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INSTRUCTION MANUAL

GUIDE D'UTILISATION

MANUAL DE INSTRUCCIONES

DW788

20" (508 mm) Heavy Duty Variable Speed Scroll Saw

Scie à découper de service intensif de 508 mm (20 po) à régulateur de vitesse

Sierra caladora de 508 mm (20") con velocidad variable para trabajo pesado

INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y PÓLIZA

DE GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUCTIVO ANTES

DE USAR EL PRODUCTO.

DW788/383329 8/6/02 10:35 AM Page 3

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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: FOR YOUR OWN SAFETY, READ INSTRUCTION MANUAL BEFORE OPERATING SAW • DO NOT WEAR GLOVES,

NECKTIES, JEWELRY OR LOOSE CLOTHING • CONTAIN LONG HAIR • ALWAYS WEAR EYE PROTECTION • INSTALL BLADE WITH

TEETH POINTING DOWNWARD TOWARD THE TABLE BEFORE OPERATING SAW • MAINTAIN PROPER ADJUSTMENT OF BLADE

TENSION BLADE GUARD BEFORE OPERATING SAW • ALWAYS ADJUST MATERIAL HOLD-DOWN SO THAT IT JUST CLEARS

WORKPIECE • KEEP FINGERS A SAFE DISTANCE FROM BLADE • MAINTAIN CONTROL OF WORKPIECE AT ALL TIMES - HOLD

FIRMLY AGAINST THE TABLE • NEVER REMOVE JAMMED OR CUT-OFF PIECES UNTIL POWER IS OFF AND BLADE HAS STOPPED •

DO NOT EXPOSE TO RAIN OR USE IN DAMP LOCATIONS • SECURE TOOL PROPERLY TO PREVENT UNEXPECTED MOVEMENT •

DO NOT OPERATE THIS MACHINE WHILE UNDER THE INFLUENCE OF ALCOHOL OR DRUGS • FAILURE TO COMPLY WITH THESE

WARNINGS MAY RESULT IN SERIOUS PERSONAL INJURY.

MOUNTING HOLES (3)

BLADE

BLADE TENSION LEVER

AIR HOSE

ON/OFF SWITCH SPEED CONTROL KNOB

UPPER ARM

BRUSH

INSPECTION

CAPS

MATERIAL HOLD-DOWN

TABLE

BEVEL LOCK KNOB BEVEL SCALE

FUSE REPLACEMENT

CAP

BLADE CLAMP

THUMBSCREW

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WARNING: For your own safety read instruction manual before

operating tool.

Grounding Instructions

In the event of a malfunction or breakdown, grounding provides a path

of least resistance for electric current to reduce the risk of electric

shock. This tool is equipped with an electric cord having an

equipment-grounding conductor and grounding plug. The plug must

be plugged into a matching outlet that is properly installed and

grounded in accordance with all local codes and ordinances. Do not

modify plug provided—if it will not fit the outlet, have the proper outlet

installed by a qualified electrician.

Improper connection of the equipment-grounding conductor can

result in a risk of electric shock. The conductor with insulation having

an outer surface that is green with or without yellow stripes is the

equipment-grounding conductor. If repair or replacement of the

electric cord or plug is necessary, do not connect the equipment-

grounding conductor to a live terminal.

Check with a qualified electrician or service personnel if the grounding

instructions are not completely understood, or if in doubt as to

whether the tool is properly grounded.

Use only 3-wire extension cords that have 3-prong grounding plugs

and 3-pole receptacles that accept the tool’s plug.

Repair or replace damaged or worn cords immediately.

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English

This tool is intended for use on a circuit that has an outlet that looks

like the one illustrated in Figure A. The tool has a grounding plug that

looks like the plug illustrated in Figure A. A temporary adapter, which

looks the adapter illustrated in Figures B and C, may be used to

connect this plug to a 2-pole receptacle as shown in Figure B if a

properly grounded outlet is not available. The temporary adapter

should be used only until a properly grounded outlet can be installed

by a qualified electrician. The green-colored rigid ear, lug, and the like,

extending from the adapter must be connected to a permanent

ground such as a properly grounded outlet box.

Important Safety Instructions

•KEEP GUARDS IN PLACE and in working order.

•KEEP WORK AREA CLEAN. Cluttered areas and benches invite

injuries.

•DON’T USE IN DANGEROUS ENVIRONMENT. Don’t use power

tools in damp or wet locations, or expose them to rain. Keep work

area well lighted.

•KEEP CHILDREN AWAY. All visitors should be kept safe distance

from work area.

•MAKE WORKSHOP KID PROOF with padlocks, master switches,

or by removing starter keys.

•DON’T FORCE TOOL. It will do the job better and safer at the rate

for which it was designed.

•USE RIGHT TOOL. Don’t force tool or attachment to do a job for

which it was not designed.

•USE PROPER EXTENSION CORD. Make sure your extension

cord is in good condition. When using and 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.

A B C

GROUNDING PIN

GROUNDED

OUTLET

BOX GROUNDING

MEANS

ADAPTER

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•OUTDOOR USE EXTENSION CORDS. When tool is used

outdoors, use only extension cords intended for use outdoors and

so marked.

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 18 16 16 14

6 - 10 18 16 14 12

10 - 12 16 16 14 12

12 - 16 14 12 Not Recommended

•WEAR PROPER APPAREL. Do not wear loose clothing, gloves,

neckties, rings, bracelets, or other jewelry which may get caught in

moving parts. Nonslip footwear is recommended. Wear protective

hair covering to contain long hair.

•ALWAYS USE SAFETY GLASSES. Also use face or dust mask it

cutting operation is dusty. Everyday eyeglasses only have impact

resistant lenses, they are NOT safety glasses.

•DON’T OVERREACH. Keep proper footing and balance at all

times.

•MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for

best and safest performance. Follow instructions for changing

accessories.

•DISCONNECT TOOLS before servicing; when changing

accessories, such as blades, bits, cutters, and the like.

•REDUCE THE RISK OF UNINTENTIONAL STARTING. Make

sure switch is in off position before plugging in.

•USE RECOMMENDED ACCESSORIES. Consult the instruction

manual for recommended accessories. The use of improper

accessories may cause risk of injury to persons.

•NEVER STAND ON TOOL. Serious injury could occur if the tool is

tipped or if the cutting tool is unintentionally contacted.

•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.

•NEVER LEAVE TOOL RUNNING UNATTENDED. TURN POWER

OFF. Don’t leave tool until it comes to a complete stop.

Additional Safety Rules for Scroll Saws

•MATERIAL HOLD-DOWN must be properly set according to these

instructions and remain in position during use.

•NEVER reach under the table when operating or make any

adjustments when it is running.

•SECURE saw to work bench or stand with clamps or mounting

hardware. Secure work bench or stand to floor.

•DO NOT use the upper arm as a lifting point.

•MAKE SURE blade tension is properly adjusted.

•AVOID awkward hand positions where a sudden slip could cause a

hand to move into a saw blade or cutting tool. DO NOT PLACE

FINGERS OR HANDS IN PATH OF THE SAW BLADE.

•WHEN REMOVING short workpieces, or cleaning up around the

table, be sure the saw is in the OFF position and blade has stopped

moving.

•NEVER turn the saw ON before clearing the table of all tools, wood

scraps, etc., except the workpiece and related feed or support

devices for the operation planned.

•CHECK for proper blade size and type.

•DO NOT attempt to saw stock that does not have a flat surface,

unless a suitable support is used.

•HOLD material firmly against table and feed into blade teeth at a

moderate speed.

•TURN OFF motor if the material resists being backed out of an

uncompleted cut. Use appropriate speed for applications.

•MAKE “relief” cuts before cutting long curves.

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•CAUTION: Some wood contains preservatives such as copper

chromium arsenate (CCA) which can be toxic. When cutting these

materials, extra care should be taken to avoid inhalation and to

minimize skin contact.

•USE a dust mask and safety glasses when sawing.

•KEEP GUARDS in place and working order.

•MAKE SURE your fingers do not contact the terminals of the power

cord when installing or removing the plug to or from the line power

source.

•NEVER overfeed or force work into the blade.

•WARNING: Do not allow familiarity (gained from frequent use of

your saw) to replace following safety rules. Always remember that a

careless fraction of a second is sufficient to inflict severe injury.

WARNING: 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.

SAVE THESE INSTRUCTIONS

Mounting

Three holes are provided in the base of the scroll saw to facilitate

mounting to a table or bench (Figure 1). Always mount your saw

firmly to prevent movement.

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Assembly

Your scroll saw comes fully assembled except for the table and

blade. To install the table, first insert the pin at the back of the arm

into the hole in the back of the table (Figure 2). Push the table until its

back surface is flush against the arm and the pin is fully inserted in

the table (Figure 3).

Using the hex wrench packed with your scroll saw, securely attach

the table to the bevel scale by tightening the bolts shown in Figure 4.

Installing the Blade

BEFORE INSTALLING A BLADE, UNPLUG THE SCROLL SAW.

The blade is held in place by the thumbscrew blade clamps attached

to the top and bottom arms of the scroll saw (Figure 5).

Before installing a blade, make sure the blade tension lever is moved

fully to the right as shown in Figure 6. Next, loosen, but do not

unscrew, the top and bottom thumbscrews (Figure 5). Thread the

blade through the hole in table, with the teeth facing toward the front

of the saw. NOTE: Scroll saws cut on the downstroke, so it is

essential that teeth face forward and down.

Insert the blade into the bottom blade clamp and securely tighten

FIG. 1

MOUNTING

HOLES

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the thumbscrew. Next, insert the top of the blade into the top blade

clamp and securely tighten the top thumbscrew.

Properly adjust the tension of the blade before operating your scroll

saw. (See: Blade Tension Lever section of this manual.)

Blade Tension Lever

Move the blade tension lever (Figure 6) to the left to increase tension

on the blade.

The proper degree of tension varies with different blade sizes. If you

are frequently breaking blades, decrease tension on the blade.

As you become more accustomed to operating your scroll saw, you

will become more proficient in fine-tuning blade tension. Practice on

scrap material when possible.

Remove the blade or release tension on the blade when not using

your scroll saw for an extended period.

Material Hold-down

The material hold-down (Figure 7) should contact the surface of the

English

FIG. 3

PIN

BACK OF TABLE

FIG. 4

HEX WRENCH

BOLTS

TABLE

FIG. 2

BEVEL SCALE

TABLE

PIN

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workpiece. To adjust the material hold-down, loosen the thumbscrew

(Figure 7) and move the rod up or down. The material hold-down

must be beveled when the table is beveled. To bevel the material

hold-down, loosen the allen screw shown in Figure 7 and bevel the

material hold-down until it is parallel to the table. Retighten the

material hold-down before cutting.

NOTE: When cutting, ensure the material hold-down does not

contact the bottom arm of the scroll saw. Your scroll saw has a

maximum thickness capacity of 2". Do not cut material thicker than

2". NEVER remove the material hold-down since it also functions as

a barrier between fingers and blade.

Air Hose

Your scroll saw features an adjustable air hose to keep your work

area free from dust and debris. Be sure to position the air hose

properly: it should blow saw dust away from the operator.

On/Off Switch

To turn the scroll saw on, press the front of the switch as shown in

Figure 8.The saw locks on automatically. To turn the tool off, press the

back of the switch. A hole is provided in the switch for insertion of a

padlock to lock the saw off (Figure 8).

Speed Control Knob

Your scroll saw features a variable speed control, from 400 to 1,750

strokes per minute. To operate the variable speed feature, turn the

speed control knob (Figure 8) with the saw running.

To increase the speed, turn the knob clockwise. The numbers on the

speed control knob represent speed ranges. One is the minimum

speed, 8 is the maximum speed.

Slower speeds are recommended for metals, plastics, harder woods

and very thin materials.

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English

FIG. 5

BLADE TENSION

LEVER

FIG. 6

BOTTOM

THUMBSCREW

TOP

THUMBSCREW

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Sawing

Hold material firmly against table. Always feed material toward the

blade. Feed the workpiece fast enough to allow the blade to cut, but

do not force material into the blade too quickly.

Beveling

The table of your scroll saw bevels 45° left and right. A detent is set at

0°. To bevel the scroll saw table, loosen the bevel lock knob

(Figure 9), and bevel the table to the desired setting, indicated by the

bevel pointer.

NOTE: Before tilting the table for bevel cuts of 45˚,check the

clearance around the lower thumbscrew. To facilitate an accurate 45˚

cut the thumbscrew and setscrew may need to change places. On the

setscrew side, sufficient clearance is available.

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FIG. 8

ON/OFF SWITCH

SPEED CONTROL KNOB

PADLOCK HOLE

Fretwork

INSIDE CUTS

Your scroll saw is ideal for making inside cuts for detail work. To make

an inside cut:

1. Drill a pilot hole in your workpiece.

2. Make sure the blade tension lever is moved fully to the right

3. Loosen the top thumbscrew blade clamp.

4. Leaving the blade held in place by the bottom blade clamp, lift

the top arm of the scroll saw, as shown in Figure 10. Thread the

saw blade through the pilot hole in your workpiece and reattach

the blade by tightening the top thumbscrew.

5.Readjust the blade tension and begin the inside cut.

Alternately, you can loosen the bottom thumbscrew blade clamp in

step 3 above, and thread the blade through the top of the workpiece.

FIG. 7 MATERIAL

HOLD-DOWN

THUMBSCREW

MATERIAL

HOLD-DOWN

ALLEN SCREW

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NOTE: Do not lift saw by upper arm. Damage will occur.

Overload Protector

Your scroll saw is equipped with a 3 amp overload protection fuse. If

your scroll saw becomes overloaded and stops operating, turn off the

scroll saw, check for a blown fuse by removing the fuse cap

(Figure 11). Your scroll saw uses fuse #3AG Fast Acting,

1 1/4" long x 1/4" diameter.

Maintenance

BRUSHES

Inspect carbon brushes regularly by unplugging tool, removing the

brush inspection cap (Figure 11) and withdrawing the brush assembly.

Keep brushes clean and sliding freely in their guides. Always replace

a used brush in the same orientation in the holder as it was prior to its

removal. If the brush is worn down to 3/8", it must be replaced. Use

only identical DEWALT brushes. New brush assemblies are available

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English

BEVEL LOCK KNOB

BEVEL SCALEBEVEL POINTER

FIG. 9

FIG. 10

FIG. 11

FUSE CAP

(PRESS TO RELEASE)

BRUSH

INSPECTION

CAPS

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30 DAY NO RISK SATISFACTION GUARANTEE

If you are not completely satisfied with the performance of your

DEWALT heavy duty industrial tool, simply return it to the participating

seller within 30 days for a full refund. Please return the complete unit,

transportation prepaid. Proof of purchase may be required.

English

at Black & Decker service centers. The tool should be allowed to “run

in” (run at no load) for 10 minutes before use to seat new brushes.

TABLE

Keep the table clean and free from oil, grease and pitch. Treat the

table with paste wax to help maintain its smooth finish.

Accessories

Use only 5" plain end scroll saw blades. 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 for your tool, contact:

DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD

21286 1-800-4-DEWALT

CAUTION: The use of any other accessory not recommended

for use with this tool could be hazardous.

Important

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.

Full Warranty

DEWALT heavy duty industrial tools are warranted for one year from

date of purchase. We will repair, without charge, any defects due to

faulty materials or workmanship. 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.

In addition to the warranty, DEWALT tools are covered by our:

See ‘Tools-Electric’

– Yellow Pages –

for Service & Sales

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