Black & Decker Corp.
USA SERVICE OPERATIONS
TECHNICAL SERVICES DEPARTMENT SB06085
SERVICE BULLETIN PAGE 1 OF 6
ISSUED: December 21, 2006
Updated: March 9, 2007
SUBJECT: RECALL TO REPAIR – SWITCH and HANDLES Written By: Ron Armacost
UNITS: DC305K TYPE 1 Reciprocating Saws
DATE CODES AFFECTED: 200601 THROUGH 200640
In cooperation with the U.S. Consumer Product Safety Commission (CPSC), DEWALT is recalling the above unit. It may be possible under certain circumstances for the wiring from the switch to short and the unit to overheat.
Order part number 649186-00 rework kit which includes a new wiring harness and handles. Follow the attached rework procedure.
Factory reworked units have a new handle set with an extra rib (see photo). They also have a new date code applied to the handle. Units in cartons with a blue dot near the UPC label have already been upgraded. The date code can be found on the bottom of the housing after the battery has been removed.
DC305 Recip Saw Repair Instructions
1. Remove cover half of handle by removing 7 screws (6 T15 and 1 T10.)
2. Remove the switch assembly and wire harness from handles.
3. Scrap original handles.
4. Remove brown and orange leads from switch in order to work outside of tool.
5. Remove remaining leads from switch along with white connector. (See photo)
6. Scrap original wire harness.
7. Insert RED lead on new wire harness in upper switch terminal, refer to picture.
8. Insert White/Brown lead in lower terminal - see picture, insert purple lead in middle switch terminal (not shown in picture)
9. Insert brown and purple leads into wire guides.
10. Insert white terminal connector into switch.
Note: Black lead must align with # 1 on switch
11. Make sure black tubing is centered in heat sink as shown.
12. Insert orange lead onto the switch terminal.
13. Insert brown lead onto upper switch terminal.
14. 1. Place switch into new handle. New handle has guides to hold wire harness.
2. Place heat sink and circuit board on guides.
3. Route orange and brown motor wire along top of handle as shown below.
4. Place battery terminal block connector into handle.
15. Install NEW handle cover half. Assemble with (6) T15 and (1) T10 screws.
16. Check with meter as in following procedure.
Step 1:Check for continuity between Terminal 2 and Terminal 10
Step 2:Check for continuity between Terminal 1 and Terminal 2
Step 3: Tool operation
• Place known-good battery pack in re-worked saw
• Observe full speed operation
• Observe variable speed operation
17. Mark the new handle half with the original tool date code and add the letter “V” behind it to signify the tool has been upgraded. The extra rib on the new handle will also signify the upgraded handle.
DEWALTâ INDUSTRIAL TOOLS
USA SERVICE OPERATIONS
PAGE 6 SB06085
Point-Of-Sale Processing:
v Select 1 Orders
v Select 2 Repair
v Enter Customer Information:
PHONE NUMBER
NAME
ADDRESS
CITY, STATE, ZIP CODE
v Select 2 Repair Type
v Complete N
v Enter Catalog Number (DC305K)
v Enter Type
v Enter UNIT Serial Number
Repair Processing for Factory Service Centers
v Charge 20 minutes @ $0.84 per minute for labor ($16.80)
v Input part number 649186-00 and quantity of 1
Authorized Service Center Involvement
DEWALT authorized service centers are to process a warranty claim on ServiceNet to recover the 649186-00 repair kit cost and labor cost. Shipping expense, where appropriate, can be credited as well. In the Special Consideration box of the claim, put in the service bulletin number for the recall which is SB06085.
Technical Services Dept., Mail Stop M397, 701 E. Joppa Rd., Towson, MD 21286 Phone: (410) 716-3900 / Fax: (410) 847-9329