DENALI AJS8203B-00 Cordless Reciprocating Saw Instruction Manual

: June 10, 2024
: DENALI

Table of Contents

DENALI AJS8203B-00 Cordless Reciprocating Saw
Product Information
Product Usage Instructions
Tool Description
- Intended Use
Preparation
- Blades
Use
Cleaning and Maintenance
- Maintenance
Frequently Asked Questions
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

DENALI AJS8203B-00 Cordless Reciprocating Saw

Product Information

Product Name: Denali V02
Model Number: 09/22
Languages Supported: English (EN), Spanish (ES), French (FR), Dutch (NL), German (DE), Polish (PL), Italian (IT), Swedish (SV)
Product Weight: Not specified
Product Dimensions: Not specified
Manufacturer: Amazon.com

Product Usage Instructions

Unbox the product and check if all the parts are included.
Ensure that the product is compatible with your device.
Refer to the user manual to learn about the different languages supported.
If required, install any necessary software or drivers for the product.
Connect the product to your device using the appropriate cables.
Turn on your device and ensure that the product is recognized.
Refer to the user manual for specific instructions on how to use the product with your device.
If you encounter any issues, refer to the troubleshooting section in the user manual or contact customer support.
When not in use, store the product in a safe and dry place to prevent damage.

WARNING Read all safety warnings, instructions, illustrations and specifications provided with this power tool.
Failure to follow all instructions listed below may result in electrics hock, fire and/or serious injury.
Save all warnings and instructions for future reference.

Tool Description

A Lock off button
B Variable speed power switch
C Handle
D Battery slot
E Orbit control lever
F Base plate
G Blade roller guide
H Blade guard
I Tool-less blade change cover
J LED light
K Locking screw
L Set screw
M Base plate adjustment lever
N Cutting blade

Intended Use

This tool is intended for making cut-throughs and cut-outs in wood, plastic, metal,ceramic plates and rubber. It is suitable for straight and curved cuts.
This tool is intended to be used on dry surfaces and areas only.
This tool is intended for private use only.
Use in well-ventilated areas.

Before First Use

DANGER Risk of suffocation!
Keep any packaging materials away from children and pets — these materials are a potential source of danger, e.g. suffocation.

Remove all the packing materials.
Remove and review all components before use.
Check the tool for transport damages.
Do not use the tool if it appears damaged.

Preparation

Blades

Blade type for different materials

The cutting blades (N) provided have been printed with the type of the material it is intended for. Use only the correct cutting blades (N) for the corresponding material.
Blades with fewer teeth, e.g. 7 teeth per inch (TPI), are typically used for cutting wood. Blades with more TPI are better for cutting metal or plastic.
It is recommended to use 14 TPI blades for plastics and soft metals and 18 TPI blades for hard metals.

Compatible blade shanks
The cutting blades (N) provided for the tool are T-shank blades. The toolless blade change cover (l) is compatible with U-shank and T-shank blades (Fig. 1).

Attaching the cutting blade

CAUTION

Take off the battery pack before attaching a cutting blade (N) to prevent accidentally starting the tool.
Use only the correct cutting blades (N) for the corresponding material.
Wear protective work gloves while handling a cutting blade (N). The cutting blade (N) can injure unprotected hands.

NOTICE
The tool is compatible with T-shank and U-shank blades.

Push and hold the tool-less blade change cover (I) up (Fig. 2).
With the back of the cutting blade (N) facing the blade roller guide (G), insert the desired cutting blade (N) into the toolless blade change cover (l) (Fig. 2).
Release the tool-less blade change cover (l).
Pull the cutting blade (N) away from the tool to verify it is installed correctly. If the cutting blade (N) comes out, repeat the installation steps.

Detaching the cutting blade

CAUTION

Take off the battery pack before detaching a cutting blade (N) to prevent accidentally starting the tool.
Wear protective work gloves while handling a cutting blade (N). The cutting blade (N) can injure unprotected hands.

Push and hold the tool-less blade change cover (l) up (Fig. 3).
Take out the cutting blade (N) (Fig. 3).
Release the tool-less blade change cover (l).
Clean and store the cutting blade (N).

Adjusting the base plate bevel angle

CAUTION
Take off the battery pack before making adjustments to prevent accidentally starting the tool.

Take care to avoid contact with the cutting blade (N) while making adjustments.
Attempting to make bevel cuts without the base plate adjustment lever (M) securely closed can result in serious injury.
Because of the increased amount of blade engagement in the work while bevel cutting and decreased stability of the base plate (F), blade binding may occur. Keep the tool steady and the base plate (F) firmly on the workpiece.

NOTICE
Always make a trial cut in scrap material along a guideline to determine how much to offset from the guideline on the workpiece to be cut.
The base plate (F) of the tool can be adjusted to create 00 or 450 bevel cuts on the workpiece.

Open the base plate adjustment lever (M) (Fig. 4).
Move the base plate (F) slightly forwards to disengage the locking tab (Fig. 5).
Position the base plate (F) to the desired angle (00 or 450) (Fig. 6).
Move the base plate (F) slight backwards to engage the locking tab (Fig. 7).
Close the base plate adjustment lever (M) (Fig. 8).

Adjusting orbital action settings
CAUTION

Take off the battery pack before making adjustments to prevent accidentally starting the tool.
Take care to avoid contact with the cutting blade (N) while making adjustments.

NOTICE
Always make a trial cut in scrap material to determine which orbital action setting is suitable for the workpiece.
The orbital setting of the tool makes the cutting blade (N) follow a circular movement which increases the cutting speed. More orbital action means faster but also more rough sawing (Fig. 9). The less orbital action is used, the more accurate the cut is (Fig. 9). The sawing orbital action of the cutting blade (N) can be adjusted to adapt to the cutting speed, cutting capacity, cutting pattern and the workpiece material.

Set the orbit control lever (E) to the desired setting:

Attaching the battery pack

CAUTION
Battery tools are always in operating condition. Therefore, take off the battery when the tool is not in use or when it is being carried.

NOTICE

Use the tool with a fully charged battery pack that is suitable for this tool. Use this tool only with the provided battery pack (model ABY5197B-OO, ABY5197B-OOE, ABY5196B-OO or ABY5196B-OOE) and charger. Use of non-compliant battery packs and chargers may cause risk of fire and/or explosion.
When placing the battery pack on the tool, be sure that the raised rib on the battery pack aligns with the groove inside the tool and that the latches snap into place properly. Improper attachment of the battery pack can cause damage to internal components.

Align the raised ribs on the battery pack with the battery slot (D) on the tool.
Slide the battery pack onto the tool (Fig. 10). The battery pack snaps and locks into place.

Detaching the battery pack

Press and hold the battery-release button located on the front of the battery pack to release it from the battery slot (D) (Fig. 11).
Slide the battery pack off the tool (Fig. 11).

Use

Operating parts
The tool has the following parts that are often used during cutting (Fig. 12).

Lock off button (A)
The lock off button (A) prevents unintentionally pressing the variable speed power switch (B). The variable speed power switch (B) can only be activated if the lock off button (A) is at the unlocked position.
Variable speed power switch (B)
Pressing the variable speed power switch (B) starts the cutting action. The tool cuts at higher speeds with increased power pressure and lower speeds with decreased power pressure.
Handle (C)
Stand behind the tool and hold the handle (C) while operating to ensure that no body parts are in the way of the cutting path of the tool.
Blade guard (H)
The blade guard (H) is intended to keep hands or other body parts to come directly come in contact with the cutting blade (N).
LED light (J)
The LED light (J) is located above the blade guard (H). The LED light (J) switches on when the variable speed power switch (B) is pressed, and switches off 8-12 seconds after it is released. It provides additional light on the cutting blade (N) and the surface of the workpiece during operation in lower- light areas.
If the tool and/or battery pack becomes overloaded or too hot, the internal sensors will switch the tool off, and the LED light (J) rapidly flashes. Rest the tool for a while or place the tool and battery pack separately under air flow for cooling.
The LED light (J) flashes slowly when the battery power is running low. Charge the battery pack or change to another full battery pack to continue using the tool.
Dust blowing action
The dust blowing action activates automatically when the variable speed power switch (B) is pressed and deactivates when it is released. It blows away the dust created during cutting for better visibility on the workpiece.

Before each use

Wear personal protective equipment (PPE). Depending on the application, use face shield, safety goggles or safety glasses. As appropriate, wear dust mask, hearing protectors, gloves and full body suit capable of stopping small abrasive or workpiece fragments (Fig. 13).
Check the tool and its accessories for damage. Do not use the tool if it is damaged or worn out.
Check for loose screws, misalignment or binding of moving parts, or any other condition that may affect the operation. If abnormal vibration or noise occurs, switch the tool off immediately and have the problem corrected before further use.
Do not attempt to modify this tool or create accessories not recommended for use with this tool. Any such alteration or modification is misuse and could result in a hazardous condition leading to possible serious injury.
Check the condition of the battery pack. Charge the battery pack if needed. Do not use the battery if it is bulging or hot.
Always firmly hold the tool by its handle and insulated grip areas. Keep the tool clean and wear clean gloves to maintain a firm grip while in use.
Check that the ventilation openings are not obstructed. Obstructed ventilation openings can cause overheating. Clean the tool with compressed dry air if needed.
Stop operating the tool immediately if bystanders are interrupting the work. Never lay the tool down until it has stopped completely. The blade may grab the surface and pull the tool out of control.
Do not work continuously for extensive amounts of time with the tool. Take breaks in between work to ensure full concentration while using the tool.
Check the base plate adjustment lever (M) is securely closed before using the tool.

Cutting tips

WARNING Risk of injury!

To make cutting easier and safer, always maintain proper control of the tool. Loss of control could cause an accident resulting in serious injury.
Maintain a firm grip and operate the variable speed power switch (B) with a decisive action. Never force the tool. Use light and continuous pressure.

To make the safest and best possible cut, follow these cutting tips:

Draw a guideline along the desired cutting line before beginning the cut.
Hold the handle (C) firmly.
Do not twist or bend the blade.
Prevent the workpiece from sliding by securing it with clamps. Do not attempt to hold a workpiece in place with hands or not at all.
Apply even pressure on the tool while cutting and make sure the base plate (F) is flat and fully in contact with the workpiece.
Always allow the blade to come to a complete stop before lifting the tool from the workpiece.
Use a rip fence (not included) for clean straight cuts.
Use a reverse tooth blade (cuts on the down stroke) to avoid chipping on the surface of laminated panels, plywood, fiber boards, chipboard and softwood.
Use masking tape on the base plate surface in contact with the workpiece to avoid scratching the surface of the workpiece.

NOTICE
When cutting across the grain, the fibers of the wood have a tendency to tear and lift. Advancing the tool slowly can minimize this effect.

Metal cutting

WARNING Risk of injury!

Never use the wood-cutting blade for cutting metals.
Never use gasoline as cutting lubricant, because normal sparking could ignite the fumes.
To cut thin sheet material, “sandwich” the material between pieces of hardboard or plywood and clamp the layers together to reduce vibration and tearing of the material.
The tool can be used to cut metals, such as sheet steel, pipe, steel rods, aluminum,brass, and copper.
If the tool jumps or bounces, use a blade with finer teeth.
If the blade seems clogged when cutting soft metal, use a blade with coarser teeth. t Use cutting oil/wax when cutting soft metals and steel. Cutting oil/wax will keep the blade cool, increase the cutting action and prolong blade life.
Thin metal should be sandwiched between 2 pieces of wood or tightly clamped onto a single piece of wood (wood on top of the metal). Draw the guideline or design on the upper piece of wood.
When cutting aluminum extrusion or angle iron, clamp the work in a bench vise and saw close to the vise jaws.
When sawing tubing and the diameter is larger than the blade depth, cut through the wall of the tubing and then insert the blade into the cut, rotating the tube while sawing.

Starting the tool

1. Set the lock off button (A) to the unlock position (Fig. 14).

Press the variable speed power switch (B)

Stopping the tool

Release the variable speed power switch (B).
Set the lock off button (A) to the lock position (Fig. 15).

Making different cuts

NOTICE
When sawing fiberglass, plaster, wallboard, or spackling compound, clean the ventilation openings frequently with a vacuum or with compressed air. These materials are highly abrasive and may accelerate the wear on motor bearings and brushes.

General cuts
Secure the workpiece with clamps. Check for clearance surrounding the workpiece to ensure that the cutting blade (N) does not come into contact with other objects.
Mark a guideline for the cut. If cutting metal, apply cutting oil/wax to the guideline.
Select and attach a suitable cutting blade (N) to the tool following 4.2 Attaching the cutting blade chapter.
Adjust the angle of the base plate (F) following 4.4 Adjusting the base plate bevel angle chapter. Make sure the base plate (F) is securely locked in place.
Set the orbit control lever (E) to the desired setting following 4.5 Adjusting orbital action settings chapter.
Rest the front edge of the base plate (F) on the workpiece without touching the cutting blade (N) to the workpiece.
Start the tool, let the cutting blade (N) reach the desired speed then follow the guideline to make the cut (Fig. 16).
After cutting, stop the tool and allow the cutting blade (N) to stop completely.
Lift the tool off the workpiece.
Rip cut using a straight edge

WARNING Risk of injury!
A rip fence (not included) can be used as a guide instead of clamping a straight edge so that the tool always travels at the same distance between the tool and the edge.

Secure the workpiece with clamps.
Clamp a straight edge to the workpiece using clamps (not included).
Mark a guideline for the cut. If cutting metal, apply cutting oil/wax to the guideline.
Select and attach a suitable cutting blade (N) to the tool following 4.2 Attaching the cutting blade chapter.
Adjust the angle of the base plate (F) following 4.4 Adjusting the base plate bevel angle chapter. Make sure the base plate (F) is securely locked in place.
Set the orbit control lever (E) to the desired setting following 4.5 Adjusting orbital action settings chapter.
Rest the front edge of the base plate (F) on the workpiece without touching the cutting blade (N) to the workpiece.
Start the tool, let the cutting blade (N) reach the desired speed.
Following the straight edge, guide the tool into the workpiece to make the cut (Fig. 17).
After cutting, stop the tool and allow the cutting blade (N) to stop completely.
Lift the tool off the workpiece.

Plunge cut

WARNING Risk of injury!
Do not plunge cut into metal.

Follow steps 1-5 of 5.6. 1 General cuts chapter.
Hold the saw firmly and rest front side of the base plate (F) on the workpiece. The cutting blade (N) is not in contact with the workpiece.
Start the tool at a slow speed and gradually increase cutting speed while cutting into the workpiece.
Let the cutting blade (N) go through the workpiece, using the base plate (F) as a pivot point until it is parallel with the workpiece (Fig. 18).
Proceed to follow the guideline to finish the cut.
After cutting, stop the tool and allow the cutting blade (N) to stop completely.
Lift the tool off the workpiece.

Cleaning and Maintenance

NOTICE

Detach the battery pack before cleaning, maintenance, storage, or transportation.
Do not immerse the tool in water or other liquids. Never hold the tool under running water.

Cleaning the housing

To clean the tool, wipe with a soft, slightly damp cloth.
Wipe the tool dry after cleaning.
Never use corrosive detergents, wire brushes, abrasive scourers, metal or sharp utensils to clean the tool.

NOTICE

The tool may be cleaned most effectively with compressed dry air. When doing so, do not exceed the pressure of 43 PSI (3 bar) and always wear safety goggles.
Certain cleaning agents and solvents damage plastic parts. Some of these are: gasoline, carbon tetrachloride, chlorinated cleaning solvents, ammonia and
household detergents that contain ammonia. Do not use cleaning agents and solvents containing these, as they can damage the tool.

Retighten the base plate

Open the base plate adjustment lever (M) halfway.
On the bottom of the base plate (F), loosen the locking screw counter-clockwise with a screwdriver (Fig. 19).
Take out the locking screw and locking ring.
Tighten the set screw clockwise with a screwdriver.
Put the locking screw and locking ring back.
Tighten the locking screw clockwise with a screwdriver.
Fully close the base plate adjustment lever (M).

Blade care

Blades become dull after some use. If the tool has to be forced to go through a cut,the blade is dull or is not clean.
Wipe a dirty blade with kerosene or similar solvent to remove the gum and pitch. t Replace the blade if it has become dull.

Repair
This tool does not contain any parts that can be repaired by the user. Contact a professional repair center or a professional technician to have the tool checked out and repaired.

Transport

Make sure the tool is secured safely for transit.
Avoid vibrations and shocks.

Storage

Clean the tool before storing.
Store the tool in its original packaging in a dry area. Keep away from children and pets.

Spare parts/replacement parts

CAUTION Risk of injury!
Using parts that are not compatible with the tool may cause accidents that can result in serious injury.

Maintenance

CAUTION Risk of injury!
Maintenance performed by unauthorized personnel may result in misplacing of internal wires and components which could cause a serious injury.

Any other servicing than mentioned in this manual should be performed by a professional repair center.