Black & decker MT1203 INSTRUCTION MANUAL

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 sparks, burns, or a fire.

• Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools,
with sharp cutting edge are less likely to bind and are easier to control.

• Check for misalignment or binding of moving parts, breakage of parts, and any other
condition that may affect the tool’s operation. If damaged, have the tool serviced
before using. Many accidents are caused by poorly maintained tools.

• Use only accessories that are recommended by the manufacturer for your model.

Accessories that may be suitable for one tool may create a risk of injury when used on
another tool.

Service

• Tool service must be performed only by qualified repair personnel. Service or

maintenance performed by unqualified personnel may result in a risk of injury.

• When servicing a tool, use only identical replacement parts. Follow instructions in the
Maintenance section of this manual. Use of unauthorized parts or failure to follow

Maintenance Instructions may create a risk of shock or injury.

SPECIFIC SAFETY RULES

• Hold tool by insulated gripping surfaces when performing an operation where the

cutting tool may contact hidden wiring or its own cord. Contact with a "live" wire will

make exposed metal parts of the tool "live" and shock the operator.

• KEEP HANDS AWAY from cutting area. Never reach underneath the material for any rea-

son. Hold front of saw by grasping the contoured gripping area. Do not insert fingers or thumb
into the vicinity of the reciprocating blade and blade clamp. Do not stabilize the saw by grip­ping the shoe.

• KEEP BLADES SHARP. Dull blades may cause the saw to swerve or stall under pressure.

WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other

construction activities contains chemicals known 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. (CCA)

Y our 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.

The label on your tool may include the following symbols.

V ..........................volts A..........................amperes

Hz ........................hertz W ........................watts

min........................minutes ......................alternating current

......................direct current

n

o........................no load speed

..........................

Class II Construction

........................earthing terminal

........................safety alert symbol .../min ..................revolutions or

reciprocations
per minute

SAFETY WARNINGS AND INSTRUCTIONS: CHARGING THE BATTERY

1. This manual contains important safety and operating instructions.

2. Before using battery charger, read all instructions and cautionary markings on (1) battery

charger, (2) battery, and (3) product using battery.

3. CAUTION: To reduce the risk of injury, charge only Black & Decker Power Packs.

Other types of batteries may burst causing personal injury and damage.

4. Do not expose charger to rain or snow.

5. Use of an attachment not recommended or sold by Black & Decker may result in a risk of

fire, electric shock, or injury to persons.

6. To reduce risk of damage to electric plug and cord, pull by plug rather than cord when dis-

connecting charger.

7. Make sure cord is located so that it will not be stepped on, tripped over, or otherwise sub-

jected to damage or stress.

8. An extension cord should not be used unless absolutely necessary. Use of improper

extension cord could result in a risk of fire, electric shock or electrocution.

a. Two-wire cords can be used with 2-wire or 3-wire extension cords. Only round jacketed

extension cords should be used, and we recommend that they be listed by Underwriters
Laboratories (U.L.). If the extension is to be used outside, the cord must be suitable for
outdoor use. Any cord marked for outdoor use can also be used for indoor work. The let­ters "W" or "WA" on the cord jacket indicate that the cord is suitable for outdoor use.

b. An extension cord must have adequate wire size (AWG or American Wire Gauge) for

safety, and to prevent loss of power and overheating. 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. When using more than one extension to make up the total length, be sure each
extension contains at least the minimum wire size.

CHART FOR MINIMUM WIRE SIZE (AWG)OF EXTENSION CORDS

NAMEPLATE RATING AMPS – 0 – 10.0

Total Extension Cord Length (ft) 25 50 75 100 125 150
Wire Gauge 18 18 16 16 14 14

CAT. NO. MT1203 FORM NO. 397362-00 PRINTED IN CHINA (AUG 00)

KEY INFORMATION YOU SHOULD KNOW :

• Charge battery full cycle before first use.

• Charger may hum; battery or charger may become warm while charging.

VEA EL ESPAÑOL EN LA CONTRAPORTADA.

SAVE THIS MANUAL FOR FUTURE REFERENCE.

INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y
PÓLIZADE GARANTÍA. ADVERTENCIA: LÉASE ESTE
INSTRUCTIVO ANTES DE USAR ELPRODUCTO.

CATALOG NUMBER

MT1203

INSTRUCTION MANUAL

GENERAL SAFETY RULES - FOR ALL BATTERY OPERATED TOOLS

WARNING! READ AND UNDERST AND ALL INSTRUCTIONS.

Failure to follow all instructions listed below, may result in electric shock, fire and/or serious

personal injury.

SAVE THESE INSTRUCTIONS

Work Area

• Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents.

• 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.

• Keep bystanders, children, and visitors away while operating a power tool.

Distractions can cause you to lose control.

Electrical Safety

• Do not abuse the cord. Never use the cord to carry the tool. Keep cord away from
heat, oil, sharp edges or moving parts. Replace damaged cords immediately.

Damaged cords may create a fire.

• A battery operated tool with integral batteries or a separate battery pack must be
recharged only with the specified charger for the battery. Acharger that may be suitable

for one type of battery may create a risk of fire when used with another battery.

• Use battery operated tool only with specifically designated battery pack. Use of any
other batteries may create a risk of fire.

Personal Safety

• Stay alert, watch what you are doing and use common sense when operating a power
tool. Do not use tool while tired or under the influence of drugs, alcohol, or
medication. A moment of inattention while operating power tools may result in serious

personal injury,

• Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your
hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair

can be caught in moving parts.

• Avoid accidental starting. Be sure switch is in the locked or off position before
inserting battery pack. Carrying tools with your finger on the switch or inserting the battery

pack into a tool with the switch on invites accidents.

• Remove adjusting keys or wrenches before turning the tool on.Awrench or a key that is
left attached to a rotating part of the tool may result in personal injury.

• Do not overreach. Keep proper footing and balance at all times. Proper footing and
balance enable better control of the tool in unexpected situations.

• Use safety equipment. Always wear eye protection. Dust mask, non-skid safety shoes,
hard hat, or hearing protection must be used for appropriate conditions.

Tool Use and Care

• 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.

• Do not force tool. Use the correct tool for your application. The correct tool will do the
job better and safer at the rate for which it is designed.

• Do not use tool if switch does not turn it on or off.Atool that cannot be controlled with the
switch is dangerous and must be repaired.

• Disconnect battery pack from tool or place the switch in the locked or off position
before making any adjustments, changing accessories, or storing the tool. Such

preventive safety measures reduce the risk of starting the tool accidentally.

• Store idle tools out of reach of children and other untrained persons. Tools are
dangerous in the hands of untrained users.

• When battery pack is not in use, keep it away from other metal objects like: paper

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RELEASE BUTTON

BOUTON DE

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FORWARD/REVERSE

BUTTON

BOUTON DE COMMANDE

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4

TORQUE
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COLLIER DE

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6

7

LOCK OFF BUTTON

BOUTON DE VERROUILLAGE EN

POSITION D’ARRÊT

TRIGGER SWITCH

INTERRUPTEUR À GÂCHETTE

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9. Use only the supplied charger when charging your tool. The use of any other charger

could damage the battery or create a hazardous condition.

10.Use only one charger when charging.

11. Do not attempt to open the charger. There are no customer serviceable parts inside.

Return to any authorized Black & Decker service center.

12.DO NOT incinerate the battery packs even if they are severely damaged or completely

worn out. The batteries can explode in a fire.

13. A small leakage of liquid from the battery cells may occur under extreme usage, charg-

ing or temperature conditions. This does not indicate a failure. However, if the outer seal

is broken and this leakage gets on your skin:
a. Wash quickly with soap and water.
b. Neutralize with a mild acid such as lemon juice or vinegar.
c. If the battery liquid gets in your eyes, flush them with clean water for a minimum of 10

minutes and seek immediate medical attention. MEDICAL NOTE: The liquid is a 25-35%

solution of potassium hydroxide.

CHARGING THE POWER PACK

THE BATTERIES IN YOUR POWER PACK ARE NOT FULLY CHARGED AT THE
FACTORY. BEFORE ATTEMPTING TO CHARGE THEM, THOROUGHLY READ ALL OF
THE SAFETY INSTRUCTIONS.

The 3 hour charger is designed to use standard household 120 volt 60 Hz power.

1. Plug the charger into any standard 120 Volt 60 Hz electrical outlet.

2. Insert the power pack into the charger as shown in Figure 1. While charging, your battery

pack may become warm to the touch; this is normal.

3. Remove pack from the charger and place in tool as shown in Fig. 2. NOTE: To remove

the battery from the tool, press in on the release buttons on both sides of the battery and

pull out.

IMPORTANT CHARGING NOTES

1. After normal usage, your power pack should be fully charged in 3 hours or less. If the

power pack is run-down completely, it may take up to 6 hours to become fully charged.

Your power pack was sent from the factory in an uncharged condition. Before attempting

to use it, it must be charged for at least 3 hours.

2. DO NOT charge the power pack in an air temperature below 40°F or above 105°F. This

is important and will prevent serious damage to the power pack. Longest life and best per-

formance can be obtained if the power pack is charged when the air temperature is about

75°F.

3. While charging, the charger may hum and become warm to touch. This is a normal con-

dition and does not indicate a problem.

4. If the power pack does not charge properly—(1) Check current at receptacle by plugging

in a lamp or other appliance. (2) Check to see if receptacle is connected to a light switch

which turns power off when you turn out the lights. (3) Move charger and power pack to

a surrounding air temperature of 40°F to 105°F. (4) If the receptacle and temperature are

OK, and you do not get proper charging, take or send the power pack and charger to your

local Black & Decker service center. See Tools Electric in yellow pages.

5. The power pack should be recharged when it fails to produce sufficient power on jobs

which were easily done previously. DO NOT CONTINUE using saw with its power pack

in a depleted condition.

O

6. T o prolong power pack life, avoid leaving the power pack on charge for more than 8 hours.

Although overcharging is not a safety concern, it can significantly reduce overall power

pack life.

7. When the battery is inserted into the charger, the red “Charging Indicator” light will come

on indicating that there is contact between the battery and charger. The light will stay on

as long as the battery is in the charger and the charger is plugged into a working outlet. It

WILL NOT flash, go out or change to a different color when the charging cycle is

complete.

PERATION

OPERATION

FITTING AND REMOVING INTERCHANGEABLE TOOL HEADS

Note: Ensure the forward / reverse switch is in the center (lock off) position.

To install a tool head, align the arrows on both the tool head and the power unit and insert
the head until it clicks into place as shown in Fig. 3. To remove, press the release button and
pull the tool head off. Remove battery from power unit and all accessories from tool

heads before removing or installing.
VARIABLE SPEED CONTROL

The power unit has a variable speed switch. The more the trigger switch is depressed the
higher the speed of the attached head. Note: Trigger does not work when there is no head
attached.

TRIGGER SWITCH & FORWARD / REVERSE / LOCK BUTTON

A forward / reverse control button determines the direction of the tool and also serves as a
lock off button. To select forward rotation, release the trigger switch and depress the forward
/ reverse control button as shown in Figure 4. To select reverse, depress the forward /
reverse control button the opposite direction. The center position of the control button locks
the tool in the off position. Note: For greatest efficiency, always use sander and saw in for­ward position.

DRILLING

Note: Ensure the forward / reverse switch is in the center (lock off) position.

KEYLESS CHUCK

To insert a drill bit or other accessory:

1. Grasp the rear half of the chuck with one hand and use your other hand to rotate the front
half in the counterclockwise direction, (Fig. 5).

2. Insert the bit or other accessory fully into the chuck, and tighten securely by holding the
rear half of the chuck and rotating the front portion in the clockwise direction as viewed from
the chuck end.

WARNING:Do not attempt to tighten drill bits (or any other accessory) by gripping the front
part of the chuck and turning the tool on. Damage to the chuck and personal injury may occur
when changing accessories.

TORQUE CONTROL

The torque adjustment collar shown in Fig. 4 has 24 settings. There are 23 screwdriving set­tings and a drilling setting which is represented by the drill bit symbol. For screwdriving pro­ceed as follows:

Set the torque adjustment to position “1”. Fit and tighten the first screw. If the clutch of your
drill starts to ratchet before the screw is correctly seated, rotate the adjustment collar as nec­essary, until the clutch slips when the head of the screw is flush with the surface of the mate­rial. Use this torque setting for the rest of the screws.

DRILLING TIPS

Always remove batteries from drill when attaching or removing accessories. When using a
keyless chuck, hand tighten firmly.

• Use sharp drill bits only.

• Support and secure work properly, as instructed in the Safety Instructions.

• Use appropriate and required safety equipment, as instructed in the Safety Instructions.

• Secure and maintain work area, as instructed in Safety Instructions.

• Run the drill very slowly, using light pressure, until the hole is started enough to keep the drill

bit from slipping out of it.

• Apply pressure in a straight line with the bit. Use enough pressure to keep the bit biting but

not so much as to stall the motor or deflect the bit.

• Hold the drill firmly to control its twisting action..

• DO NOT CLICK THE TRIGGER OF A STALLED DRILLOFF AND ON IN AN ATTEMPT TO

START IT. DAMAGE TO THE DRILL CAN RESULT.

• Minimize stalling on breakthrough by reducing pressure and slowly drilling through the last

part of the hole.

• Keep the motor running while pulling the bit out of a drilled hole. This will help reduce jam-

ming.

• Use a cutting lubricant when drilling metals. The exceptions are cast iron and brass which

should be drilled dry. The lubricants that work best are sulphurized cutting oil or lard oil.
Bacon grease will also serve.

• When using twist drill bits to drill holes in wood, it will be necessary to pull the bits out fre-

quently to clear chips from the flutes.

• Make sure switch turns drill on and off.

WARNING: It is important to support the work properly and to hold the drill firmly to pre-

vent loss of control which could cause personal injury.

SAWING

Note: Ensure the forward / reverse switch is in the center (lock off) position.

INSTALLING BLADES

Your jig saw uses the Quick Clamp™ blade changing system. To install a blade, lift the Quick
Clamp™ lever (Figure 6). Insert the saw blade shank fully into the blade clamp. Release the
lever and the blade will be clamped securely in place. The back of the blade should be just
touching the roller support guide. Ensure the blade teeth are facing forward.

ROLLER SUPPORT GUIDE

The roller support guide on your jig saw improves its performance when cutting tough mate­rials by adding support to the blade. Lubricating the guide roller with a drop of oil from time
to time will extend the roller life.

USING THE JIG SAW

The jig saw is equipped with a lock off switch. To start the saw, first depress the lock off but­ton shown in Fig. 7 followed by the trigger switch (Fig.4) You can then release the lock off
button.

SHOE ADJUSTMENT FOR ANGLE CUTTING

The shoe plate can be angled to 45º on one side. To do this, first loosen the screw at the base
of the saw head until the shoe can freely move. The shoe should then be repositioned in the
forward slot and the screw retightened. To reset the shoe to a square cut, loosen the clamp
screw and move the shoe so that the clamp screw is against the rear of the slot. Retighten
clamp screw.

GENERAL CUTTING

Be sure material is firmly secured. Don’t attempt to turn on the unit when blade is against
material to be cut. This could stall the motor. Place front of shoe on material to be cut and
hold jig saw shoe down firmly against the work surface while cutting. Don’t force the tool; let
the blade cut at its own speed. Whenever possible, clamp or support work close to the line
of cut; when the cut is completed, shut off power and lay the tool aside before loosening the
work.

METAL & PLASTIC CUTTING

In cutting thin gauge sheet metals, it is best to clamp wood or plywood to the bottom of the
metal sheet; this will insure a clean cut without the danger of vibration or tearing of metal.
Use a fine-tooth blade for ferrous metals (for those that have an iron content); and use a
coarser blade for nonferrous metals (those that do not have an iron content).

Cutting thin metal will take longer than cutting relatively thick wood so do not be tempted to
speed up the process by forcing the saw. Spread a thin film of cutting lubricant along the cut­ting line, (any light weight oil). Use low speeds for cutting metals, plastics and composition
tile. When cutting laminated plastic, place the finished side down and use a fine tooth hollow
ground blade.

POCKET CUTTING

• Measure the surface to be cut and mark clearly with a pencil. Next tip the saw forward until

the front edge of the shoe sits firmly on the work surface.

• Switch the tool on and allow it to attain maximum speed.

• Grip the handle firmly and lower the back edge of tool until the blade cuts smoothly into

material. Always be sure blade reaches its complete depth before starting to cut.

SANDING

Note: Ensure the forward / reverse switch is in the center (lock off) position.

ATTACHING SANDPAPER

The sander uses pre-cut nylon backed sheets of abrasive of a specific size. To fit the abra­sive, align the it with the sanding pad and press it firmly in place.

Ensure the abrasive evenly overlaps the base. Never use your sander without an abrasive or
accessory. The abrasive supplied with your tool has two replacement tips. This design allows
you to interchange and or rotate the diamond tips. To rotate the tip, remove it from the pad,
rotate it 180º and press it back on the hook base. Note: Remove the two replacement tips
from the abrasive before use, these can be used later when the original diamond tip wears.

SANDING LEAD BASED PAINT

Sanding of lead based paint is NOT RECOMMENDED due to the difficulty of controlling the
contaminated dust. The greatest danger of lead poisoning is to children and pregnant
women.

Since it is difficult to identify whether or not a paint contains lead without a chemical analy­sis, we recommend the following precautions when sanding any paint:

PERSONAL SAFETY

• No children or pregnant women should enter the work area where the paint sanding is

being done until all cleanup is completed.

• A dust mask or respirator should be worn by all persons entering the work area. The filter
should be replaced daily or whenever the wearer has difficulty breathing.

• Note: Only those dust masks suitable for working with lead paint dust and fumes should be
used. Ordinary painting masks do not offer this protection. See your local hardware dealer
for the proper (NIOSH approved) mask.

• NO EA TING, DRINKING or SMOKING should be done in the work area to prevent ingesting
contaminated paint particles. Workers should wash and clean up BEFORE eating, drinking
or smoking. Articles of food, drink, or smoking should not be left in the work area where dust
would settle on them.

ENVIRONMENTAL SAFETY

• Paint should be removed in such a manner as to minimize the amount of dust generated.

• Areas where paint removal is occurring should be sealed with plastic sheeting of 4 mils

thickness.

• Sanding should be done in a manner to reduce tracking of paint dust outside the work area.

CLEANING AND DISPOSAL

• All surfaces in the work area should be vacuumed and thoroughly cleaned daily for the

duration of the sanding project. Vacuum filter bags should be changed frequently.

• Plastic drop cloths should be gathered up and disposed of along with any dust chips or
other removal debris. They should be placed in sealed refuse receptacles and disposed of
through regular trash pick-up procedures. During cleanup, children and pregnant women
should be kept away from the immediate work area.

• All toys, washable furniture and utensils used by children should be washed thoroughly
before being used again.

ACCESSORIES

Recommended accessories for use with your tool are available from your local dealer or
authorized service center. If you need assistance regarding accessories, please call:

1-800-54-HOW-TO. (800-544-6986)

WARNING: The use of any accessory not recommended for use with this tool could be

hazardous.

IMPORTANT: To assure product SAFETY and RELIABILITY, repairs, maintenance and
adjustment should be performed by authorized service centers or other qualified service
organizations, always using identical replacement parts

THE RBRC™ SEAL

The RBRC™ (Rechargeable Battery Recycling Corporation)
Seal on the nickel-cadmium battery (or battery pack) indicates that the costs to recy­cle the battery (or battery pack) at the end of its useful life have already been paid
by Black & Decker. In some areas, it is illegal to place spent nickel-cadmium batter­ies in the trash or municipal solid waste stream and the RBRC program provides an envi­ronmentally conscious alternative.

RBRC in cooperation with Black & Decker and other battery users, has established programs
in the United States and Canada to facilitate the collection of spent nickel-cadmium batter­ies. Help protect our environment and conserve natural resources by returning the spent
nickel-cadmium battery to an authorized Black & Decker 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, or call 1-800-8-BATTERY.

SERVICE INFORMATION

Black & Decker offers a full network of company-owned and authorized service locations
throughout North America. All Black & Decker Service Centers are staffed with trained per­sonnel to provide customers with efficient and reliable power tool service.

Whether you need technical advice, repair, or genuine factory replacement parts, contact the