DeWalt DW899 Instruction Manual

DEWALT Industrial Tool Company, P.O. Box 158, 626 Hanover Pike, Hampstead, MD 21074 Printed in U.S.A. (MAY97-CD-1) Form No. 384346
DW899 Copyright © 1997

DW899/384346 IM 5/2/02 1:44 PM Page 2

INSTRUCTION MANUAL
GUIDE D'UTILISATION
MANUAL DE INSTRUCCIONES

DW899
8-Gauge Nibbler

Grignoteuse de calibre 8
Cortadora de lámina calibre 8

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

DW899/384346 IM 5/2/02 1:44 PM Page 3

Important Safety Instructions

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

Safety Instructions 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. Do not use tool in presence of flammable liquids
or gases.

• GUARD AGAINST ELECTRIC SHOCK. Prevent body contact

with grounded surfaces. For example; pipes, radiators, ranges, and
refrigerator enclosures.

• KEEP CHILDREN AWAY. Do not let visitors contact tool or

extension cord. All visitors should be kept away from work area.

• 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 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.

• 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 dust mask 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.

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)

AUXILIARY

HANDLE

TRIGGER

SWITCH

SHOE

DIE

OIL FLOW
CONTROL

KNOB

LOCK

BUTTON

BRUSH INSPECTION

CAP (2)

DW899/384346 IM 5/2/02 1:44 PM Page 4

• 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 safer 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 tool with finger
on switch. Be sure switch is off when plugging in.

• EXTENSION CORDS. Use only 3-wire extension cords that have
3-prong grounding-type plugs and 3-pole receptacles that accept
the tool’s plug. Replace or repair damaged cords. Make sure your
extension cord is in good condition.

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

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.

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

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

• 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 damaged
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.

Grounding Instructions

This tool should be grounded while in use to protect the operator from
electric shock. The tool is equipped with a 3-conductor cord and 3­prong 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 V,
it has a plug that looks like that shown in sketch A. If it is for use on
150 to 250 V, it has a plug that looks like that shown in sketch D. An
adapter, sketches B and C, is available for connecting sketch A type
plugs to 2-prong receptacles. The green-colored rigid ear, lug, or the
like, extending from the adapter must be connected to a permanent
ground, such as a properly grounded outlet box. No adapter is
available for a plug as shown in sketch D. ADAPTER SHOWN IN
FIGURES B and C IS NOT FOR USE IN CANADA.

1

English

DW899/384346 IM 5/2/02 1:44 PM Page 1

2

SAVE THESE INSTRUCTIONS

Motor

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

Volts 50/60 Hz or “AC only” means your tool must be operated on
alternating current and never with direct current.

Voltage decrease of more than 10% will cause loss of power and
overheating. D

EWalt tools are factory tested; if this tool does not operate,

check power supply.

Switch

Depress the trigger switch to turn the tool on. Releasing the trigger
turns the tool off. To lock the trigger in the on position for continuous
operation, depress the trigger, push in the lock button on the left
side of the handle, and then release the trigger. To release the
locking mechanism, depress trigger fully, then release it.

Operation

The nibbler will cut U.S. standard 8-gauge mild steel and 3/16" non­ferrous metals. It will also cut U.S. standard 10-gauge stainless steel
easily; however, due to hardness variations in stainless steel, it is best
to first consult your local D

EWAL T field representative about such jobs

in order to obtain maximum life and efficiency from your tool.

1. Always be sure that area to be cut is oiled. An oiler device is
located at the front of the tool, and will automatically oil the area to

English

be cut. Lubricant flow is controlled by turning the knurled knob
(Figure 1).

To refill automatic oiler, remove oil filler plug (Figure 1). Be sure vent

hole in plug is kept open to ensure poper flow. For cutting mild
steel, use SAE 20W oil; for non-ferrous metals, use light oil.

2. Properly adjust stripper.
a. Loosen the 2 stripper mounting screws (Figure 1).
b. Place metal to be cut between die and stripper.
c. Lock stripper into position so that the metal is flat against the

die, and the ball of the oiler in the stripper is just touching the
metal. Average clearance of .010"-.015" is preferred. If punch is
dulled, more clearance may be required to clear the resulting
burr.

d. Be sure stripper mounting screws are tightened securely .

3. Grasp the tool, turn switch on and feed tool into material. Hold tool
so that it feeds with minimum operator pressure.

NOTE: Hard materials will dull the punches and dies. When dulling
occurs, tool will become difficult to feed into material. In addition,
the metal will begin to show burrs along the cut. Keep dies and
punches sharp at all times.

Removing Punch

1. Operate the crank down mechanism (with a screwdriver) to align
the punch retaining set screw with the clearance hole at the rear of
the shoe.

2. Loosen punch retaining set screw until punch slides free.

3. Remove die by taking out the 2 die screws located at an angle at
the bottom rear of the shoe.

4. Remove the 2 stripper mounting screws. If there is any side play
or forward play, replace stripper or it will cause severe wear and
damage to the shoe.

5. Slide punch and stripper out of shoe.

AB CD

GROUNDING PIN

GROUNDED

OUTLET

BOX

GROUNDING

MEANS

GROUNDING PIN

ADAPTER

DW899/384346 IM 5/2/02 1:44 PM Page 2

6. Replace punch and reassemble tool by reversing steps 2-5
above.

BE SURE TO THOROUGHLY CLEAN AND LIGHTLY OIL ALL
LOCATING SURFACES BEFORE REASSEMBLY TO PREVENT
DAMAGE TO TOOL. ALSO MAKE CERT AIN THAT STRIPPER IS
SECURELY LOCKED IN POSITION AND PUNCH IS PROPERLY
SEATED BEFORE FINALLY TIGHTENING THE PUNCH
RETAINING SET SCREW.

Removing Die

1. Remove 2 die screws located an an angle at bottom rear of shoe
and remove die (Figure 1).

2. If sharpening of die is required, sharpen on a surface grinder by
removing material from only the top surface of the die. Grinding by
a qualified machine shop is preferred. CAUTION: Remember
that the total amount of metal removed from both the punch and
the die cannot exceed 3/32".

3. Clean die and shoe surface thoroughly.

4. Insert die in tool.

5. Replace screws and tighten securely.

Maintenance

Nibblers should be cleaned, inspected, and lubricated at certified
D

EWAL T service centers every month with heavy usage, every two or

three months with light usage.
Inspect carbon motor brushes frequently by unplugging tool,

removing the brush inspection caps, and withdrawing the brush and
spring assembly. Replace the assembly when the brushes are worn
down to the line closest to the spring, or when spring exerts
insufficient pressure to hold brush against commutator. Keep brushes
clean and sliding freely in their guides.

Saturate the felt oiler with SAE 10W or 20W motor oil once very day
of operation in normal use.

3

English

FIG. 1

CRANK DOWN

SLOT

OIL FILLER

PLUG

OIL FLOW

CONTROL KNOB

STRIPPER

SHOE

STRIPPER MOUNTING

SCREWS (2)

DIE

DIE SCREWS (2)

CLEARANCE HOLE

FELT OILER

DW899/384346 IM 5/2/02 1:44 PM Page 3