DeWalt DW304P, DW303, DW303M - VS Reciprocating Saw Manual

General Safety Instructions

Read and understand all instructions. Failure to follow all instructions listed below, may result in electric shock, fire and/or serious personal injury.

WORK AREA

• Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents.
• 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.
• Keep bystanders, children, and visitors away while operating a power tool. Distractions can cause you to lose control.

ELECTRICAL SAFETY

• Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances. Never remove the grounding prong or modify the plug in any way. Do not use any adaptor plugs. Check with a qualified electician if you are in doubt as to whether the outlet is properly grounded. If the tools should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user. Applicable only to Class I (grounded) tools
• Double insulated tools are equipped with a polarized plug (one blade is wider than the other.) This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized outlet. Do not change the plug in any way. Double insulation eliminates the need for the three wire grounded power cord and grounded power supply system. Applicable only to Class II (double insulated) tools.
• Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is grounded.
• Don't expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
• Do not abuse the cord. Never use the cord to carry the tools or pull the plug from an outlet. Keep cord away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately. Damaged cords increase the risk of electric shock.
• When operating a power tool outside, use an outdoor extension cord marked "W-A" or "W." These cords are rated for outdoor use and reduce the risk of electric shock. Recommended Minimum Wire Size for Extension Cords Total Length of Cord

PERSONAL SAFETY

• Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use tool while tired or under the influence of drugs, alcohol, or medication. A moment of inattention while operating power tools may result in serious personal injury,
• Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts. Air vents often cover moving parts and should also be avoided.
• Avoid accidental starting. Be sure switch is off before plugging in. Carrying tools with your finger on the switch or plugging in tools that have the switch on invites accidents.
• Remove adjusting keys or wrenches before turning the tool on. A wrench or a key that gine is left attached to a rotating part of the tool may result in personal injury.
• Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the tool in unexpected situations.
• Use safety equipment. Always wear eye protection. Dust mask, non-skid safety shoes, hard hat, or hearing protection must be used for appropriate conditions.

TOOL USE AND CARE

• Use clamps or other practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control.
• Do not force tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed.
• Do not use tool if switch does not turn it on or off. Any tool that cannot be controlled with the switch is dangerous and must be repaired.
• Disconnect the plug from the power source before making any adjustments, changing accessories, or storing the tool. Such preventative safety measures reduce the risk of starting the tool accidentally.
• Store idle tools out of reach of children and other untrained persons. Tools are dangerous in the hands of untrained users.
• Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools, with sharp cutting edges are less likely to bind and are easier to control.
• Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tools operation. If damaged, have the tool serviced before using. Many accidents are caused by poorly maintained tools.
• Use only accessories that are recommended by the manufacturer for your model. Accessories that may be suitable for one tool, may become hazardous when used on another tool.

SERVICE

• Tool service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury.
• When servicing a tool, use only identical replacement parts. Follow instructions in the Maintenance section of this manual. Use of unauthorized parts or failure to follow Maintenance Instructions may create a risk of electric shock or injury.

Additional Specific Safety Rules

• Hold tool by insulated gripping surfaces when performing an operation where the cutting tool 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.
• 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.

Wear appropriate personal hearing protection during use. Under some conditions and duration of use, noise from this product may contribute to hearing loss.

Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known 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 (CCA).

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.

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.

• The label on your tool may include the following symbols.

V	volts	A	amperes
Hz	hertz	W	watts
min	minutes		alternating current
	direct current		no load speed
	Class II Construction		earthing terminal
	safety alert symbol	/min	revolutions per minute

Switch (Variable Speed)

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.

Use of very slow speed is recommended only for beginning a cut. Prolonged use at very slow speed may damage your saw.

Blade Clamping DW303

TURN OFF AND UNPLUG SAW.

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 bladeclamp(E). Locate hole in blade (F) over pin (G) on reciprocating shaft.
3. Tighten set screw. If the blade should break off and the shank does not come out of theclamp, be sure the set screw is loose and eject the shank with a nail or pointed object.

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

Blade Clamp Release Lever DW303M and DW304P (Fig.3)

TURN OFF AND UNPLUG SAW.

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.

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

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

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.

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.

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)

STARING POSITION FOR POCKET CUTTING

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

Lubrication

Your tool was properly lubricated before leaving the factory. In from two to six months, depending upon use, take or send your tool to a Service Center, or authorized service station, for a complete cleaning, inspection and lubrication. Tools used constantly on production jobs will need relubrication more often. Also, tools "out of service" for long periods should be relubricated before being put back to work.

Accessories

Recommended accessories for use with your tool are available at extra cost from your local service center.

The use of any non-recommended accessory may be hazardous.

If you need assistance in locating any accessory, please contact DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286 or call 1-800-4 DEWALT (433-9258).

Repairs

To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including brush inspection and replacement) should be performed by authorized service centers or other qualified service organizations, always using identical replacement parts.

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. For warranty repair information, call 1-800-4-DEWALT. 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.