DeWalt DW896 TYPE 2 Owner’s Manual

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DEWALT Industrial Tool Co,, 701 East Joppa Road, Baltimore, MD 21286

The following are trademarks for one or more DEWALT power 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,

Definitions: Safety Guidelines

The definitions below describe the level of severity for each signal word.

Please read the manual and pay attention to these symbols. ADANGER: Indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury. _WARNING: Indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury. _CAUTION: Indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate injury. CAUTION: Used without the safety alert symbol indicates a poten-

tially hazardous situation which, if not avoided, may result in property

damage.

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 Rules - For All Tools

A WARNING! Read all instructions. Failure to follow all instructions listed below

may result in electric shock, fire and/or serious injury. The term "power tool" in all of the warnings listed below refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool

SAVE THESE INSTRUCTIONS

1) WORK AREA SAFETY

a) Keep work area clean and well lit. Cluttered or dark areas invite accidents. b) 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.

c) Keep children and bystanders away while operating a power tooL Distractions can

cause you to lose control

2) ELECTRICAL SAFETY

a) Power tool plugs must match the outlet. Never modify the plug in any way. Do not

use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock

b) Avoid body contact with earthed or grounded surfaces such as pipes, radiators,

ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.

c) Do not expose power tools to rain or wet conditions. Water entering a power tool will

increase the risk of electric shock

d) Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the

power tooL Keep cord away from heat, oil, sharp edges or moving parts. Damaged

or entangled cords increase the risk of electric shock. Replace or repair damaged cords. Make sure your extension cord is in good condition. Use only 3-wire extension cords that have 3-prong grounding-type plugs and 3-pole receptacles that accept the tool's plug.

e) When operating a power tool outdoors, use an extension cord suitable for outdoor

use. Use of a cord suitable for outdoor use reduces 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, ff in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

Minimum Gauge 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

10 - 12 16 16 14 12 12 - 16 14 12 Not Recommended

3) PERSONAL SAFETY

a) Stay alert, watch what you are doing and use common sense when operating a

power tool. Do not use a power tool while you are tired or under the influence of

drugs, alcohol or medication. A moment of inattention while operating power toolsmay result in serious personal injury.

b) Use safety equipment. Always wear eye protection. Safety equipment such as

dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.

c) Avoid accidental starting. Ensure the switch is in the off-position before plugging

in. Carrying power tools with your finger on the switch or plugging in power tools that have the switch on invites accidents.

d) Remove any adjusting key or wrench before turning the power tool on. A wrench or

a key left attached to a rotating part of the power tool may result in personal injury.

e) Do not overreach. Keep proper footing and balance at all times. This enables better

control of the power tool in unexpected situations.

f) Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and

gloves away from moving parts. Loose clothes, jeweftery or long hair can be caught in moving parts. Air vents often cover moving parts and should also be avoided.

g) ff devices are provided for the connection of dust extraction and collection facilities,

ensure these are connected and properly used. Use of these devices can reduce dust- related hazards.

4) POWER TOOL USE AND CARE

a) Do not force the power tooL Use the correct power tool for your application. The

correct power tool will do the job better and safer at the rate for which it was designed.

b) Do not use the power tool if the switch does not turn it on and off. Any power tool that

cannot be controlled with the switch is dangerous and must be repaired.

c) Disconnect the plug from the power source and/or the battery pack from the power

tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.

d) Store idle power tools out of the reach of children and do not allow persons

unfamiliar with the power tool or these instructions to operate the power tool Power tools are dangerous in the hands of untrained users.

e) Maintain power tools. Check for misallgnment or binding of moving parts, breakage

of parts and any other condition that may affect the power tools operation, ff damaged, have the power tool repaired before use. Many accidents are caused by

poorly maintained power tools.

f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting

edges are less likely to bind and are easier to control

g) Use the power tool, accessories and tool bits etc., in accordance with these

instructions and in the manner intended for the particular type of power tool, taking into account the working conditions and the work to be performed. Use of the power

tool for operations different from those intended could result in a hazardous situation.

5) SERVICE

a) Have your power tool serviced by a qualified repair person using only identical

replacement parts. This will ensure that the safety of the power tool is maintained.

Additional Specific Safety Instructions for Nibblers

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

• Cut material at or below rated capacity. Remember, material thickness increases as gauge number deceases (14 gauge is thicker than 16 gauge). 14 gauge thickness is .075" (1.9 mm); 16 gauge is .060" (1.5 mm).

• NEVER have any part of your body near the blades. Serious personal injury may result.

• Keep hands away from cutting area. A moment of inattention while operating power tools may result in serious personal injury.

• AL WAYS wear gloves when handling sheet metal The edges are sharp and can cause seri- ous personal injury.

• Firmly secure the piece of metal to be cut to prevent movement during cutting.

• ALWAYS start tool before engaging material to be cut.

• Always wear safety shoes to protect your feet from sharp metal debris on the floor.

• DO NOT use the nibbler with any kind of accessory or attachment.

• Keep all screws tight. Check periodically for loosening.

• Do not place anything into the motor housing openings.

• Clean out your tool often, especially after heavy use. Dust and grit containing metal particles often accumulate on interior surfaces and could create an electric shock hazard.

• Stay clear of end pieces that may fall after being cut off. Contact with a sharp edge could result in personal injury.

• Always keep the power cord away from the edge of the material being cut. Sharp edges can result in the cord insulation being cut. This condition may create an electrical hazard.

_ WARNING: AL WAYS use safety glasses. Everyday eyeglasses are NOT safety glasses. Also use face or dust mask if cutting operation is dusty. ALWAYS WEAR CERTIFIED SAFETY

EQUIPMENT:

• ANSI Z87.1 eye protection (CAN/CSA Z94.3),

• ANSI $12.6 ($3.19) hearing protection,

• NIOSH/OSHA/MSHA respiratory protection.

_ WARNING: Always wear proper personal hearing protection that conforms to ANSI $12.6 ($3.19) during use. Under some conditions and duration of use, noise from this product

may contribute to hearing loss.

WARNING: Always use eye protection. Aft users and bystanders must wear eye protection

that conforms to ANSI Z87.1. _},WARNING: Some dust created by power sanding, sawing, grinding, drifting, 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).

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 weft 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/OSHA approved 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 m .................. alternating current

--- ............. direct current no .................. no load speed

(_) .................. Class I Construction _ ................... earthing terminal

FIG. 1

(grounded) _ .................. safety alert symbol

[] .................. Class II Construction .../min ............ revolutions or

(double insulated) reciprocation per minute

BPM .............. beats per minute

SAVE THESE INSTRUCTIONS

Motor

Your DEWALT tool is powered by a DEWALT-built motor. Be sure your power supply agrees with the nameplate marking.

Voltage decrease of more than 10% will cause loss of power and overheating. DEWALT tools are factory tested; if this tool does not operate, check power supply.

COMPONENTS (Fig. 1, 2)

WARNING: Never modify the power tool or any part of it. Damage or personal injury could

result.

A. Punch

B. Die C. Paddle Switch D. Lock Button

INTENDED USE The DW896 16-gauge nibbler has been designed for professional cutting at various work sites

(i.e., construction sites). DO NOT use under wet conditions or in presence of flammable liquids or gases.

These 16-gauge nibblers are professional power tools. DO NOT let children come into contact with the tool. Supervision is required when inexperienced operators use this tool.

Switches (Fig. 1)

To start tool, depress the paddle switch (C). To turn the tool off, release the paddle. The paddle switch can be locked on by engaging the lock button (D) located near the rear of the tool, while

holding the paddle depressed. Always be sure that the tool is not locked on before plugging in. To turn the tool off when it is locked on, squeeze and release the paddle once.

OPERATION (Fig. 2-6) FIG.4

,& WARNING: To reduce the risk of serious personal injury, turn tool off and disconnect tool from power source before making any adjustments or removing/installing attachments

or accessories.

Make sure the knurled ring (F, Fig. 2) is tight prior to use. Keep fingers away from cutter and other moving parts.

The nibbler cuts a slot in the work 6 mm wide so remember to compensate for this when marking out and calculating material requirements.

When starting the cut from an edge, place the nibbler so the slot in the die engages the work and the edge is against the punch, which is the moving part when cutting (Fig. 4).

Start the nibbler by depressing the paddle switch. Hold the body parallel to the work surface. Exert only enough forward pressure to start the nibbler cutting and maintain this pressure.

Extra pressure will not increase the rate of cut as the amount of material removed at each cutting stroke is fixed and the rate of cut is dependent only on the speed of the nibbler. The cutting line FIG. 6

of the work should be lightly coated with oil to lubricate the punch and die while cutting. NOTE: Punch and die should be lubricated by immersing in a good quality cutting oil approxi-

mately every 30 feet of cutting. When the cut is to be started or finished within the periphery of the work, a 1/2" (13 mm) hole

must first be drilled in the work at the start or finish point. This enables the die to be entered or withdrawn as it is larger in diameter than the slot being cut in the work (Fig. 5).

Circular holes should be cut in the manner shown in Figure 6, starting at the 1/2" (13 mm) diam- eter hole within the circle.

Setting the Cutter (Fig. 2, 3)

The cutter can be set to cut in any direction relative to the body. Release the set screw in the knurled ring (F, Fig. 2) with key provided and unscrew the ring by rotating in a counterclockwise

direction as viewed from the cutter. Loosen ring just enough to be able to rotate the die (B, Fig. 3). Set the die so that the connecting

web (E) is on the opposite side of the direction of cut. Fully tighten the knurled ring and lock by tightening the set screw.

Punch and Die Replacement (Fig 7, 8)

After a period of cutting, the punch will become blunted and require replacement. At the same time, check the die for sharpness and replace if necessary.

1. To remove the die, release the knurled ring (F, Fig. 7). Having removed the die (B), rotate the motor by turning the armature fan, accessible through the side cooling slot, until the punch retaining nut is clear of the face of the gearbox.

2. With the spanner provided, release this nut (G) counterclockwise and remove the punch (A), Figure 8. Assemble in reverse order.

MAINTENANCE

_ WARNING: To reduce the risk of serious personal injury, turn tool off and disconnect tool from power source before making any adjustments or removing/installing attachments

or accessories.

• Check that the punch and die are sharp. If either is dull, sharpen or replace.

• Periodically dip the shoe in oil.

• This is a precision tool. Use it carefully and store it in a protected place.

Cleaning

A WARNING: Blow dirt and dust out of all air vents with dry air at least once a week. Wear

proper ANSI Z87.1 (CAN/CSA Z94.3) eye protection and proper NIOSH/OSHA/MSHA respiratory protection when performing this.

_kWARNING: Never use solvents or other harsh chemicals for cleaning the non-metallic parts of the tooL These chemicals may weaken the plastic materials used in these parts. Use a cloth dampened only with water and mild soap. Never let any liquid get inside the tool; never immerse

any part of the tool into a liquid.

Lubrication

Your tool was properly lubricated before leaving the factory. In from two to six months, depending upon use, take or send your tool to a DEWALT Service Center or other qualified service organization for a complete cleaning, inspection and relubrication.

Tools used constantly on production or heaw duty jobs or exposed to heat may require more frequent lubrication. Tools "out of service" for long periods should be relubricated before being put back into service.

Motor Brushes

When the brushes on this tool become worn out, the tool will automatically stop and prevent damage to the motor. Brush replacement should be performed by DEWALT service centers.

Accessories

_ WARNING: Since accessories, other than those offered by DEWAL T, have not been tested

with this product, use of such accessories with this tool could be hazardous. To reduce the risk of injury, only DEWAL T, recommended accessories should be used with this product.

Recommended accessories for use with your tool are available at extra cost from your local dealer or authorized service center. If you need assistance in locating any accessory, please contact DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286, call 1-800-4-

DEWALT (1-800-433-9258) or visit our website www.dewalt.com.

Repairs

To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustments (including brush inspection and replacement) should be performed by a DEWALT factory service center, a DEWALT authorized service center or other qualified service personnel. Always use identical replacement parts.

FIG. 2

Three Year Limited Warranty

DEWALT will repair, without charge, any defects due to faulty materials or workmanship for three years from the date of purchase. This warranty does not cover part failure due to normal wear or tool abuse. For further detail of warranty coverage and warranty repair information, visit www.dewalt.com or call 1-800-4-DEWALT (1-800-433-9258). This warranty does not apply to accessories or damage caused where repairs have been made or attempted by others. This warranty gives you specific legal rights and you may have other rights which vary in certain states or provinces.

In addition to the warranty, DEWALT tools are covered by our:

DEWALT will maintain the tool and replace worn parts caused by normal use, for free, any time during the first year after purchase.

If you are not completely satisfied with the performance of your DEWALT Power Tool, Laser, or Nailer for any reason, you can return it within 90 days from the date of purchase with a receipt for a full refund - no questions asked.

LATIN AMERICA: This warranty does not apply to products sold in Latin America. For products sold in Latin America, see country specific warranty information contained either in the packaging, call the local company or see website for warranty information.

FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are missing, call 1-800-4-DEWALT for a free replacement.

FIG. 8

1 YEAR FREE SERVICE

90 DAY MONEY BACK GUARANTEE

DW896 16 GAUGE NIBBLER

SER.

TO REDUCE THE RISK OF

INSTRUCTION MANUAL ALWAYS USE PROPER EYE AND RESPIRATORY PROTECTION.

DEWALT INOOSTRIAL TOOL CO,, BALTIMORE, M[ 21286 USA

FO_ SERVICE INFORMATIO N, CALL 1-800"4-OEWALT www.D_WALT.com

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INJURY, USER MUST READ

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INSTRUCCIONES. UTILICE SIEMPRE LA PROTECCION ADECUADA PARA LA VISTA Y PARALAS VIAS RESPIRATORIAS.

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