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DC9180 Product Service Plan

DC9180 Product Service Plan. Page 1. The purpose of this document is to: Determine if a DC9180, battery is OK or Failed Provide suggestions for potential digital communication failures

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DC9180 Product Service Plan

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  1. DC9180 Product Service Plan Page 1

  2. The purpose of this document is to: • Determine if a DC9180, battery is OK or Failed • 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. Page 2

  3. 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 Page 3

  4. 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 Page 3

  5. Step #3 • Place pack in known good high drain tool such as a drill, recip or circ saw. • Observe full speed operation PASS FAIL • Tool operates in full speed in a consistent manner. • Failure to run in full speed. Inconsistent operation. Page 4

  6. Step #4 • Place pack in known good high drain drill such as the DC925, DC927. • Cycle the trigger 20 times as fast as possible. PASS FAIL • Tool runs each time the trigger is actuated. • The tool shuts off randomly and may or may not come back on. Page 5

  7. Digital Communication Check 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 Page 6

  8. 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 • Worn, broken, painted or damaged terminals • Terminals are in good condition Page 7

  9. Digital communication check #2 PART 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. Page 8

  10. Digital communication check #2 PART B • 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. Battery not fully seated PASS FAIL • Terminals are in good condition • Pack is fully seated in the charger and charges for 90 Seconds • Bent or broken terminals • Pack is fully seated in the charger and shows a problem mode blink anytime within 90 seconds. Page 9

  11. Nano Terminal layout Negative and Digital communication Positive 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 within the 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. Page 10

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