DeWalt DW897, DW897-220 Instruction Manual

DEWALT Industrial Tool Company, P.O. Box 158, 626 Hanover Pike, Hampstead, MD 21074 Printed in Country MAY97-1) Form No. 384328
DW897/897-220 Copyright © 1997

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INSTRUCTION MANUAL
GUIDE D'UTILISATION
MANUAL DE INSTRUCCIONES

DW897/DW897-220
16 Gauge Nibbler
Grignoteuse de calibre 16

Cortadora de lamina calibre 16

INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y PÓLIZA
DE GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUCTIVO ANTES
DE USAR EL PRODUCTO.

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IMPORTANT SAFETY

INSTRUCTIONS (FOR ALL TOOLS)

WARNING: When using electric tools, basic safety precautions
should always be followed to reduce risk of fire, electric shock, and
personal injury, including the following:

READ ALL INSTRUCTIONS

Double Insulation

Double insulated tools are constructed throughout with two separate
layers of electrical insulation or one double thickness of insulation
between you and the tool’s electrical system. Tools built with this
insulation system are not intended to be grounded. As a result, your
tool is equipped with a two prong plug which permits you to use
extension cords without concern for maintaining a ground
connection.

NOTE: Double insulation does not take the place of normal safety
precautions when operating this tool. The insulation system is for
added protection against injury resulting from a possible electrical
insulation failure within the tool.

CAUTION: WHEN SERVICING USE ONLY IDENTICAL RE­PLACEMENT PARTS. Repair or replace damaged cords.

Polarized Plugs(DW897)

Polarized plugs (one blade is wider than the other) are used on
equipment to reduce the risk of electric shock. When provided, this
plug will fit into a polarized outlet only one way. If the plug does not
fit fully into the outlet, reverse the plug. If it still does not fit, contact a
qualified electrician to install the proper outlet. Do not change the
plug in any way.

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)

DW897/DW897-220 16-Gauge
Profile Nibbler

PADDLE SWITCH

SWITCH

LOCK

BUTTON

PUNCH

GUIDE

HEAD

SHOE

DIE

PUNCH

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For All Tools:

• KEEP WORK AREA CLEAN. Cluttered areas and benches invite
injuries.

• CONSIDER WORK AREA ENVIRONMENT. Don’t expose power
tools to rain. Don’t use power tools in damp or wet locations. Keep
work area well lit.

• GUARD AGAINST ELECTRIC SHOCK. Prevent body contact
with grounded surfaces; for example, pipes, radiators, ranges,
and refrigerator enclosures.

• KEEP CHILDREN AWAY. All visitors should be kept away from
work area. Do not let visitors contact tool or extension cord.

• STORE IDLE TOOLS. When not in use, tools should be stored in
dry, and high or locked-up place — out of reach of children.

• DON’T FORCE A TOOL. It will do the job better and safer at the
rate for which it was intended.

• USE RIGHT TOOL. Don’t force small tool or attachment to do the
job of a heavy duty tool. Don’t use tool for purpose not intended; for
example, don’t use circular saw for cutting tree limbs or logs.

• DRESS PROPERLY. Do not wear loose clothing or jewelry. They
can be caught in moving parts. Rubber gloves and non-skid
footwear are recommended when working outdoors. Wear
protective hair covering to contain long hair.

• USE SAFETY GLASSES. Also use face or dustmask if operation
is dusty.

• DON’T ABUSE CORD. Never carry tool by cord or yank it to
disconnect from receptacle. Keep cord from heat, oil, and sharp
edges.

• SECURE WORK. Use clamps or a vise to hold work. It’s safer than
using your hand and it frees both hands to operate tool.

• DON’T OVERREACH. Keep proper footing and balance at all
times.

• MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for
better and safe performance. Follow instructions for lubricating and
changing accessories. Inspect tool cords periodically and if

damaged have repaired by authorized service facility. Inspect
extension cords periodically and replace if damaged. Keep
handles dry, clean, and free from oil and grease.

• DISCONNECT OR LOCK OFF TOOLS when not in use, before
servicing, and when changing accessories, such as blades, bits,
cutters.

• REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of
checking to see that keys and adjusting wrenches are removed
from tool before turning it on.

• AVOID UNINTENTIONAL STARTING. Don’t carry plugged-in tool
with finger on the switch. Be sure the switch is off when plugging
in.

• EXTENSION CORDS. Make sure your extension cord is in good
condition. 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 18161614
6 - 10 18 16 14 12
10-1216161412
12 - 16 14 12 Not Recommended

• STAY ALERT. Watch what you are doing. Use common sense.
Do not operate tool when you are tired.

• OUTDOOR USE EXTENSION CORDS. When tool is used
outdoors, use only extension cords intended for use outdoors and
so marked.

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• CHECK DAMAGED PARTS. Before further use of the tool, a
guard or other part that is damaged should be carefully checked
to determine that it will operate properly and perform its intended
function. Check for alignment of moving parts, binding of moving
parts, breakage of parts, mounting, and any other conditions that
may affect its operation. A guard or other part that is defective
should be properly repaired or replaced by an authorized service
center unless otherwise indicated elsewhere in this instruction
manual. Have defective switches replaced by authorized service
center. Do not use tool if switch does not turn it on and off.

• DO NOT OPERATE portable electric tools near flammable liquids
or in gaseous or explosive atmospheres. Motors in these tools
normally spark, and the sparks might ignite fumes.

• CAUTION: When drilling or driving into walls, floors or wherever
live electrical wires may be encountered, DO NOT TOUCH ANY
METAL PARTS OF THE TOOLS! Hold the tool only by insulated
grasping surfaces to prevent electric shock if you drive into a live
wire.

SAVE THESE INSTRUCTIONS

FOR FUTURE USE

Operating Rules for Nibblers

1. Always wear safety glasses and protective gloves.

2. Wear safety shoes to protect your feet from sharp metal debris on
floor.

3. Cut material at or below rated capacity. Remember, material
thickness increases as gauge number decreases (14 gauge is
thicker than 16 gauge). 14 gauge thickness is .075” (1,9 mm); 16
gauge is .060” (1,5 mm).

4. Keep all screws tight. Periodically check them for loosening.

5. Unplug tool before making any adjustments.

6. Do not put anything into a motor housing opening.

7. Keep tool clean. Blow off any metal debris and dirt from tool.

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

PADDLE SWITCH

To start the tool, depress the paddle switch. To turn the tool off,
release the paddle. The switch can be locked on be engaging the
lock button located near the rear of the tool while holding the paddle
depressed. Always be sure that the tool is not locked on before
plugging it in. To turn the tool off when it is locked on, squeeze and
release the paddle once.

Operation

TURN OFF TOOL AND DISCONNECT FROM POWER SUPPLY
BEFORE MAKING ANY ADJUSTMENTS. Always wear safety
glasses and protective gloves.

Lubricate surface of material with oil. The profile nibbler is designed
to cut corrugated, flat, and box steel forms.

The tool is factory assembled with the punch oriented forward for
cutting flat and shallow corrugated material. T o cut deeper corrugated
metals and box sections, rotate the head 90˚ to either side to use tool
sideways.

The shoe can be aligned in three positions: left, forward, and right.
(See Figure 2).

T o rotate the head, loosen the set screw . T urn the head in the desired
direction. NOTE: Do not rotate the head in a complete circle as this
will change the punch engagement in the die.

Rotate the shoe and turn the set screw in until you feel the set screw
engage a recess in the shoe. Tighten the set screw firmly.
Periodically recheck this screw for tightness.

Sharpening Punches

Never cut with a blunt, dull punch or die. Punches can be sharpened

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up to 1/8” (3mm). To remove the punch, loosen the head set screw
about 4-5 turns (See Figure 2). Slide the shoe assembly from the
head. Unscrew the punch from the connecting rod bushing. Punch
may be resharpened carefully on a bench grinder with a fine grit
wheel. Be careful that the punch does not become shorter than the
minimum length of 2.44 inches (2-7/16 inches or 61mm). Punches
shorter than this will not engage the die sufficiently and must be
replaced. The ground face must be square to the punch axis. After
grinding, carefully stone the ground edges to remove burrs. Do not
round over corners.

Reassembly of Nibbler Head

Screw the punch fully into the connecting rod bushing. Slide the shoe
assembly over the end of the punch and into the head. NOTE:
Lubrication groove in punch face must not be exposed at front of
shoe. Turn the shoe to desired cut orientation. Tighten set screw.
Next, check punch engagement.

Checking Punch Engagement

Since the punch length is now changed, the punch engagement may
have to be adjusted. Check punch engagement by placing a flat
blade screwdriver in the cam shaft slot and turning the shaft. (See
Figure 2) Punch should dip .020” to .04” (.5 to 1.0mm) into the die at
the full down stroke position. Too much punch dip into the die will
result in a loss of capacity (bottom of punch will not clear die enough
on up stroke.)

Punch Engagement Adjustment

If the punch engagement should need adjustment, loosen the set
screw and rotate shoe either clockwise (punch deeper into die) or
counterclockwise (punch out of die). Tighten set screw firmly. Turn
cam shaft with screwdriver in slot to check punch engagement
(moving punch fully down). Repeat as necessary.

Die Replacement

If the die becomes dull, replace it. Replace old die by removing two
screws at the front (Figure 2). Install new die and tighten screws.
Recheck punch engagement and adjust punch depth if necessary.

Wear Plate

This tool is equipped with a wear plate to increase the life of the
shoe (See Figure 3). The wear plate fits between the shoe and the
punch. Anytime the punch, punch guide or die is removed, inspect

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Figure 2

Figure 3

HEAD

CAM

SHAFT

PUNCH

SET

SCREW

SHOE

PUNCH

GUIDE

CONNECTING

ROD BUSHING

DIE

HEAD

PUNCH

SHOE

PUNCH

GUIDE

WEAR
PLATE

CAM

SHAFT

DIE

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