DeWalt DW896 TYPE 3 Owner’s Manual

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The following are trademarks for one or more DEWAI..] 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.

The definitions below describe the levelof 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. A CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result

in minor or moderate injury. NOTICE: Indicates a practice not related to personal injury which, if not avoided, may

result in property damage.

IFYOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALTTOOL, CALL US TOLL FREE AT: 1-800-4-DEWALT (1-800-433-9258}.

WARNING: To reduce the risk of injury, read the instruction manual.

General Power Tool Safety Warnings

A ARNIN!! Read all safety warnings and all instructions. Failure to follow the

warnings and instructions may result in electric shock, fire and/or serious injury,

The term "power tool" in the warnings refers to your mains-operated (corded) power tool or

battery-operated (cordless) power tool.

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 apower 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.

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.

f) If operating a power tool in a damp location is unavoidable, use a ground fault

circuit interrupter (GFCl) protected supply. Use of a GFC/ reduces the risk of electric shock.

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 tools may result in serious personal injury,

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

Definitions: Safety Guidelines

SAVE ALL WARNINGS AND INSTRUCTIONS

FOR FUTURE REFERENCE

b) Use personal protective equipment. Always wear eye protection. Protective

equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection

used for appropriate conditions will reduce personal injuries.

c) Prevent unintentional starting. Ensure the switch is in the off position before

connecting to power source and/or battery pack, picking up or carrying the tooL Carrying power tools with your finger on the switch or energizing 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.

0 Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing

and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.

g) If devices are provided for the connection of dust extraction and collection

facilities, ensure these are connected and properly used. Use of dust collection 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 andlor 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 misalignment or binding of moving parts,

breakage of parts and any other condition that may affect the power tool's operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.

t) 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, 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 inserious personal injury,

• ALWAYS wear gloves when handling sheet metal. The edges are sharp and can cause serious 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.

• Air vents often cover moving parts and should be avoided. Loose clothes, jewelry or long hair can be caught in moving parts.

• An extension cord must have adequate wire size (AWG or American Wire Gauge) for safety. 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. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. When using more than one extension to make up the total length, be sure each individual extension contains at least the minimum wire size. The following table shows the correct size to use depending on cord length and nameplate ampere rating. If 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 (meters)

Ampere Rating 120V 25 (7.6) 50 (15.2) 100 (30.5) 150 (45.7)

More Not More Than

0 6

10 12

_, WARNING: ALWAYS 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.

A WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of California 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.

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.

A WARNING: Use of this tool can generate and/or disperse 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,

Than

6 10 12

240V 50 (15.2) 100 (30.5) 200 (61.0) 300 (91.4)

AWG

18 16 16 14 18 16 14 12 16 16 14 12

14 12 Not Recommended

A WARNING: Always wear proper personal hearing protection that conforms to ANSI

S 12.6 ($3.19) during use. Under some conditions and duration of use, noise from this product may contribute to hearing loss.

• The label on your tool may include the following symbols. The symbols and their definitions are as follows:

V..................... volts

Hz................... hertz

min ................. minutes

--- or DC .....direct current

(_)................... Class I Construction

(grounded)

[] ................... Class II Construction

(double insulated)

.../min ............ per minute

IPM ................. impacts per minute

SPM ............... strokes per minute

A......................... amperes

W........................ watts

"_ or AC ............. alternating current

_-_or AC/DC ......alternating or direct current

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

n......................... rated speed

G ....................... earthing terminal

A ........................ safety alert symbol

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

RPM ................... revolutions per minute

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

SAVE THESE INSTRUCTIONS FOR FUTURE USE

Motor

Be sure your power supply agrees with the nameplate marking. Voltage decrease of more than 10% will cause loss of power and overheating. DEWALTtools are factory tested; if this tool does

not operate, check power supply.

COMPONENTS (Fig. 1)

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

A. Punch C. Paddle Switch

B. Die 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.

ADJUSTMENTS

A WARNING: Toreduce the risk of injury, turn unit off and disconnect it from power source before installing and removing accessories, before adjusting or when making

repairs. An accidental start-up can cause injury.

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)with key provided and unscrew the ring by rotating in acounterclockwise direction

as viewed from the cutter.

Loosen ring just enough to be able to rotate the die (B). 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 4, 5)

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). 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 5. Assemble in reverse order.

OPERATION

A WARNING: To reduce the risk of injury, turn unit off and disconnect it from power source before installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

Switches (Fig. 1)

Tostart 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.

Toturn the tool off when it is locked on, squeeze and release the paddle once.

Cutting Tips (Fig. 2, 6-8)

• 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. 6).

• 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 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

approximately 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. 7).

• Circular holes should be cut in the manner shown in Figure 8, starting at the 1/2" (13 mm)

diameter hole within the circle.

MAINTENANCE

Cleaning

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

To minimize the risk of eye injury, always wear ANSI Z87.1 approved eye protection when

performing this. A WARNING: 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 heavy 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 DEWALTservice centers.

FIG. 1

FIG. 2

FIG. 4

FIG. 3

DIRECTIONOF CUT

SENSDECOUPE

DIRECCIONDECORTE

FIG. 5

FIG.6 FIG. 7

FIG. 8

Accessories

A WARNING: Since accessories, other than those offered by DLiWALT,have not been tested with this product, use of such accessories with this tool could be hazardous. To reduce the risk

of injury, only DEWALTrecommended 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

DEWALTIndustrial 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 adjustment (including

brush inspection and replacement) should be performed by a DEWALTfactory service center,

a DEWALT authorized service center or other qualified service personnel. Always use identical

replacement parts.

Thank you for your purchase. Register your product now for:

• WARRANTY SERVICE: Registering your product will help you obtain more efficient warranty service in case there is a problem with your product.

• CONFIRMATION OF OWNERSHIP: In case of an insurance loss, such as fire, flood or theft, your registration of ownership will serve as your proof of purchase.

• FOR YOUR SAFETY: Registering your product will allow us to contact you in the unlikely event a safety notification is required under the Federal Consumer Safety Act.

Three Year Limited Warranty

D_WALT 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-D_WALT (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, DfiiiWALTtools are covered by our:

1 YEAR FREE SERVICE

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

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