DeWalt DWM120 Instruction Manual

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DEWALT Industrial Tool Co., 701 Joppa Road, Baltimore, MD 21286
(AUG08) Part No. 662802-00 DWM120 Copyright©2008 DEWALT
The following are trademarks for one or more DEWALT power tools: the yellow and black color
scheme; the "D" shaped air intake grill; the array of pyramids on the handgrip; the kit box configura-
tion; and the array of lozenge-shaped humps on the surface of the tool.
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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.
_ CAUTION: Indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury.
CAUTION: Used without the safety alert symbol indicates a potentially hazardous
situation which, if not avoided, may result in property damage.
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IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL,
CALL US TOLL FREE AT: 1-800-4-DEWALT (1-800-433-9258).
WARNING: To reduce the risk of injury, read the instruction manual.
General Power Tool Safety Warnings
_ ARNING! Read all safety warnings and instructions Failure to follow the warnings
and instructions may result in electric shock, fire and/or serious injury,
SAVE ALL WARNINGS AND INSTRUCTIONS
FOR FUTURE REFERENCE
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 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) ff operating a power tool in a damp location is unavoidable, use a ground fault
circuit interrupter (GFCl) 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.
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 energising 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.
f) Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing
and gloves away from moving parts. Loose clothes, jewellery or long hair can be
caught in moving parts.
g) ff 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 and/or 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, ff 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 Safety Rules - Portable Band Saws
• Hold tool by insulated gripping surfaces when performing an operation where the
cutting tool may contact hidden wiring. Contact with a "live" wire will make exposed
metal parts of the tool "live" and shock the operator.
• Keep hands away from cutting area and blade. Keep one hand on the main handle and
the other hand on the front handle to prevent loss of control which could result in personal
injury.
• Always make sure the portable band saw is clean before using.
• Always cease operation at once ffyou notice any abnormality whatsoever.
• Always be sure all components are mounted properly and securely before using tooL
• Always handle the band saw blade with care when mounting or removing it.
• Always keep your hands out of the line of the band saw blade.
• Always wa# until the motor has reached full speed before starting a cut.
• Always keep handles dry, clean, and free of oil and grease. Hold the tool firmly when in
use.
Always be alert at all times, especially during repetitive, monotonous operations. Always
be sure of position of your hands relative to the blade.
Never remove work stop.
Stay clear of end pieces that may fall after cutting off. They may be hot, sharp and/or
heavy, Serious personal injury may result.
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, ff in doubt, use the next heavier gauge. The
smaller the gauge number, the heavier the cord.
Ampere Rating
More Not More
Than Than
0 6
6 10
10 12
12 16
Minimum Gauge for Cord Sets
Volts Total Length of Cord in Feet (meters)
120V 25 (7.6) 50 (15.2) 100 (30.5) 150 (45.7)
240V 50 (15.2) 100 (30.5) 200 (61.0) 300 (91.4)
AWG
18
18
16
14
16
16
16
12
16 14
14 12
14 12
Not Recommended
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.
_ 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.
WARNING: Use of this tool can generate and/or disburse 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
.... ............... direct current
(_) .................... Class I Construction
(grounded)
[] .................... Class II Construction
(double insulated)
.../min ............. per minute
SFPM .............. surface feet per minute
A ................ amperes
W ............... watts
............. alternating current
............. alternating or direct current
no .............. no load speed
............... earthing terminal
.............. safety alert symbol
BPM ........... beats per minute
RPM .......... revolutions per minute
SAVE THESE INSTRUCTIONS FOR FUTURE USE
COMPONENTS (FIG. 1, 2)
A. Multi-position bail handle I. Speed wheel
B. Sight light J. Rubber bumpers
C. Trigger switch K. Hang hook
D. Main handle L. Pulley
E. Work stop M. Blade guard
R Guide rollers N. Rubber tires
G. Blade tracking adjustment O. Blade
H. Blade tension lever R Sight light switch
ASSEMBLY
Blades
This portable band saw is setup for use with .020" (0.5 mm) thick, 1/2" (12.5 mm) wide and
44-7/8" (1140 mm) long blades. DO NOT use .025 (.64 mm) thick blades.
_ CAUTION: The use of any other blade or accessory might be hazardous. DO NOT use
any other type of accessory with your band saw. Blades used on stationary band saws are of
different thickness. Do not attempt to use them on your portable unit.
Blade Selection
In general, first consider the size and shape of the work, and the type of material to be cut.
Remember, for the most efficient cutting, the coarsest tooth blade possible should be used in a
given application, because the coarser the tooth, the faster the cut. In selecting the appropriate
number of teeth per inch of the band saw blade, at least two teeth should contact the work
surface when the blade is rested against the workpiece. As a rule of thumb, soft materials
usually require coarse tooth blades, while hard materials require fine tooth blades. Where a
smoother finish is important, select one of the finer tooth blades.
Select the appropriate band saw blade according to the material type, dimensions, and
number of teeth. See Blade Description chart.