DeWalt DW898 TYPE 3 Owner’s Manual

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(SEP12) Part No. N193853 DW898 Copyright © 2002, 2005, 2007, 2012 DEWALT

The followiare trademarks for one or more DEWAL.] power tools: the yellow and black color scheme, the "D" shaped air

intake grill, the array of pyramids on the handgrip, the kit box configuralion, 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

J

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.
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 persona/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

Than

6
10
12

16

_, 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,

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 thisproduct
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)

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

A. Head

B. Punch

C. Cover ring

D. Die

E. Housing
F. Paddle switch

G. Switch lock button

H. Set screw

INTENDED USE

The DW898 14-gauge nibbler is 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.
The14-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

_ 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.

To Rotate Head (Fig. 2, 3)

The head (A)can be aligned in three positions: left, forward, and right (See Fig. 2). To rotate the
head (A), loosen the set screw (H). Turn 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 housing (E) in the head (A)and turn the set screw (H) in until you feel the set screw

engage a recess in the shoe. Tighten the set screw firmly. Periodically recheck this screw for
tightness.

The nibbler head (A) is designed to fitthrough a 3/4" (19 mm) diameter hole for starting a cut in
the middle of the work. Nibbling can be done in any direction from this hole. A punch width
indicator is provided on the front of the housing to allow users to follow a line closely (Fig. 3).
The bottom of the housing has a .51" (13 mm) diameter template guide (L) to allow for use of
templates. See Figures 2 and 3 for template guide surface. The thickness of the template
should be such that the total thickness of the template and workpiece is 13/64" to 1/4"
(5 to 6.5 mm). The shape of the template must be .1" (2.5 mm) away from the shape to be

nibbled. The tool should be guided so that the outside diameter (.51" or 13 mm) of the housing
always rests on the template.

Changing Punches (Fig. 2)

Never cut with a blunt, dull punch. Punches can be sharpened until they reach a length of

2.72" (69 mm). Shorter punches are unserviceable. To remove the punch (B), loosen the head
set screw (H) about 4-5 turns (See Fig. 2). Slide the housing (E) from the head (A). Unscrew

the punch (B) from the connecting rod bushing (J). 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. 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 (Fig. 2)

Screw the punch (B) fully into the connecting rod bushing (J). Slide the housing (_ over the
end of the punch and into the head. Turn the housing (E)to desired cut orientation. Tighten set

screw (H). Next, check punch engagement.

Checking Punch Engagement (Fig. 2)

Since the punch (B) length is now changed, the punch engagement may have to be adjusted.
Check punch engagement by placing a flat blade screwdriver inthe cam shaft (I)slot and turning
the shaft (See Fig. 2). Punch should dip .020" to .06" (.5 to 1.15 mm)into the die at the full down
stroke position. Too much punch dip into the die will result in a lossof capacity (bottom of punch
will not clear die enough on up stroke.)

Punch Engagement Adjustment (Fig. 2)

If the punch engagement should need adjustment, loosen the set screw (H)and rotate shoe

either clockwise (punch deeper into die) or counterclockwise (punch out of die). Tighten set
screw firmly. Turn cam shaft (I) with screwdriver in slot to check punch engagement (moving

punch fully down). Repeat as necessary.

Die Replacement (Fig. 2)

Ifthe die (D) becomes dull, replace it. Replace old die by pushing the cover ring (C) up and out

of the die groove. Knock out the retaining pin under the cover ring with a drift punch. Pull die off
the carrier shaft (K). Install new die (D)on carrier shaft (K). Align cross hole in die with groove in

carrier shaft. Install pin. Snap cover ring (C) over die in groove provided.

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 (F).To turn the tool off, release the paddle. The paddle
switch can be locked on by engaging the lock button (G) 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. 1)

• Lubricate surface of material with oil. The nibbler is designed to cut flat and shallow
corrugated metal.

NOTE: Punch and die should be lubricated by immersing in a good quality cutting oil

approximately every 30 feet (9 m) of cutting

• The tool is factory assembled with the punch (B)oriented forward for cutting flat and shallow
corrugated material.

MAINTENANCE

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.

FIG. 1

FIG 2

!I

K

A

F

A

E

L

FIG 3

A

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iiiiiii!

B

I

J

E

L

D

D

C

• 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

_ 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

Self lubricatingbearings are used in the tool and periodic relubrication isnot required, However,
it is recommended that, once ayear, you take or send the tool to a service center for a thorough
cleaning and inspection.

Accessories

i_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. Toreduce the risk
of injury, only DEWALT 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
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 DEWALT factory service center,
a DFWALT authorized service center or other qualified service personnel. Always use identical
replacement parts.

Register Online

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.

Register online at www.dewalt.com/register.

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, DEWALTtools 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.

90 DAY MONEY BACK GUARANTEE

Ifyou 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 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 (1-800-433-9258) for a free replacement.

DW898. GAUGE.,BBLE

SER.

TO REDUCE THE RiSK OF

iNSTRUCTiON MANUAL ALWAYS USE PROPER EYE AND
RESPIRATORY PROTECTION.

DEWALTiNDUSTRiALTOOLCO.,BALTIMORE,MD 21286 USA

FORSERVICEINFDOMATiON,CALL 1-800-4-DEWALT www.DEWALT.com

iNJURY, USER MUST READ

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