DeWalt DW866 Instruction Manual
DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286 Printed in U.S.A. (JUN98-CD-1) Form No. 384621-01
DW866 Copyright © 1998
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INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y PÓLIZA
DE GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUCTIVO ANTES
DE USAR EL PRODUCTO.
INSTRUCTION MANUAL
GUIDE D'UTILISATION
MANUAL DE INSTRUCCIONES
DW866
12” (105mm) Cut-off Machine
Machine à tronçonner de 105 mm (12 po)
Máquina cortadora de 105 mm (12”)Máquina cortadora de 105 mm (12”)
384621-01/DW866 1/8/02 2:27 PM Page 3
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 adapter 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.
• Double insulated tools are equipped with a polarized plug (one
blade is wider than the other.) This plug will fit in a polarized
outlet only one way. If the plug does not fit fully in the outlet,
reverse the plug. If it still does not fit, contact a qualified
electrician to install a polarized outlet. Do not change the plug
in any way. Double insulation eliminates the need for the three
wire grounded power cord and grounded power supply system.
• 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.
English
IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS
OR ANY D
EWALT TOOL, CALL US TOLL FREE AT:
1-800-4-DEWALT (1-800-433-9258)
General Safety Rules
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
WARNING: Improper connection of the equipment grounding
conductor can result in the risk of electric shock. Check with a
qualified electrician or service person if you are in doubt as to
whether the outlet is properly grounded. Do not modify the plug
provided with the appliance. If it will not fit the outlet, a proper outlet
must be installed by a qualified electrician.
We recommend that you never disassemble the tool or try to do any
rewiring in the electrical system. Any repairs should be performed
only by authorized service centers. Should you be determined to
make a repair yourself, remember that the green colored wire is the
grounding wire. Never connect this green wire to a live terminal. If
you replace the plug on the power cord, be sure to connect the green
wire only to the grounding (longest) prong on a three-prong plug.
Never remove the grounding prong.
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.
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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 18161614
6 - 10 18 16 14 12
10-1216161412
12 - 16 14 12 Not Recommended
Grounding
This tool should be grounded while in use to protect the operator from
electric shock. The tool is equipped with an approved threeconductor cord and three-prong grounding type plug to fit the proper
grounding type receptacle. The green (or green and yellow)
conductor in the cord is the grounding wire. Never connect the green
(or green and yellow wire to a live terminal.
If your unit is intended for use on less than 150 volts, it has a plug
similar to that shown in Figure A. An adapter, Figures B and C, is
available for connecting Figure A plugs to two-prong receptacles.
The green-colored rigid ear, lug, etc., must be connected to a
permanent ground such as a properly grounded outlet box.
Whenever the adapter is used, it must be held in place by a metal
screw.
ADAPTER SHOWN IN FIGURES B and C IS NOT FOR USE IN
CANADA.
1
English
AB CD
GROUNDING PIN
GROUNDED
OUTLET
BOX
GROUNDING
MEANS
GROUNDING PIN
ADAPTER
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 clothing, jewelry, or long hair can be caught
in moving parts.
• 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 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 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.
• 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
384621-01/DW866 1/8/02 2:27 PM Page 1
• 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 Instructions for
Cut-Off Machine
CAUTION: When cutting into walls, floors or wherever live
electrical wires may be encountered, DO NOT TOUCH ANY METAL
PARTS OF THE TOOL! Hold the tool only by insulated grasping
surfaces to prevent electric shock if you cut into a live wire.
• ALWA YS WEAR EYE PROTECTION WHEN USING THIS T OOL.
• Use of accessories not specified in this manual is not
2
…/min ..............revolutions or reciprocation per minute
....................earthing terminals
....................safety alert symbol
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, changing 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. T ools are dangerous 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 tools
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 maintenance performed by unqualified
personnel could result in a risk of injury.
English
TRIGGER
SWITCH
BRUSH
CAP
FIELD
CASE
BAIL
HANDLE
GUARD
DEPTH
ADJUSTMENT
WING NUT
384621-01/DW866 1/8/02 2:27 PM Page 2
recommended and may be hazardous. Use of power boostersthat
would cause the tool to be driven at speeds greater than its rated
speed constitutes misuse.
• Before attaching any wheel, check its manufacturer’s specifications and be sure that its safe operating speed is higher than
the no-load speed of the tool as shown on the nameplate.
• Before using, inspect each grinding wheel for cracks or flaws. If
such a crack or flaw is evident- discard the wheel. The wheel
should also be inspected whenever you think the tool may have
been dropped. Do not set unit down on wheel.
• When starting the tool (with a new or replacement wheel installed)
hold the tool in a well protected area. Never start the tool with a
person in line with the wheel. This includes the operator.
• In operation, avoid bouncing the wheel or giving it rough treatment.
If this occurs, stop the tool and inspect the wheel.
• Clean your tool out periodically.
• Protect personnel and combustible material in work area from
sparks generated by this tool.
SAVE THESE INSTRUCTIONS
Motor
Be sure your power supply agrees with the nameplate marking.
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.
Controls (Figures 1 and 2)
CAUTION: Grasp tool firmly with both hands before attempting to
start.To start, grasp switch handle firmly and squeeze to depress
trigger. To stop tool, release trigger.
GUARD ADJUSTMENT: Disconnect tool from power supply and be
sure switch is in off position before adjusting guard. Guard may be
adjusted approximately 80˚ by loosening the guard adjustment knob.
3
English
Grasp the guard firmly and rotate to desired angle. Lock in position
by tightening the guard adjustment knob.
NOTE: The two guard mounting screws on each end of the clamp
should not be over-tightened, in order to allow the guard to rotate.
SPINDLE LOCK PIN is used to lock the spindle when changing
accessories. To engage the lock pin, disconnect the tool from the
power supply and be sure switch is in off position. Depress the lock
pin and turn the wheel and spindle until the lock pin engages the
spindle. Use wrench, supplied with the unit, to unscrew the spindle
nut and remove or mount accessories. Spindle and nut have right
hand threads.
NOTE: Slot in wrench handle may be used for additional leverage
when tightening or loosening wing nuts. Wrench is a standard part
furnished with the unit. Shoe can be adjusted to give a 4” maximum
depth of cut.
Operation
1. The tool is supplied with a cord and a 3-prong plug. Compare
voltage marked on nameplate of tool with that of your power supply
before plugging in tool. The voltages must be the same.
2. Before turning on tool, grasp both handles firmly and pick up tool.
Make sure nothing is near or in line with the wheel. Line up wheel
with material to be cut.
3. Turn on unit and feed wheel into work slowly, but with firm
pressure, while keeping the shoe firmly and squarely against the
work. Don not force the tool. For maximum efficiency and wheel
life, keep the wheel speed high.
Depth of Cut
The depth of cut can be adjusted by loosening the two wing nuts on
the outside of the guard. NOTE: The slot in handle of included
wrench may be used for additional leverage when loosening or
tightening the wing nuts.
384621-01/DW866 1/8/02 2:27 PM Page 3
4
TO CUT METALS AND THIN MATERIALS
For minimum operator effort and greatest efficiency when cutting
metals and other thin materials, adjust shoe for maximum depth of
cut (Figure 3).
TO CUT STONE OR MASONRY MATERIALS
For maximum effectiveness, set the wheel exposure to about 1/2”
(13mm)beyond the shoe. For many applications, the material will
readily break along the 1/2” (13mm) deep scored line. If a deeper
cut is needed, increase the depth of cut in approximately 1/2” (13mm)
increments. See Figure 4.
Installing Abrasive Wheels (Figure 5)
1. TURN OFF TOOL AND DISCONNECT FROM POWER SUPPL Y.
2. Lay unit on a firm surface with bottom of shoe facing up.
3. Loosen shoe adjustment wing nuts, bring shoe up to minimum
cutting depth and tighten wing nuts. This step allows more
freedom in removing spindle nut and washers.
4. Using 1 1/8” (28mm) open end wrench (supplied with unit) remove
spindle nut, outer clamp washer and used wheel if one is installed.
Hold spindle from turning with spindle lock pin. Spindle threads
are right hand.
5. Select proper wheel, use only those approved accessories
specified in this manual. Never use wheels rated lower than
nameplate speed of unit.
6. Make sure inner clamp washer is in place and ears are engaged
with spindle flats. Slip wheel through bottom of shoe and slip
wheel over spindle. Be sure wheel goes over pilot diameter. of
inner clamp washer. Slip on outer clamp washer. Start threading
on spindle nut which will self align outer clamp washer. Engage
spindle lock pin and tighten nut with wrench. Do not over tighten
spindle nut.
7. Turn wheel by hand to make sure the wheel is properly centered,
that the wheel does not hit the shoe or guard and nut and that nut
and flanges are tight.
English
Figure 1
Figure 2
BAIL HANDLE
WEAR RING (GEAR CASE
COVER UNDERNEATH)
FIELD
SPINDLE
LOCK PIN
GUARD MOUNTING
SCREWS
GUARD
ADJUSTMEN
T KNOB
GEAR CASE
MOUNTING
SCREWS (4)
TRIGGER
SHOE
GUARD
DEPTH ADJUSTMENT
WING NUTS
384621-01/DW866 1/8/02 2:27 PM Page 4
5
English
Figure 3
Figure 4
YES
NO
NO
YES
METALS OR THIN
MATERIAL
MASONRY
MATERIAL
Applications
1/8” (3mm) max. gauge sheet metal
concrete, cinder blocks and bricks
reinforcing rod- generally under 3/4” (19mm) diameter
1/8”(3mm) diameter concrete wire mesh
corrugated floor and ceiling form (concrete forms)
electrical conduit 1/8” (3mm) wall thickness
1/8” (3mm) max. thick structural forms such as channel, angles,
plate, etc.
NOTE: The cutting of materials heavier than those listed above are
not recommended due to the possibility of electrical overloading.
Conversion From Right Handed to Left
Handed
Operation
NOTE: This machine is assembled at the factory with the spindle on
right side of the unit for right handed operation.
1. TURN OFF TOOL AND DISCONNECT FROM POWER SUPPLY.
2. Place unit on a firm, flat work surface.
3. Remove brush caps and brushes.
4. Remove bail handle by removing guard adjusting knob and hex
bolt.
5. Remove the 4 gear case mounting screws.
6. Remove gear case.
7. Remove wear ring.
8. Pry the gear case cover, with armature attached, from field case.
The armature and gear case cover are one subassembly.
9. IMPORTANT:Notice a flat tab projecting from the gear case cover
and a corresponding recess in the gear case opposite the spindle.
Line up these two features and reassemble the gear case and
cover.
10. Replace the wear ring on the field case.
11.Rotate the field case and switch handle assembly 180˚. Then,
when viewing from the cord end, with the trigger switch down, the
spindle should be on the left side of the unit.
12. Replace the 4 gear case mounting screws.
13. Rotate the guard until the shoe faces in the same direction as the
switch guard. Be sure the guard is on the spindle bearing hub as
far as it will go and tighten guard mounting screws.
14. Replace the bail handle with the bolt and the guard adjusting knob.
15. Replace brushes and brush caps.
Accessories
Recommended accessories for use with your tool are available at
extra cost from your distributor or authorized service center.
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6
CAUTION: The use of any non-recommended accessory may be
hazardous.
Accessory Maximum Safe Speed
Masonry Wheel* 6300 RPM
(Silicon Carbide) 12” Dia. x 1/8” Thick x 1” Hole
Metal Cutting Wheel* 6300 RPM
(Aluminum Oxide) 12” Dia. x 1/8” Thick x 1” Hole
*Internally Reinforced
Cleaning
Blowing dust and grit out of the main housing by means of an air
hose is recommended and may be done as often as dirt is seen
collecting in and around the air vents. The motor should be running
while air is being blown into the vents.
Lubrication
Except for the needle roller bearings used at the upper end of the
spindle, closed-type, grease-sealed ball bearings are used
throughout. These bearings have sufficient lubrication packed in
them at the factory to last the life of the bearing. The needle bearings
mentioned above receive their lubrication from the grease in the gear
case.
Gears should be relubricated every 60 to 90 days, depending upon
use. This lubrication should only be attempted by experienced power
tool repair technicians like the mechanics at B&D service centers.
Brushes
Inspect carbon brushes often. Replace when brushes are worn down
to the identifying groove or when spring exerts insufficient pressure
to hold brush against commutator. Keep brushes clean and sliding
free in brass inserts.
English
Figure 5
SPINDLE NUT
ABRASIVE
WHEEL
OUTER
CLAMP
WASHER
INNER CLAMP
WASHER
WRENCH
SPINDLE
LOCK PIN
384621-01/DW866 1/8/02 2:27 PM Page 6
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