DeWalt DWE304 TYPE 2, DWE304 TYPE 1 Owner’s Manual

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DEWALT Industrial ToolCo., 701 East Joppa Road, Baltimore, MD 21286

(MAR14) Part No. N391690 DW303, DW303M, DW304P, DWE304

The following are trademarks for one or more DEWALT power tools: the yellow and black color scheme; the

"D" shaped air intake gril; 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. _DANGER: 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.

J_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.

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-g258}.

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

General Power Tool Safety Warnings

_ ARNING! Read all safety warnings and all instructions. Failure to follow the warnings

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

SAVE ALL WARNINGS AND INSTRUCTIONS

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 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 p/ugs 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 ifyour 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.

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

circuit interrupter (GFCI) protected supply. Use of a GFCI 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,

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.

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, 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 Rules

• Hold power tool by insulated gripping surfaces when performing an operation where the cutting accessory may contact hidden wiring or its own cord. Cutting accessory

contacting a "live" wire may make exposed metal parts of the tool "live" and could give the operator an electric shock

• Use clamps or another practical way to secure and support the workpiece to a stable

platform. Holding the work by hand or against your body leaves it unstable and may lead to

loss of control.

• Do not operate this tool for long periods of time. Vibration caused by the operating action of this tool may cause permanent injury to fingers, hands, and arms. Use gloves to provide extra cushion, take frequent rest periods, and limit daily time of use.

• 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

16gauge 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

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 EQUIPMENX

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

• ANSI $12.6 ($3. 19)hearing protection,

• NIOSH/OSHA/MSHA respiratory protection.

_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. Toreduce

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.

_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,

_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.

• 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

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

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

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

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

Not More

Than

6 10 12

(grounded)

(double insulated)

120V 25 (7.6) 50 (15.2) 100 (30.5) I 150 (45.7) 240V 50 (15.2) 100 (30.5) 200 (61.0) I 300 (91.4)

AWG

18 18 16

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

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

'_ or AC ............. alternating current

or AC/DC ...... alternating or direct current

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

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

@ ....................... earthing terminal

t_........................ safety alert symbol

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

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

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

16 16 16

16 14 14 12 14 12

Not Recommended

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. DEWALT tools are factory tested; if this tool does

not operate, check power supply.

COMPONENTS (Fig. 1-3)

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

A. Trigger switch E. balde clamp

B. Set screw F. Blade

C. Blade shank G. Pin

D. Reciprocating shaft H. Blade clamp release lever

Switch (Variable Speed) (Fig. 1)

The variable speed trigger switch (A)will give you added versatility The further the trigger is depressed the higher the speed of the saw. To turn the tool "OFF" release the trigger.

A CAUTION: Use of very slow speed is recommended only for beginning a cut. Prolonged use at

very slow speed may damage your saw.

ASSEMBLY AND 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,

Blade Clamping (Fig. 2) (DW303)

TO INSTALL BLADE INTO SAW

1. Loosen set screw (B).

2. Insert blade shank (C) from the front between the reciprocating shaft (D) and the blade clamp (E). Locate hole in blade (F)over pin (G) on reciprocating shaft.

3. Tighten set screw. Ifthe blade should break off and the shank does not come out of the clamp, be sure the set screw is loose and eject the shank with a nail or pointed object.

A CAUTION: THE BLADE GUARD IS THERE FOR YOUR SAFETY. DO NOT REMOVE IT.

Blade Clamp Release Lever (Fig. 3) (DW303M, DW304P, DWE304)

TO INSTALL BLADE INTO SAW

1. Pull blade clamp release lever (H) up.

2. Insert blade shank from the front.

3. Push blade clamp release lever down.

TO REMOVE BLADE FROM SAW

1 Open blade clamp release lever

2. Remove blade.

A CAUTION: THE BLADE GUARD IS THERE FOR YOUR SAFETY. DO NOT REMOVE IT.

OPERATION

_ 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,

Cutting with Blade in Horizontal Position (Fig. 4A) (DW304P, DWE304)

Installing a blade in the horizontal orientation allows cutting close to floors, walls or ceilings where

limited clearance is available. Ensure that the Blade Guard is pressed against the framing to avoid kickback.

Flush-To Cutting (Fig. 5)

The compact design of the saw motor housing and spindle housing permits extremely close cutting to floors, corners and other difficult areas.

A CAUTION: When sawing into walls, floors or wherever "live" electrical wires may be encountered,

DO NOT TOUCH ANY FRONT METAL PARTS OF THE TOOL! Hold the tool only by the plastic handle and housing to prevent electric shock if you saw into a "live" wire.

,&CAUTION: Always wear eye protection while operating this power tool

Wood Cutting (Fig. 6)

Before cutting any type of wood, be sure it is firmly anchored or clamped to prevent slipping. Place

blade lightly against work to be cut, switch on saw motor and allow it to obtain maximum speed before applying pressure. Always hold saw firmly with both hands while cutting. Whenever possible,

the saw shoe must be held firmly against the material being cut. This will prevent the saw from jumping or vibrating and minimize blade breakage.

Metal Cutting (Fig. 7)

This unit has different metal cutting capacities depending upon type of blade used and the metal to be cut. Use a finer blade for ferrous metals and a coarse blade for non-ferrous materials. In thin

gauge sheet metals it is best to clamp wood to both sides of sheet. This will insure a clean cut without excess vibration or tearing of metal. Always remember not to force cutting blade as this reduces blade life and causes costly blade breakage.

NOTE: It is generally recommended that when cutting metals you should spread a thin film of oil or

other coolant along the line ahead of the saw cut for easier operation and longer blade life.

Pocket Cutting (Fig. 8) (Wood Only)

The initial step in pocket cutting is to measure the surface area to be cut and mark clearly with a pencil, chalk or scriber. Insert pocket cutting blade in blade clamp and tighten blade clamp securely.

Next, tip the saw backward until the back edge of the shoe is resting on the work surface. Now switch motor on, always permitting blade to attain maximum speed. Grip handle steadily and begin a slow, deliberate upward swing with the handle of the saw. Blade will begin to feed into material. Always be sure blade is completely through material before continuing with pocket cut.

NOTE: In areas where blade visibilty is limited, use the edge of the saw shoe as a guide. Lines for any given cut should be extended beyond edge of cut to be made.

MAINTENANCE

_ 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,

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.

,_,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.

Accessories

i_,WARNING: Since accessories, other than those offered by DEWALT,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. Ifyou 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

Toassure product SAFETYand RELIABILITY, repairs, maintenance and adjustment (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. 1

FIG.2

FIG. 3

FIG. 7

FIG. 8

ROCK TOOL UP TO NORMAL CUTTING POSITION

AFTER BLADE HAS CUT THROUGH MATERIAL

BERCER L'OUTIL EN POSITION NORMALE DE

COUPE _,PRES AVOIR TRAVERSI_ MATI_RIAU AVEC

LA LAME

BALANCEE LA HERRAMIENTA HASTA LA

POSICION DE CORTE NORMAL DESPUES DE HACER

EL CORTE A TRAVES DEL MATERIAL

FIG. 4

STARTING POSITION FOR POCKET CUTTING

POSICION DE INICIO PARA EL CORTE DE BOLSILLO

FIG. 4A

POSITION DE DEPART POUR LES COUPES

EN RETRAIT

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