DeWalt D28770 Instruction Manual

INSTRUCTION MANUAL

GUIDE D’UTILISATION

MANUAL DE INSTRUCCIONES

D28770

Heavy Duty Deep Cut Variable Speed Band Saw

Scie à ruban à vitesse variable de service intensif pour coupes profondes

Sierra de banda para trabajo pesado, de velocidad variable para cortes profundos

INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y PÓLIZA

DE GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUCTIVO ANTES

DE USAR EL PRODUCTO.

Questions? See us on the World Wide Web at www.dewalt.com

DEWALTIndustrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286

(APR04) Form No. 624781-00 D28770 Copyright © 2004

The following are trademarks for one or more DEWALTpower tools: the yellow and black color scheme; the “D” shaped
air intake grill; the array of pyramids on the handgrip; the kit box configuration; and the array of lozenge-shaped humps
on the surface of the tool.

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL,
CALL US TOLL FREE AT:

1-800-4-DEWALT (1-800-433-9258)

General Safety Instructions

WARNING! Read and understand 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 acci-

dents.

• 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

• Grounded tools must be plugged into an outlet properly installed and grounded in
accordance with all codes and ordinances. Never remove the grounding prong or
modify the plug in any way. Do not use any adaptor plugs. Check with a qualified
electrician if you are in doubt as to whether the outlet is properly grounded. If the

tools should electrically malfunction or break down, grounding provides a low resistance
path to carry electricity away from the user.

• Avoid body contact with grounded surfaces such as pipes, radiators, ranges and
refrigerators. There is an increased risk of electric shock if your body is grounded.

• Don’t expose power tools to rain or wet conditions. Water entering a power tool will
increase the risk of electric shock.

• Do not abuse the cord. Never use the cord to carry the tools or pull the plug from an

outlet. Keep cord away from heat, oil, sharp edges or moving parts. Replace dam­aged cords immediately. Damaged cords increase the risk of electric shock.

• When operating a power tool outside, use an outdoor extension cord marked “W-A”
or “W.” These cords are rated for outdoor use and reduce the risk of electric shock. When

using an extension cord, be sure to use one heavy enough to carry the current your prod­uct will draw. 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 cord
length and nameplate ampere rating. If in doubt, use the next heavier gage. The smaller
the gage number, the heavier the cord.

Minimum Gage for Cord Sets

Volts Total Length of Cord in Feet

120V 0-25 26-50 51-100 101-150
240V 0-50 51-100 101-200 201-300

Ampere Rating

More Not more AWG
Than Than

0-6 18 16 16 14
6 - 10 18 16 14 12

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 per-

sonal injury.

• Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your
hair, clothing, and gloves away from moving parts. Loose clothing, jewelry, or long hair
can be caught in moving parts. Air vents often cover moving parts and should also be
avoided.

• Avoid accidental starting. Be sure switch is off before plugging in. Carrying tools with
your finger on the switch or plugging in tools that have the switch on invites accidents.

• Remove adjusting keys or wrenches before turning the tool on. A wrench 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 bal-
ance enables 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. Any tool that cannot be controlled
with the switch is dangerous and must be repaired.

• Disconnect the plug from the power source before making any adjustments, chang-
ing accessories, or storing the tool. Such preventative safety measures reduce the risk
of starting the tool accidentally.

• Store idle tools out of reach of children and other untrained persons. Tools are dan-

gerous in the hands of untrained users.

• Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained

tools, with sharp cutting edges 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 become hazardous when used on
another tool.

SERVICE

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

tenance performed by unqualified personnel could 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 electric shock or injury.

Additional Safety Rules - Portable Band Saws

• Hold tool by insulated gripping surfaces when performing an operation where the
cutting tool may contact hidden wiring. Contact with a “live” wire will make exposed

metal parts of the tool “live” and shock the operator.

• Keep hands away from cutting area and blade. Keep one hand on the main handle and
the other hand on the front handle to prevent loss of control which could result in personal
injury.

• Always make sure the portable band saw is clean before using

• Always cease operation at once if you notice any abnormality whatsoever.

• Always be sure all components are mounted properly and securely before using tool.

• Always handle the band saw blade with care when mounting or removing it.

• Always keep your hands out of the line of the band saw blade.

• Always wait until the motor has reached full speed before starting a cut.

• Always keep handles dry, clean, and free of oil and grease. Hold the tool firmly when in use.

• Always be alert at all times, especially during repetitive, monotonous operations. Always be
sure of position of your hands relative to the blade.

• Never remove material guide.

• Stay clear of end pieces that may fall after cutting off. They may be hot, sharp and/or heavy.
Serious personal injury may result.
WARNING: DO NOT modify and/or use this tool for any application other than for which it

was designed.

WARNING: Exercise extreme caution when cutting blind into conduit and pipe. Be sure the

object being cut does not contain electrical wires, gases, or water, etc., which could create haz­ardous conditions causing personal injury and property damage.

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

struction 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).
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.

• Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling,

and other construction activities. 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 absorption of harmful chemicals.
WARNING: Use of this tool can generate and/or disburse dust, which may cause serious

and permanent respiratory or other injury. Always use NIOSH/OSHAapproved respiratory pro­tection appropriate for the dust exposure. Direct particles away from face and body.

• The label on your tool may include the following symbols. The symbols and their definitions

are as follows:

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 per minute

sfpm ........surface feet per minute

SAVE THESE INSTRUCTIONS

COMPONENTS (FIG. 1, 2)

A. Auxiliary handle I. Speed knob
B. Sight light J. Rubber bumpers
C. Trigger switch K. Hang hook
D. Main handle L. Pulley
E. Material guide M. Blade guard
F. Guide rollers N. Rubber tires
G. Guide roller adjustment O. Blade
H. Blade tension lever P. Sight light switch

ASSEMBLY
Blades

This portable band saw is setup for use with .020" (0.5 mm) thick, 1/2" (12.5 mm) wide and
44-7/8" (1140 mm) long blades. To use .025 (.64 mm) thick blades, please contact an author­ized D

EWALT service center.

CAUTION: The use of any other blade or accessory might be hazardous. DO NOT use any

other type of accessory with your band saw. Blades used on stationary band saws are of
different thickness. Do not attempt to use them on your portable unit.

Blade Selection

In general, first consider the size and shape of the work, and the type of material to be cut.
Remember, for the most efficient cutting, the coarsest tooth blade possible should be used in a
given application, because the coarser the tooth, the faster the cut. In selecting the appropriate
number of teeth per inch of the band saw blade, at least two teeth should contact the work sur­face when the blade is rested against the workpiece. As a rule of thumb, soft materials usually
require coarse tooth blades, while hard materials require fine tooth blades. Where a smoother
finish is important, select one of the finer tooth blades.
Select the appropriate band saw blade according to the material type, dimensions, and num­ber of teeth. See Blade Description chart.

CAUTION: The following table is intended as a general guide only. Determine the type of

material and dimension of the workpiece and select the most appropriate band saw blade.

CAUTION: Never use the band saw to cut resin materials which are subject to melting.

Melting of resin material caused by high heat generated during cutting may cause the band saw
blade to become bound to the material, possibly resulting in overload and burn-out of the motor.

Blade Speed

Your D28770 portable band saw is equipped with variable speed for greater versatility.
Turn the speed knob (I) to select the desired speed (Fig. 1).
When cutting copper, brass, bronze, aluminum, cast iron, angle iron, and mild steel, use a
higher speed. Rotate the speed knob to a higher speed

.

When cutting plastic pipe, tougher steels, chrome steel, tungsten steel, stainless steel, and
other problem materials, use low speed. Rotate the speed knob to a lower speed.
NOTE: When cutting plastic pipe, higher speeds may melt plastic.

Removing and Installing Blades

CAUTION: Turn off and unplug the tool before making any adjustments or removing/

installing attachments or accessories.

CAUTION: Blade tension lever is under spring pressure. Maintain control of lever when

releasing blade tension.

TO REMOVE BLADE (FIG. 1, 2)

1. Rotate the blade tension lever (H) clockwise until it stops to release tension in blade.

2. Turn the saw over and place it on a workbench or table with the cord to the left.

3. Begin removing the blade at the blade guard (M) and continue around the pulleys (L).
When removing the blade, tension may be released and the blade may spring free. SAW
BLADES ARE SHARP. USE CARE IN HANDLING THEM.

BLADE DESCRIPTION

Type of band saw blade Bi-Metal

Number of teeth 24 18 14 10 14/18 10/14

Workpiece thickness

1/8" and under • •

1/8"- 1/4" • •

1/4" - 13/32" • •

13/32" and over •

624781-00,D28770 4/15/04 4:24 PM Page 1

4. Inspect the guide rollers (F1, F2) and remove any large chips which may be lodged in
them. Lodged chips can prevent rotation of the guide rollers and cause flat spots on the
guide rollers.

5. Rubber tires (N) are mounted on the pulleys (L). The rubber tires should be inspected for
looseness or damage when changing the blade. Wipe any chips from the rubber tires on
the pulleys. This will extend tire life and keep the blade from slipping. If any looseness or
damage occurs, the tool should be brought to an authorized D

EWALT service center for

repair or replacement as soon as possible. Continued use of the tool with loose or dam­aged rubber tires will cause unstable travel of the band saw blade.

TO INSTALL BLADE

1. Position the blade so that the teeth are on the bottom and angled toward the material
guide, as shown in Figures 1 and 3.

2. Slip the blade into the guide rollers, as shown in Figure 4.

3. Holding the blade in the guide rollers, place it around both pulleys (L) and through the
material guide (E), as shown in Figure 5.

4. Make sure that the blade is fully inserted into the guide rollers and positioned squarely
against the rubber tires.

5. Gently turn the saw over so that the pulleys rest on your work bench or table and rotate
the blade tension lever (H) counterclockwise until it stops. Make sure the teeth face away
from the bandsaw (Fig. 1, 3).

6. Turn the saw on and off a few times to ensure that the blade is seated properly.

Adjustments

CAUTION: Turn off and unplug the tool before making any adjustments or

removing/installing attachments or accessories.

MATERIAL GUIDE ADJUSTMENT

To support large workpieces, the material guide should be lowered following these steps:

1. Loosen the two M6 screws (Q), shown in Figure 1, with the Allen wrench provided.

2. Move the material guide (E) to the desired position (Fig 5).

3. Securely tighten M6 screws.

LOCATION ADJUSTMENT OF GUIDE ROLLERS - for straighter cuts of smaller pieces

For straight cuts on smaller pieces, adjust the guide rollers using the following steps:

1. Loosen 14mm bolt (G).

2. Move the front guide roller (F1) closer to the material.

3. Tighten 14mm bolt.

OPERATION
Motor

Be sure your power supply agrees with the voltage marked on the nameplate. 120 Volts AC
60Hz means alternating current only. Voltage decrease of more than 10% will cause loss of
power and overheating. All D

EWALT tools are factory-tested. If this tool does not operate,

check the power supply line for blown fuses and the plug and receptacle for proper contact.
There are certain applications for which this tool was designed.
This band saw is designed to cut various types of material up to 4-3/4" (120.7 mm) diameter
or 4-3/4" (120.7 mm) x 4-3/4" (120.7 mm) rectangular shape at 90˚.

WARNING: Thoroughly remove any oil or grease from the workpiece before securing in a

vise or other clamping device. If the workpiece is not secure, it may come loose during the cut­ting and/or cause breakage, which may result in serious personal injury.

WARNING: Never connect the power tool unless the available AC power is of the same

voltage as that specified on the nameplate of the tool. Never connect this power tool to a DC
power source.

WARNING: If the power cord is connected to the power source with the trigger switch

turned ON the power tool will start suddenly and could cause a serious accident.

Trigger Switch

To start the tool, squeeze the trigger switch (C). To turn the tool off, release the switch.

Cutting

CAUTION: Refer to Figure 9 for recommended cutting positions for various materials.

NOTE: Select and use a band saw blade that is most appropriate for the material being cut.

See Blade Description.
This portable band saw may be hung using the hang hook (K). Hang tool on a pipe vice or
other suitable, stable structure. (Fig. 2)

1. Mount the material to be cut solidly in a vise or other clamping device. Never attempt to
use this tool by resting it on a work surface and bringing the material to the tool. Always
securely clamp the workpiece and bring the tool to the workpiece, securely holding the tool
with two hands as shown in Figure 6.

2. If additional light is needed, a sight light (B) can be activated using the sight light switch (P)
as shown in Figure 1. If replacement is required, return to an authorized service center or
other qualified service personnel, always using identical replacement parts.

3. Bring the material guide (E) into contact with the workpiece. Turn the saw ON.

4. When saw reaches desired rotation speed, slowly and gently tilt the main body of the tool
to bring the band saw blade into contact with the workpiece. Do not apply additional pres­sure in excess of the weight of the main body of the tool. Carefully avoid bringing the band
saw blade suddenly and heavily into contact with the upper surface of the workpiece. This
will cause serious damage to the band saw blade. To obtain maximum service life of the
band saw blade, ensure there is no sudden impact at the beginning of the cutting operation.

5. As shown in Figures 6 and 7, straight cutting can be accomplished by keeping the band
saw blade aligned with the side surface of the motor housing. Any twisting or cocking of
the blade will cause the cut to go offline and decrease the life of the blade.

A

B

D

E

F1

I

H

G

BLADE

DIRECTION

DIRECTION DE

LA LAME

DIRECCIÓN DE

LA HOJA

C

L

J

A

D

L

E

K

FIG 4

FIG. 8

Item Model D28770

Motor Type Protected type, series commutator motor

Power source single-phase, AC 60Hz
Voltage 120 volts
Full-load current 6 amp

Band Saw Dimensions 1/2" x 44-7/8" x .020" (12.5 mm x 1140 mm x .5 mm)

Blade Peripheral speed 80 - 280 ft/min (25-85 m/min)
Max. Cutting Pipe outer dimensions 4-3/4" (120,7 mm)
Dimensions Stock 4-3/4" x 4-3/4" (120,7 mm x 120,7 mm)

Net Weight 15 lbs. (6.8 kg)

Cord 3 conductor type captive cable 8.0 ft. (2.4 m)

FIG. 1

FIG. 2

FIG. 5

J

O

P

M

N

Q

LOOSEN

DESSERRER

AFLOJE

E

BLADE DIRECTION
DIRECTION DE LA LAME
DIRECCIÓN DE LA HOJA

R

YES / OUI / SÍ

NO / NON / NO

FIG. 9

RECOMMENDED CUTTING POSITIONS / POSITIONS DE COUPE
RECOMMANDÉES / POSICIONES DE CORTE RECOMENDADAS

FIG. 6 FIG. 7

D

F2

PROPER FILL LEVEL / NIVEAU DE REMPLISSAGE APPROPRIÉ /

NIVEL DE LLENADO CORRECTO

POSITION OF TEETH ON LEFT SIDE OF MACHINE

POSITION DES DENTS DU CÔTÉ GAUCHE, SUR

LE CÔTÉ DE LA MACHINE

POSICIÓN DE LOS DIENTES SOBRE LADO

IZQUIERDO DEL COSTADO DE LAMÁQUINA

Article Modèle D28770
Moteur Type Type protégé, série moteur à collecteur

Circuit d’alimentation électrique monophasé, c.a., 60Hz
Tension 120 volts
Courant de pleine charge 6 A

Lame de scie Dimensions 12,5 mm x 1 140 mm x 0,5 mm

à ruban (1/2 po x 44-7/8 po x .020 po)

Vitesse périphérique 25 à 85 m/min (80 à 280 pi/min)

Dimensions Dimensions externes du tuyau 120,7 mm (4-3/4 po)

maximales Matériau à couper 120,7 mm x 120,7 mm

de la coupe (4-3/4 po x 4-3/4 po)

Poids net 6,8 kg (15 lb)

Cordon Fiche à 3 broches et à 3

conducteurs de 2,4 m (8,0 pi))

Artículo Modelo D28770

Motor Tipo Motor conmutador en serie, tipo protegido

Fuente de alimentación CA 60 Hz, monofásica
Voltaje 120 voltios
Corriente a plena carga 6 amperios

Hoja de la sierra Dimensiones 12,5 mm x 1 140 mm x 0,5 mm

de banda (1/2 pulg. x 44-7/8 pulg. x .020 pulg.)

Velocidad periférica 25 - 85 m/min (80 - 280 pies/min)

Dimensiones Dimensiones exteriores

máximas de de tubería 120,7 mm (4-3/4 pulg.)

corte Material a cortar 120,7 x 120,7 mm (4-3/4 x 4-3/4 pulg.)

Peso neto 6,8 kg (15 lb.)

Cable Cable cautivo de 3 conductores, de 2,4 m

(8,0 pies) de largo

YES / OUI / SÍ

YES / OUI / SÍYES / OUI / SÍ

YES / OUI / SÍ

YES / OUI / SÍ

NO / NON / NO

NO / NON / NO

NO / NON / NO

NO / NON / NO

NO / NON / NO

FIG. 3

624781-00,D28770 4/15/04 4:24 PM Page 2