the Accessories section for further information on appropriate accessories.

Magnet Engagement Lever (Fig. N)

The magnetic strength can be switched by using the magnet engagement lever 2 . Moving the magnet engagement lever towards the middle position increases the magnetic power to 15%. This is a feature to provide some user assistance while securing the unit into place.
Moving the magnet engagement lever to the left position increases the magnet power to 100%.
With the magnet engagement lever positioned to the right the magnetic power is turned off. When moving the handle from the left to the right the collar 37 on the handle must be lifted to move out of either 100% engaged or 15% engaged.

NOTE: The unit will not turn on until the magnet engagement lever is in the left position at 100%.

Gear Selector (Fig.L)

CAUTION: Do not change gears while motor is running.
The machine is equipped with a two‑gear selector to vary the speed/torque ratio.

1. Press in the gear selector button 32 and rotate the gear selector dial 5 into the desired mode.
2. LOW SPEED AND HIGH TORQUE: Rotate the gear selector to the left for low speed and high torque.
   HIGH SPEED AND LOW TORQUE: Rotate the gear selector to the right for high speed and low torque.

Speed Selection (Fig. A)

The tool features five speed settings for greater versatility.

1. To select a higher RPM setting, rotate the speed selector 4 to a higher number.
2. To select a lower RPM setting, rotate the speed selector to a lower number.

If the tool does not change speeds, confirm that the speed selection switch is completely engaged in the forward or back position.

Refer to the Speed (RPM) and Drill Settings chart at the back of this section for speed and cutter size recommendations.

Forward/Reverse Button (Fig. M)

A forward/reverse control button 3 determines the direction of bit rotation.
NOTE: The reverse feature of this tool is used for tapping screw holes. Reverse speed will be 350 rpms in low gear and 680 rpm in high gear regardless of variable speed.
To select forward rotation , release the ON/OFF switch 1 and switch the forward/reverse control button towards the forward icon 40 .
To select reverse, switch the forward/reverse control button towards the reverse icon 41 .

Adjusting the Motor Height (Fig. I)
The motor height can be adjusted to accommodate the need for more or less bit clearance over the workpiece.

1. Loosen the motor slide lever 12 .
2. Position the motor to the desired height.
3. Tighten the motor slide lever firmly to secure the motor in position.

NOTE: There are three set screws 38 along the side of the frame that can be tigthened or loosened to adjust how easily the motor housing moves with the feed handle 6.

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.

Carry handle (Fig. J)

This carry handle has two functions:

• Carry the tool when it is in vertical position.
• Protect the battery from dropping off in its folded position for tool’s upside down application.

Installing and Removing the Battery Pack (Fig. J, K)

WARNING: Ensure the tool/appliance is in the off position before inserting the battery pack.

WARNING: Keep cutting fluid away from the battery pack. Contact with cutting fluid may cause the batteryhousing to crack. If battery comes in contact with cutting fluid, clean the battery immediately.

NOTE: It is highly recommended that battery packs with oil resistant housings (glass filled nylon, designated by a G suffix in the model number) be used. For best results, make sure your battery pack is fully charged.
To install the battery pack 29 into the battery port 31 press and hold the carry handle release button 23 and move the carry handle 22 into the vertical position. Align the battery pack with the rails inside the battery port and slide it in 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 and hold the carry handle release button 23 and move the carry handle 22 into the vertical position. Press the release button 30 and firmly pull the battery pack out of the battery port. Insert it into the charger as described in the charger section of this manual.
NOTE: If the battery is still difficult to remove with the carry handle in the vertical position, press and hold the carry handle release button and push the carry handle a little further towards the front of the tool to create more space for the battery to be removed.

Prior to operation

WARNING: Inspect the chain before each use, for wear or damage. Replace if necessary.
Try a few simple projects using scrap material until you develop a “feel” for the machine.

Switching On and Off (Fig. A)

In order to operate properly, the machine has to be switched following the procedure as described below.

Switching the power on and off

WARNING: In a vertical or upside down application, the tool will drop off from the workpiece if the magnet engagement lever is NOT at the 100% position.

Push the power switch 1 up (I) to run the tool.
NOTE: The tool will not run unless magnet is at 100% engagement. An orange light will illuminate indicating the magnet is not fully engaged.
Press the switch down (0) to shut down the tool.

E‑Clutch® System and Low Voltage Indicator LED (Fig. A)

The DCD1623 is equipped with the DeWALT E‑Clutch® system. This feature senses the motion of the tool and shuts the tool down if necessary. The E‑Clutch® indicator 24 will illuminate red to indicate status.
The working LED on the front of the magnetic base 20 will flash to alert the user of low voltage conditions.

operating the tool.
RED SOLID| E‑Clutch® System has been activated (ENGAGED)| With the tool properly supported, release trigger. The tool will function normally when the trigger is depressed again and the indicator light will go out.
ORANGE SOLID| The magnet engagement lever is not in the 100% position with the power switch on.| Move the magnet engagement lever to the 100% position.
WHITE FLASHING| Low voltage battery conditions| Suspend use of the tool and replace with fully charged battery.

Drilling with Annular Cutters

1. Annular cutters only cut material at the periphery of the hole, rather than converting the entire hole to shavings. As a result the energy required to make a hole is lower than for a twist drill.
2. When drilling with an annular cutter, it is not necessary to drill a pilot hole.

CAUTION: Do not touch the cutter or the parts close to the cutter immediately after operation, as they may be extremely hot and cause burns to the skin. Ensure nobody is in the work area where the metal core is ejected.

Drilling Conditions

The ease with which material can be drilled is dependent on several factors including tensile strength and abrasion resistance. Hardness and /or strength is the usual criterion, wide variations in machine ability can exist among material showing similar physical properties. The drilling conditions are dependent on requirements for tool life and surface finish. These conditions are further restricted by the rigidity of the tool and the workpiece, lubrication and machine power available. The harder the material the lower the cutting speed. Some materials of low hardness contain abrasive substances leading to rapid cutting edge wear at high speeds. Feed rates are governed by rigidity of set‑up, volume of material to be removed, surface finish and available machine power.

Drilling a Hole (Fig. A)

1. Always apply an appropriate cutting fluid/coolant on the cutting area.
2. Lower the guard 10 so that it screens the surface to be drilled.
3. Make sure the drill point or cutter pilot is properly installed over the spot to be drilled.
4. Push the power switch 1 up (I) to run the tool.
5. Slowly feed the accessory into the workpiece using the feed handle 6 .
6. At the start of the cut, apply light pressure to allow the accessory to perform the initial groove.
7. Continue applying sufficient pressure to achieve a smooth progressive cut. Do not force.
8. Take extra care when the accessory is about to break through the surface to prevent splintering.
9. Always turn off the motor, the magnet and the power, in that particular order, when work is finished and before removing the battery.

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.

Your DeWALT power tool has been designed to operate over a long period of time with a minimum of maintenance. Continuous satisfactory operation depends upon proper tool care and regular cleaning.

Tool Connect™ Chip (Fig. O)

Optional Accessory

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.

Your tool is Tool Connect™ Chip ready and has a location for installation of a Tool Connect™ Chip.
Tool Connect™ Chip is an optional application for your smart device (such as a smart phone or tablet) that connects the device to utilize the mobile application for inventory management functions.
Refer to Tool Connect™ Chip Instruction Sheet for more information.

Installing the Tool Connect™ Chip

1. Remove the retaining screws 34 that hold the Tool Connect™ Chip protective cover 36 into the tool.
2. Remove the protective cover and insert the Tool Connect™ Chip into the empty pocket 35 .
3. Ensure that the Tool Connect™ Chip is flush with the housing. Secure it with the retaining screws and tighten the screws.
4. Refer to Tool Connect™ Chip Instruction Sheet for
   further instructions.

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 procedure.

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 product 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 product are available at extra cost from your local dealer or authorized service center. If you need assistance in locating any accessory, please contact DeWALT call 1‑800‑4‑DeWALT (1‑800‑433‑9258) or visit our website: www.dewalt.com

Repairs

The charger and batteries are not serviceable. There are no serviceable parts inside the charger or battery pack.

WARNING: To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including brush inspection and replacement, when applicable) should be performed by a DeWALT factory service center or a DeWALT 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.

Three Year Limited Warranty

For warranty terms, go to https://www.dewalt.com/Legal/Warranty/3‑Year‑Limited‑Warranty.
To request a written copy of the warranty terms, contact: Customer Service at DeWALT Industrial Tool Co., 701 East Joppa Road, Towson, MD 21286 or call 1‑800‑4‑DeWALT (1‑800‑433‑9258).

LATIN 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 LABEL REPLACEMENT: If your warning labels become illegible or are missing, call 1‑800‑4‑DeWALT (1‑800‑433‑9258) for a free replacement.

Speed (RPM) and Drill Settings (with DCB609G)

For 1‑1/2″ diameter or thicker than 1″ and above use a 9Ah pack.

If you have questions or comments, contact us.
www.DEWALT.com

References

• Call2Recycle | Leading the Charge For Battery Recycling
• DEWALT® Power Tools Official Site | Guaranteed Tough®

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>