DeWalt DW716 TYPE2, DW716 TYPE1 Owner’s Manual
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INSTRUCTION MANUAL
GUIDE D'UTILISATION
MANUAL DE INSTRUCCIONES
DW716 (120 Volt), DW716 (230 Volt)
INSTRUCTIVO DE OPERACION, CENTROS DE SERVICIO Y POLIZA
DE GARANTiA. ADVERTENCIA: LI2ASE ESTE INSTRUCTIVO ANTES
DE USAR EL PRODUCTO.
12" Double Bevel Compound Miter Saw
Scie coulissante a onglets mixtes, 305 mm (12 po)
Sierra ingletadora compuesta de doble bisel de 305 mm (12")
TABLE OF CONTENTS
DOUBLE INSULATION/POLARIZED PLUG INSTRUCTIONS ...................................... 2
SAFETY INSTRUCTIONS FOR ALL TOOLS .................................................... 2
ADDITIONAL SAFETY RULES ........................................................................ 2
ELECTRICAL CONNECTION ........................................................................ 3
ACCESSORIES .............................................................................................................. 3
BLADE DESCRIPTIONS ................................................................................................ 4
UNPACKING YOUR SAW ............................................................................. 4
SPECIFICATIONS .......................................................................................................... 4
FAMILIARIZATION ....................................................................................... 5
BENCH MOUNTING ...................................................................................................... 5
CHANGING OR INSTALLING A NEW BLADE .............................................................. 6
TRANSPORTING THE SAW .......................................................................... 6
ADJUSTMENTS .......................................................................................... 6
MITER SCALE ADJUSTMENT ................................................................... 7
MITER POINTER ADJUSTMENT ................................................................ 7
BEVEL SQUARE TO TABLE .................................................................................... 7
BEVEL POINTER ...................................................................................................... 7
BEVEL STOP ADJUSTMENT .................................................................................... 7
FENCE ADJUSTMENT ............................................................................. 7
AUXILIARY FENCE .................................................................................................... 7
AUTOMATIC ELECTRIC BRAKE .............................................................................. 7
GUARD ACTUATION AND VISIBILITY ........................................................ 8
MITER LOCK ADJUSTMENT .................................................................................... 8
CONTROLS .................................................................................................................... 8
OPERATION .................................................................................................................... 9
SWITCH ...................................................................................................................... 9
CUTTING WITH YOUR SAW .................................................................................... 9
CROSSCUTS ................................................................................................................ 9
BEVEL CUTS ................................................................................................................ 9
QUALITY OF CUT ........................................................................................................ 9
BODY AND HAND POSITION .................................................................................... 9
CLAMPING THE WORKPIECE .............................................................................. 10
SUPPORT FOR LONG PIECES .............................................................................. 10
CUTTING PICTURE FRAMES, SHADOW BOXES
AND OTHER FOUR-SIDED PROJECTS ................................................................ 10
CUTTING TRIM MOLDING AND OTHER FRAMES .............................................. 10
CUTTING COMPOUND MITERS ............................................................................ 10
VERNIER SCALE ...................................................................................................... 10
CUTTING BASE MOLDING .................................................................................... 11
CUTTING CROWN MOLDING ................................................................................ 11
SPECIAL CUTS ............................................................................................................ 12
REMOVING AND REPLACING THE BELT .................................................................. 13
MAINTENANCE ............................................................................................................ 13
WARRANTY .................................................................................................................. 13
TROUBLESHOOTING GUIDE ...................................................................................... 14
TABLE 1: COMPOUND MITER CUT .......................................................................... 15
BRUSHES .................................................................................................. 8
IFYOUHAVEANYQUESTIONSORCOMMENTSABOUTTHISORANYDEWALT
TOOL,CALLUSTOLLFREEAT:1-800-4-DEWALT(1-800-433-9258)
Important Safety Instructions
always be followed to reduce risk of fire, electric shock, and personal injury,
A WARNING: When using electric tools, basic safety precautions should
including the following:
READ ALL INSTRUCTIONS
Double Insulation
Double insulated tools are constructed throughout with two separate layers of electrical
insulation or one double thickness of insulation between you and the tool's electrical
system. Tools built with this insulation system are not intended to be grounded. As a result,
your tool is equipped with a two prong plug which permits you to use extension cords
without concern for maintaining a ground connection.
NOTE: Double insulation does not take the place of normal safety precautions when
operating this tool. The insulation system is for added protection against injury resulting
from a possible electrical insulation failure within the tool.
_\CAUTION: WHEN SERVICING USE ONLY IDENTICAL REPLACEMENT PARTS.
Repair or replace damaged cords.
Polarized Plugs
Polarized plugs (one blade is wider than the other) are used on equipment to reduce the
risk of electric shock. When provided, this plug will fit in the 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 the proper outlet. Do not change the plug in any way.
Safety Instructions For All Tools
• KEEP GUARD IN PLACE and in working order.
• REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see that
keys and adjusting wrenches are removed from spindle before turning tool on.
• KEEP WORKAREA CLEAN. Cluttered areas and benches invite accidents.
• DON'T USE IN DANGEROUS ENVIRONMENT. Don't use power tools in damp or wet
locations, or expose them to rain or snow. Keep work area well lighted.
• KEEP CHILDREN AWAY. All visitors should be kept at a safe distance from work area.
• MAKE WORKSHOP KID PROOF with padlocks, master switches, or by removing
starter keys.
• DON'TFORCE TOOL. It will do the job better and be 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.
• WEAR PROPER APPAREL. No loose clothing, gloves, neckties, rings, bracelets, or
other jewelry to get caught in moving parts. Non-slip footwear is recommended. Wear
protective hair covering to contain long hair. Air vents may cover moving parts and
should also be avoided.
• ALWAYS WEAR SAFETY GLASSES. Also use face or dust mask ff cutting operation
is dusty. Everyday glasses have only impact resistant lenses, they are NOT safety
glasses. All users and bystanders must wear eye protection that conforms to ANSI
Z87.1. (CAN/CSA Z94.3)
• SECURE WORK. Use clamps or vise when you cannot secure the workpiece on the
table and against the fence by hand or when your hand will be dangerously close to the
blade (within 6").
• 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 lubricating and changing accessories.
• DISCONNECT TOOLS before servicing; when changing accessories such as blades,
bits, cutters, etc.
• REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure switch is in OFF
position before plugging in.
• USE RECOMMENDED ACCESSORIES. Consult the instruction manual for recom-
mended 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 cut-
ting 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 per-
form 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 opera-
tion. A guard or other part that is damaged should be properly repaired or replaced. Do
not use tool if switch does not turn it on and off.
• NEVER LEAVE TOOL RUNNING UNATTENDED. TURN POWER OFF. Don't leave
tool until it comes to a complete stop.
• DO NOT OPERATE ELECTRIC TOOLS NEAR FLAMMABLE LIQUIDS OR IN
GASEOUS OR EXPLOSIVE ATMOSPHERES. Motors in these tools may spark and
ignite fumes.
• EXTENSION CORDS. Make sure your extension cord is in good condition. When using
an 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 small-
er the gage number, the heavier the cord.
Minimum Gage for Cord Sets
Volts Total Length of Cord in Feet
120V 0-25
240V 0-50
Ampere Rating
More Not more AWG
ThanThan
0 6 18 16 16 14
6 10 18 16 14 12
10 - 12 16 16 14 12
12 - 16 14 12 Not Recommended
26-50 51-100 101-150
51-100 101-200 201-300
Additional Safety Rules For Miter Saws
A CAUTION: FAILURE TO HEED THESE WARNINGS MAY RESULT IN PERSONAL
INJURYAND SERIOUS DAMAGE TO THE SAW.
• DO - Protect electric supply line with at least a 15 ampere time-delay fuse or a circuit
• DO - Make certain the blade rotates in the correct direction and that the teeth at the
• DO - Be sure all clamp handles are tight before starting any operation.
• DO - Be sure all blade and clamp washers are clean and recessed sides of collars are
• DO - Keep saw blade sharp.
• DO - Keep motor air slots free of chips and dirt.
• DO - Use blade guards at all times.
• DO - Keep hands outofpath ofsawblade.
• DO - Shut off power, disconnect cord from power source and wait for saw blade to stop
• DO - Support long work with an outboard tool rest.
breaker.
bottom of the blade are pointing to the rear of the miter saw.
against blade. Tighten arbor screw securely.
before servicing or adjusting tool
• DON'T - Attempt to operate on anything but designated voltage.
• DON'T - Operate unless all clamp handles are tight.
• DON'T - Use blades larger or smaller than those which are recommended.
• DON'T - Wedge anything against fan to hold motor shaft.
• DON'T - Force cutting action. (Stalling or partial stalling of motor can cause major
damage. Allow motor to reach full speed before cutting.)
• DON'T - Cut ferrous metals (Those with any iron or steel content) or any masonry.
• DON'T- Use abrasive wheels. The excessive heat and abrasive particles generated by
them will damage the saw.
• DON'T - Allow anyone to stand behind saw.
• DON'T - Apply lubricants to the blade when it's running.
• DON'T - Place either hand in the blade area when the saw is connected to the power
source.
• DON'T - Use blades rated less than 4800 R.P.M.
• DO NOT - Cut small pieces without clamping. Keep hands 6" or more from blade.
• DON'T - Operate saw without guards in place.
• DON'T- Perform any operation freehand.
• DON'T - Reach around or behind saw blade.
• DON'T - Place hands closer than 6 inches from the saw blade.
• DO NOT - Reach underneath the saw unless it is turned off and unplugged. The saw
blade is exposed on the underside of the saw.
• DO NOT- Move either hand from saw or workpiece or raise arm until blade has stopped.
• DO NOT - Use lubricants or cleaners (particularly spray or aerosol) in the vicinity of the
plastic guard. The polycarbonate material used in the guard is subject to attack
by certain chemicals.
• Never use without kerf plate, and replace when kerf plate is damaged because small
chip accumulation under saw may interfere with saw blade or may cause instability of
workpiece when cutting.
CAUTION: Do not connect unit to electrical power source until complete instructions are
read and understood.
ACAUTION: Wear appropriate personal hearing protection during use. Under some
conditions and duration of use, noise from this product may contribute to hearing loss.
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.
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, orlay
on the skin may promote absorption of harmful chemicals.
A 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.
For your convenience and safety, the following warning labels are on your miter saw.
ON MOTOR HOUSING:
WARNING: FOR YOUR OWN SAFETY, READ INSTRUCTION MANUAL
BEFORE OPERATING SAW.
WHEN SERVICING, USE ONLY IDENTICAL REPLACEMENT PARTS.
DO NOT EXPOSE TO RAIN OR USE IN DAMP LOCATIONS.
ALWAYS WEAR EYE PROTECTION.
ON MOVING FENCES: ALwAYsAIJJIJSTFENCEP,IJPERLYBEFIJSEUSE.
AL WAYS ADJUST FENCE PROPERL Y CLAMRSMALLRIECESREFRRECljmNG.SEEMANIJAL
BEFORE USE. Clamp smafl pieces ,ERRAMIENTA.ASEGURE[ASPiEZASPEQIJENASANTESBE
before cutting. See manual. TOUJOIJRSRIEGLERLEGUIDE AVANT L'UT|LISATION. FIXERLES
ON GUARD: IJ'UTlUSA'aON.
AJIJSTE[A 6UJA DEIJIDAMENTE ANTES DEIJT/LIZAR [A
CORTAR[AS, CIJNSULTE ELMANUAL
PETJTSOBJETS AVANT RE LESSCJER,CONSULTERLEGUIDE
DANGER- KEEP AWAY FROM BLADE.
ON UPPER GUARD:
PROPERLY SECURE BRACKET WITH BOTH SCREWS KEEPAWAV
BEFORE USE. MA,VE,E,SALEJAOIJ
ON TABLE: (2 PLACES) , OELA.IJJA
FROM BLADE
S'ELOIGNER BE LA LAME
ALWAYS TIGHTEN ADJUSTMENT KNOBS BEFORE USE. KEEP
HANDS 6" FROM PATH OF SAW BLADE.
NEVER PERFORM ANY OPERATION FREEHAND.
NEVER CROSS ARMS IN FRONT OF BLADE.
THINK! YOU CAN PREVENT ACCIDENTS.
DO NOT OPERATE SAW WITHOUT GUARDS IN PLACE. TURN
OFF TOOL, KEEP SAW HEAD DOWN AND WAIT FOR SAW TO STOP BEFORE
MOVING HANDS, WORKPIECE OR CHANGING SETTINGS.
UNPLUG TOOL BEFORE CHANGING BLADE, MOVING OR SERVICING UNIT.
ON BASE:
Electrical Connection
Be sure your power supply agrees with the nameplate marking. 120 volts, AC means that
your saw will operate on alternating current. The switch is suseptible to failure if direct cur-
rent is used. Avoltage decrease of 10 percent or more will cause a loss of power and over-
heating. All DEWALT tools are factory tested. If this tool does not operate, check the power
supply.
Accessories
Recommended accessories for use with your tool are available at extra cost from your
local service center.
_ CAUTION: The use of any non-recommended accessory such as dado sets, molding
cutters, or abrasive wheels 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 (1-800-
433-9258).
Optional Accessories
The following accessories, designed for your saw, may be helpful. In some cases, other
locally obtained work supports, length stops, clamps, etc., may be more appropriate. Use
care in selecting and using accessories.
Laser Guide System: DW7187
Laser is available at extra cost from DEWALT Service Centers and your home
improvement retailer. Instructions for installation are included with the accessory. Read
and follow all directions for safe installation and use.
Extension, Work Support: DW7080
Used to support long overhanging workpieces, the work support is user assembled.
Your saw table is designed to accept two work supports; one on each side.
Adjustable Length Stop: DW7051
Requires the use of one work support (page 4). It is used to make repetitive cuts of the
same length from 0 to 42".
Clamp:DW7082
Usedforfirmlyclampingworkpiecetothesawtableforprecisioncutting.
DustBag:DW7053(Includedwithsomemodels)
Equippedwithazipperforeasyemptying,thedustbagwillcapturethemajority
ofthesawdustproduced(notshown).
NOTE:Deflectorondustspoutchannelsdebristoground.Spouthasaprovision
toattachavacuumhosetocollectsawdust.Liftdustspouttoconnecthose.
CrownMoldingFence:DW7084
Usedforprecisioncuttingofcrownmolding.
KerrPlateBlank:DW7055
Usedtolimitbacksidetearoutofmaterialorasareplacementkerrplate.
SAWBLADES:ALWAYSUSE12"SAWBLADESWITH1"ARBORHOLES.SPEED
RATINGMUSTBEATLEAST4800RPM.Neveruseasmallerdiameterblade.Itwill
notbeguardedproperly.
BLADE DESCRIPTIONS
TOOTH
APPLICATION MODEL # DIAMETER TEETH GRIND
Construction Saw Blades (thin kerf with anti-stick rim)
General Purpose DW3123 12" 32 ATB
Fine Crosscuts DW3126 12" 60 ATB
Fine Crosscuts DW3128 12" 80 ATB
Woodworking Saw Blades (provide smooth, clean cuts)
Fine crosscuts DW7648 12" 60 ATB
Fine crosscuts DW7649 12" 80 ATB
Ultra-fine crosscuts DW7650 12" 96 ATB
Laminates DW7661 12" 80 TCG
Solid surface
and plastics DW7668 12" 80 Mod TCG
Non-ferrous metals DW7666 12" 80 TCG
END
PLATE
LOCKNUTS
DW7082
DW7080
DW7051
KNOBS
TOP HOLE
(USE FOR
DW716)
BRACKET
Unpacking Your Saw
Check the contents of your miter saw carton to make sure that you have received all
parts. In addition to this instruction manual, the carton should contain:
1. One No. DW716 miter saw.
2. One DEWALT 12" dia. saw blade
3. One blade wrench in wrench pocket shown in Figure 2.
4. One DW7053 dustbag (some models).
Specifications
CAPACITY OF CUT
50° miter left and right
48° bevel left and right
0° miter
Max. Height 3.6" (91.5mm)
Max. Width 7.9" (200.7mm)
45° miter
Max. Height 3.6" (91.5mm)
Max. Width 5.5" (140mm)
Result Width 7.2" (183mm)
Result Height 2.9" (73.7mm)
Result Width 4.9" (125mm)
Result Height 2.9" (73.7mm)
45° bevel- Left
Max. Height 2.3" (58.4 mm) Result Width 7.4" (188mm)
Max. Width 7.9" (200.7mm) Result Height 1.9" (48.3 mm)
45° bevel- Right
Max. Width 7.9" (200.7mm) Result Height 1.1" (28mm)
Max. Height 1.6" (40.6 mm) Result Width 7.1" (180.3mm)
DW7084
Your saw is capable of cutting baseboard moldings 0.9"
(22.9mm) thick by 6.0" (152.4mm) tall on a 45° right or left
miter.
NOTE: Your saw is capable of cutting the following once a
special setup procedure is followed (see Special Cuts).
0° miter height 1.5" (38.1 mm)
width 10" (255 mm)
45° miter
height 1.5" (38.1 mm)
width 7.5" (190.5 mm)
DRIVE
120 Volt Motor
1675 Watts (max in)
3600 RPM
Multi-V Belt
Automatic Electric Brake
15 Amp Motor
Cut Helical Gears
Roller Bearings
Carbide Blade
Familiarization
Your miter saw is fully FIG. 1 ....
assembled in the carton. _
Open the box and lift the saw _ .....
out by the convenient carry- _
ing handle, as shown in
Figure 1.
Place the saw on a smooth,
flat surface such as a work-
bench or strong table.
Examine Figure 2 to become familiar with the saw and its
various parts. The section on adjustments will refer to
these terms and you must know what and where the
parts are.
Press down lightly on the operating handle and pull out the
lock down pin, as shown in Figure 2. Gently release the
downward pressure and hold the arm allowing it to rise to its
full height. Use the lock down pin when carrying the saw
from one place to another. Always use the carrying handle
to transport the saw or the hand indentations shown in
Figure 2.
Bench Mounting
Holes are provided in all four feet to facilitate bench mount-
ing, as shown in Figure 2. (Two different sized holes are
provided to accommodate different sizes of screws. Use
either hole, it is not necessary to use both.) Always mount
your saw firmly to a stable surface to prevent movement.
To enhance the tool's portability, it can be mounted to a
piece of 1/2" or thicker plywood which can then be
clamped to your work support or moved to other job sites
and reclamped.
OPERATING HANDLE
LOCK DOWN
PIN
0° BEVEL STOP
ADJUSTMwENT_
GUARD
SCALE
FIG. 2
RIGHT SIDE
FENCE
CARRY HANDLE
MOTOR END
CAP _
MOTOR
FENCE LOCK
KNOB
DUST
SPOUT
LOCK KNOB
0° BEVEL
OVERRIDE KNOB
TRIGGER
SWITCH
LOCK DOWN
PIN
HANDLE
LEFT SIDE
FENCE
FENCE LOCK
KNOB
HAND
INDENTATIONS
BENCH MOUNTING MITER
HOLES SCALE
MITER
LOCK LEVER
45°BEVEL
OVERRIDE
LEVERS
45°
BEVEL STOP
ADJUSTMENT
SCREW
BEVEL STOP
33.85 ° PAWLS
BLADE
WRENCH
NOTE: If you elect to mount your saw to a piece of ply-
wood, make sure that the mounting screws don't protrude
from the bottom of the wood. The plywood must sit flush on
the work support. When clamping the saw to any work sur-
face, clamp only on the clamping bosses where the mount-
ing screw holes are located. Clamping at any other point
will surely interfere with the proper operation of the saw.
A CAUTION: To prevent binding and inaccuracy, be sure
the mounting surface is not warped or otherwise uneven.
If the saw rocks on the surface place a thin piece of mate-
rial under one saw foot until the saw sits firmly on the
mounting surface.
IMPORTANT SAFETY
INSTRUCTIONS
Changing or Installing a New Saw
Blade (Fig. 3)
A CA UTION:
• Neverdepress the spindle Iockbutton while the blade is
under power or coasting.
• Do not cut ferrous metal (containing iron or steel) or
masonry or fiber cement product with this miter saw.
FIG. 3
FIG. 3A
4. Depress the spindle lock button (C) while carefully
rotating the saw blade by hand until the lock engages.
5. Keeping the button depressed, use the other hand and
the wrench provided (D) to loosen the blade screw.
(Turn clockwise, left-hand threads)
6. Remove the blade screw (E), outer clamp washer (F),
and blade (G). The 1" (25.4mm) blade adapter (H), if
used, and the inner clamp washer (I), may be left on
the spindle.
FIG.3B
E F
G
4. Install the blade screw and, engaging the spindle lock,
tighten the screw firmly with wrench provided. (Turn
counterclockwise, left-hand threads)
NOTE: When using blades with a 5/8" (15.88mm) diameter
blade hole, the blade adapter will not be used and should
be stored in a safe place for future use.
5. Return the guard bracket to its original position and
firmly tighten the guard bracket screw to hold bracket
in place.
A WARNING:
• The guard bracket must be returned to
its original position and the screw
tightened before activating the saw.
• Failure to do so may allow the guard to
contact the spinning saw blade result-
ing in damage to the saw and severe
personal injury.
Transporting the Saw
TURN OFF AND UNPLUG THE MITER SAW BEFORE
ATTEMPTING TO MOVE IT OR MAKE ANY ADJUST-
MENTS WHAT SO EVER!
In order to conveniently carry the miter saw from place to
place, a carrying handle has been included on the top of
the saw arm and hand indentations in the base, as shown
in Figures 2, 4.
FIG. 4
B
D
Removing the Blade
1. Unplug the saw.
2. Raise the arm to the upper position and raise the lower
guard (A) as far as possible.
3. Loosen, but do not remove guard bracket screw (B)
until the bracket can be raised far enough to access
the blade screw. Lower guard will remain raised due to
the position of the guard bracket screw.
NOTE: For blades with a blade hole of 5/8" (15.88mm), the
1" (25.4mm) blade adapter is not used.
Installing a Blade
1. Unplug the saw.
2. With the arm raised, the lower guard held open and
the pivot plate raised, place the blade on the spindle,
onto the blade adapter [if using a blade with a 1"
(25.4mm) diameter blade hole] and against the inner
clamp washer with the teeth at the bottom of the blade
pointing toward the back of the saw.
3. Assemble the outer clamp washer onto the spindle.
Adjustments
PERFORM ALL ADJUSTMENTS WITH THE MITER
SAW UNPLUGGED.
NOTE: Your miter saw is fully and accurately adjusted at
the factory at the time of manufacture. If readjustment due
to shipping and handling or any other reason is required,
follow the steps below to adjust your saw.
Oncemade,theseadjustmentsshouldremainaccurate.
Takealittletimenowtofollowthesedirectionscarefullyto
maintaintheaccuracyofwhichyoursawiscapable.
MITERSCALEADJUSTMENT(FIG.5)
Placeasquareagainstthesaw'sfenceandblade.(Donot
touchthetipsofthebladeteethwiththesquare.Todoso
willcauseaninaccuratemeasurement.)Unlockmiterlock
lever(J)andswingthemiterarmuntilthemiterlatchlocks
itatthe0miterposition.Donotlockmiterlocklever(J).If
thesawbladeisnotexactlyperpendiculartothefence,
loosenthethreescrewsthatholdthemiterscaletothe
baseandmovethescaleleftorrightuntilthebladeisper-
pendiculartothefence,asmeasuredwiththesquare.
Retightenthethreescrews.Paynoattentiontotheread-
ingofthemiterpointeratthistime.
MITER POINTER ADJUSTMENT (FIG. 5, 6)
To unlock, lift the miter lock lever (J) up and squeeze the
miter latch (K) to move the miter arm to the zero position.
With the miter lock lever unlocked allow the miter latch to
snap into place as you rotate the miter arm to zero.
Observe the pointer and miter scale through the viewing
opening shown in Figure 6. Ifthe pointer does not indicate
exactly zero, loosen the screw holding the pointer in place,
reposition the pointer and tighten the screw.
BEVEL SQUARE TO TABLE (FIG. 7)
To align the blade square to the rotary table, lock the arm
in the down position. Place a square against the blade
taking care to not have the square on top of a tooth.
Loosen the bevel lock knob (L) and ensure the arm is
firmly against the 0° bevel stop. Move the 0 ° bevel stop
adjusting screw (T) as necessary so that the blade is at
zero degrees bevel to the table.
BEVEL POINTER (FIG. 7)
If the bevel pointer (M) does not indicate zero, loosen the
screw that holds it in place and move the pointer as nec-
essary. Do not remove the steel plate in front of the bevel
pointer. This plate prevents wood resin from accumulating
on the bevel scale during use.
ADJUSTING THE BEVEL STOP TO 45° LEFT OR
RIGHT (FIG. 8)
NOTE: Adjust the 45 ° bevel angles only after performing
the 0° bevel angle and pointer adjustment. Ensure the 45°
bevel override levers (N) are pushed inward to obtain an
accurate adjustment.
To adjust the right 45 ° bevel angle, loosen the bevel lock
knob (L) and pull the bevel stop override knob (S) to over-
ride the 0° bevel stop. When the saw is fully to the right, if
the pointer does not indicate exactly 45°, turn the right
bevel stop screw (O) until the pointer indicates 45 °.
To adjust the left 45° bevel stop, first loosen the bevel lock
FIG. 5
FIG. 7
FIG. 6
MITER
SCALE
POINTER
K
POINTER
ADJUSTMENT
SCREW
knob (L) and tilt the head to the left. Ifthe pointer does not
indicate exactly 45°,turn the left bevel stop screw until the
pointer reads 45 °.
ADJUSTING THE BEVEL STOP TO 33.85 ° (FIG. 8)
NOTE: Adjust the 33.85 ° bevel angles only after performing
the 0° bevel angle and pointer adjustment.
To set the 33.85 ° bevel angle, flip out the stop pawls (P).
Loosen the bevel lock knob (L) and tilt the head to the left.
If the pointer does not indicate exactly 33.85 °, turn the
screw contacting the pawl until the pointer reads 33.85 °.
To adjust the right 33.85° bevel angle, flip out the stop
pawl. Loosen the bevel lock knob (L) and pull the bevel
stop override button (S) to override the 0° bevel stop.
When the saw is fully to the right, if the pointer does not
indicate exactly 33.85 °, turn the screw contacting the pawl
until the pointer indicates 33.85 °.
FENCE ADJUSTMENT
Turn Off and Unplug the Miter Saw
In order that the saw can bevel to a full 48 degrees left or
right, the fences can be adjusted to provide clearance. To
adjust a fence, loosen the plastic knob (Figure 8, R), and
slide the fence outward. Make a dry run with the saw
turned off and check for clearance. Adjust the fence to be
as close to the blade as practical to provide maximum
workpiece support, without interfering with arm up and
down movement. Tighten knob securely. When the bevel
operations are complete, don't forget to relocate the fence.
NOTE: The guide groove of the fences can become
clogged with sawdust. If you notice that it is becoming
clogged, use a stick or some low pressure air to clear the
guide groove.
_ WARNING: Always use eye protection. All users and
bystanders must wear eye protection that conforms to
ANSI Z87.1. (CAN/CSA Z94.3)
AUTOMATIC ELECTRIC BRAKE
Your saw is equipped with an automatic electric blade
brake which stops the saw blade within 5 seconds of
trigger release. This is not adjustable.
On occasion, there may be a delay after trigger release to
brake engagement. On rare occasions, the brake may not
engage at all and the blade will coast to a stop.
If a delay or "skipping" occurs, turn the saw on and off 4 or
M
5 times. If the condition persists, have the tool serviced by
an authorized DEWALT service center.
Always be sure the blade has stopped before removing it
from the kerf. The brake is not a substitute for guards.
Ensure your own safety by giving the saw your complete
attention.
FIG. 8
FIG. 9
SCREWS
(two each
side)
FIG. 10
down. To adjust, put the miter lock handle in the up posi-
tion. Using a 3/32 hex wrench, loosen the set screw (W)
on the pivot pin. Using a slotted screwdriver, adjust the
lock rod in 1/8 clockwise turn increments to increase the
lock force. To ensure the miter lock is functioning proper-
ly, re-lock miter lock handle to a non-detent miter angle.
Tighten set screw.
Brushes
DISCONNECT PLUG FROM POWER SUPPLY.
Inspect carbon brushes regularly by unplugging tool,
removing the motor end cap (Fig. 2), lift the brush spring
and withdraw 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
N
O
P
to its removal. Carbon brushes have varying symbols
stamped into their sides, and if the brush is worn down to
approximately 1/2 inch, the spring will no longer exert pres-
sure and they must be replaced. Use only identical
DEWALT brushes. Use of the correct grade of brush is
FIG. 11
essential for proper operation of electric brake. New brush
assemblies are available at DEWALT service centers. The
tool should be allowed to "run in" (run at no load) for 10
minutes before use to seat new brushes. The electric
brake may be erratic in operation until the brushes are
properly seated (worn in). Always replace the brush
inspection cap after inspection or servicing the brushes.
While "running in" DO NOT TIE, TAPE, OR OTHERWISE
LOCK THE TRIGGER SWITCH ON. HOLD BY HAND
ONLY.
Controls
/
w
GUARD ACTUATION AND VISIBILITY
The blade guard on your saw has been designed to auto-
matically raise when the arm is brought down and to lower
over the blade when the arm is raised.
The guard can be raised by hand when installing or remov-
ing saw blades or for inspection of the saw. NEVER RAISE
THE BLADE GUARD MANUALLY UNLESS THE SAW IS
TURNED OFF.
NOTE: Certain special cuts of large material will require
that you manually raise the guard. See page 13.
The front section of the guard is Iouvered for visibility
while cutting. Although the louvers dramatically reduce
flying debris, they are openings in the guard and safety
glasses should be worn at all times when viewing
through the louvers.
V
MITER LOCK ADJUSTMENT (FIG. 11)
The miter lock rod should be adjusted if the table of the
saw can be moved when the miter lock handle is locked
Your compound miter saw has several main controls,
which will be discussed briefly here. For more information
on these controls, see the respective sections later in the
manual.
MITER CONTROL (FIG. 5)
The miter lock/adjustment lever and trigger allows you to
miter your saw 50° left and right. To miter the saw, unlock
miter lock lever (J) by pulling upward, squeeze the detent
trigger (K) and set the miter angle desired on the miter
scale. Lock miter lock handle by pressing downward.
Override the detent trigger by rotating knob (Fig. 10, V).
TRIGGER SWITCH (FIG. 2)
The trigger switch turns your saw on and off. A hole is pro-
vided in the trigger for insertion of a padlock to secure the
saw.
BEVEL LOCK (FIG. 8)
The bevel lock knob (L) allows you to bevel the saw 48° left
or right. To loosen the handle and adjust the bevel setting,
turn the handle counterclockwise, the saw head bevels
easily to the left or to the right once the 0° bevel override
knob (S) is pulled. To tighten, turn the handle clockwise.
Bevel degree markings are on the bottom front of the saw
arm (Fig. 7, M).
0°BEVELOVERRIDE(FIG.8)
Thebevelstopoverride(S)allowsyoutobevelthesawto
therightpastthe0°mark.
Thesawwillautomaticallystopat0°whenbroughtupfrom
theleft.Tomovepast0°totheright,pullthebevelstop
knob.Thestopknobcanbelockedoutbypullingtheknob
outandrotatingit180°.
45°BEVELSTOPOVERRIDES(FIG.8)
Thebevelstopoverrides(N)areheldsecurewiththeir
attachmentscrewtopreventinadvertentmovement.Use
thebit onthebladewrenchto loosentheattachment
screw.Thisallowstheslides,tobepulledoutwardandthe
sawheadtopivotpastthe45°mark.Besuretoretighten
theattachmentscrewwhenfinished.
33.85°BEVELSTOPS(FIG.8)
Thetwopawls(P)areusedtostopthesawheadbevel
settingat33.85°.Thissettingisusedprimarilyforcutting
crownmoldingslaidflatonthetable.
HEADDOWNLOCKPIN(FIG.8)
Tolockthesawheadinthedownposition,pushthehead
down,pushthepin(U)inandreleasethesawhead.This
willholdthesawheadsafelydownformovingthesaw
fromplacetoplace.Torelease,pressthesawheaddown
andpullthepinout.
Operation
Plug the saw into any household 60 Hz power source.
Refer to the nameplate for voltage. Be sure the cord will
not interfere with your work.
SWITCH
To turn the saw on, depress the trigger switch. To turn the
tool off, release the switch. Allow the blade to spin up to full
operating rpm before making the cut. Release the trigger
switch and allow the brake to stop the blade before raising
the saw head. There is no provision for locking the switch
on, but a hole is provided in the trigger for insertion of a
padlock to lock the saw off.
CUTTING WITH YOUR SAW
NOTE: Although this saw will cut wood and many non-
ferrous materials, we will limit our discussion to the cutting
of wood only. The same guidelines apply to the other mate-
rials. DO NOT CUT FERROUS (IRON AND STEEL)
MATERIALS OR MASONRY WITH THIS SAW. Do not
use any abrasive blades.
CROSSCUTS
Cutting of multiple pieces is not recommended but can be
done safely by ensuring that each piece is held firmly
against the table and fence. A crosscut is made by cutting
wood across the grain at any angle. A straight crosscut is
made with the miter arm at the zero degree position. Set
the miter arm at zero, hold the wood on the table and
firmly against the fence. Turn on the saw by squeezing
the trigger.
FIG. 12
FIG. 12A
PROPER CUT
IMPROPER CUT
When the saw comes up to speed (about 1 second) lower
the arm smoothly and slowly to cut through the wood. Let
the blade come to a full stop before raising arm.
Miter crosscuts are made with the miter arm at some angle
other than zero. This angle is often 45 degrees for making
corners, but can be set anywhere from zero to 50 degrees
left or right. After selecting the desired miter angle, be sure
to lock miter lock lever. Make the cut as described above.
BEVEL CUTS
A bevel cut is a crosscut made with the saw blade at a
bevel to the wood. In order to set the bevel, loosen the
bevel clamp knob and move the saw to the left as desired.
(It is necessary to move the fence to allow clearance).
Once the desired bevel angle has been set, tighten the
bevel clamp knob firmly.
Bevel angles can be set from 48 degrees right to
48 degrees left and can be cut with the miter arm set
between zero and 50 degrees right or left. At some
extreme angles, the right or left side fence might have to
be removed. To remove the left or right fence, unscrew the
knobs several turns and slide the fence out.
QUALITY OF CUT
The smoothness ofany cut depends on a number of variables.
Things like material being cut, blade type, blade sharpness
and rate of cut all contribute to the quality ofthe cut.
When smoothest cuts are desired for molding and other
precision work, a sharp (60 tooth carbide) blade and a
slower, even cutting rate will produce the desired results.
Ensure that material does not creep while cutting, clamp it
securely in place. Always let the blade come to a full stop
before raising arm.
If small fibers of wood still split out at the rear of the work-
piece, stick a piece of masking tape on the wood where the
cut will be made. Saw through the tape and carefully
remove tape when finished.
For varied cutting applications, refer to the list of recom-
mended saw blades for your saw and select the one that
best fits your needs (page 4).
BODY AND HAND POSITION (FIG. 12)
Proper positioning of your body and hands when operating
the miter saw will make cutting easier, more accurate and
safer. Never place hands near cutting area. Place hands
no closer than 6" from the blade. Hold the workpiece tight-
ly to the table and the fence when cutting. Keep hands in
position until the trigger has been released and the blade
has completely stopped. ALWAYS MAKE DRY RUNS
(UNPOWERED) BEFORE FINISH CUTS SO THAT YOU
CAN CHECK THE PATH OF THE BLADE. DO NOT
CROSS HANDS, AS SHOWN IN FIGURE 12A.
Keep both feet firmly on the floor and maintain proper bal-
ance. As you move the miter arm left and right, follow it and
stand slightly to the side of the saw blade. Sight through
the guard louvers when following a pencil line.
CLAMPINGTHEWORKPIECE
Turn Off and Unplug Saw.
If you cannot secure the workpiece on the table and
against the fence by hand, (irregular shape, etc.) or your
hand would be less than 6" from the blade, a clamp or
other fixture must be used.
For best results use the DW7082 clamp made for use with
your saw. It is available for purchase at your local retailer
or DEWALT service center.
Other aids such as spring clamps, bar clamps or C-clamps
may be appropriate for certain sizes and shapes of materi-
al. Use care in selecting and placing these clamps. Take
time to make a dry run before making the cut. The left or
right fence will slide from side to side to aid in clamping.
NOTE: ALWAYS MAKE DRY RUNS (UNPOWERED)
BEFORE FINISH CUTS TO CHECK THE PATH OF THE
BLADE. ENSURE A CLAMP DOES NOT INTERFERE
WITH THE ACTION OF THE SAW OR GUARDS.
_, WARNING: A workpiece that is clamped, balanced and
secure before a cut may become unbalanced after a cut
is completed. An unbalanced load may tip the saw or
anything the saw is attached to, such as a table or work-
bench. When making a cut that may become unbalanced,
properly support the workpiece and ensure the saw is
firmly bolted to a stable surface.
SUPPORT FOR LONG PIECES
Turn Off and Unplug Saw.
ALWAYS SUPPORT LONG PIECES.
Never use another person as a substitute for a table
extension; as additional support for a workpiece that is
longer or wider than the basic miter saw table or to help
feed, support or pull the workpiece.
For best results, use the DW7080 extension work support
to extend the table width of your saw. Available from your
dealer at extra cost. Support long workpieces using any
convenient means such as sawhorses or similar devices to
keep the ends from dropping.
CUTTING PICTURE FRAMES, SHADOW BOXES AND
OTHER FOUR-SIDED PROJECTS
To best understand how to make the items listed here, we
suggest that you try a few simple projects using scrap
wood until you develop a "FEEL" for your saw.
Your saw is the perfect tool for mitering corners like the one
shown in Figure 14. Sketch A in Figure 13 shows a joint
made by using the bevel adjustment to bevel the edges of
the two boards at 45 degrees each to produce a 90 degree
corner. For this joint the miter arm was locked in the zero
position and the bevel adjustment was locked at 45
degrees. The wood was positioned with the broad flat side
against the table and the narrow edge against the fence.
The cut could also be made by mitering right and left with
the broad surface against the fence.
CUTTING TRIM MOLDING AND OTHER FRAMES
Sketch B in Figure 13 shows a joint made by setting the
miter arm at 45 degrees to miter the two boards to form a
FIG. 13
A
FIG. 15
CENTER MARK ON VERNIER SCALE
ALIGNS WITH DESIRED WHOLE ANGLE
ON MITER SCALE (24 ° RIGHT MITER)
1/4° VERNIER MARK ALIGNS WITH
CLOSEST WHOLE DEGREE MARK ON
MITER SCALE (24-1/4 ° RIGHT MITER)
FIG. 14
FIG. Vl
KERF
PLATE
MITER
ANGLE
FIG. V2
90 degree corner. To make this type of joint, set the bevel
adjustment to zero and the miter arm to 45 degrees. Once
again, position the wood with the broad flat side on the
table and the narrow edge against the fence.
The two sketches in Figure 13 are for four side objects
only.
As the number of sides changes, so do the miter and bevel
angles. The chart below gives the proper angles for a vari-
ety of shapes.
(The chart assumes that all sides are of equal length.) For
a shape that is not shown in the chart, use the following
formula. 180 degrees divided by the number of sides
equals the miter (if the material is cut vertically) or bevel
angle (if the material is cut laying flat).
- EXAMPLES -
NO. SIDES ANGLE MITER OR BEVEL
4 45°
5 36°
6 30°
7 25.7 °
8 22.5 °
9 20°
10 18°
CUTTING COMPOUND MITERS
A compound miter is a cut made using a miter angle and a
bevel angle at the same time. This is the type of cut used
to make frames or boxes with slanting sides like the one
shown in Figure 15.
NOTE: If the cutting angle varies from cut to cut, check that
the bevel clamp knob and the miter lock knob are secure-
ly tightened. These knobs must be tightened after making
any changes in bevel or miter.
The chart shown on page 15 will assist you inselecting the
proper bevel and miter settings for common compound
miter cuts. To use the chart, select the desired angle "A"
(Figure 15) of your project and locate that angle on the
appropriate arc in the chart. From that point follow the
chart straight down to find the correct bevel angle and
straight across to find the correct miter angle.
Set your saw to the prescribed angles and make a few
trial cuts. Practice fitting the cut pieces together until you
develop a feel for this procedure and feel comfortable
with it.
Example: To make a four-sided box with 26° exterior
angles (Angle A, Figure 15), use the upper right arc. Find
26° on the arc scale. Follow the horizontal intersecting line
to either side to get miter angle setting on saw (42°).
Likewise, follow the vertical intersecting line to the top or
bottom to get the bevel angle setting on the saw (18°).
Always try cuts on a few scrap pieces of wood to verify
settings on saw.
VERNIER SCALE
Your saw is equipped with a vernier scale for added preci-
sion. The vernier scale allows you to accurately set miter
lO
angles to the nearest 1/4 degree. To use the vernier scale
follow the steps listed below.
(As an example, let's assume that the angle you want to
miter is 24-1/4 degree right).
1. Turn off miter saw.
2. Set the miter angle to the nearest whole degree
desired by aligning the center mark in the vernier
scale, shown in Figure V1, with the whole degree num-
ber etched in the miter scale. Examine Figure V2
closely; the setting shown is 24 degrees right miter.
3. To set the additional 1/4 degree, squeeze the miter
arm lock and carefully move the arm to the RIGHT until
the 1/4 degree vernier mark aligns with the CLOSEST
degree mark on the miter scale. In our example, the
closest degree mark on the miter scale happens to be
25 degrees. Figure V2 shows a setting of 24-1/4
degrees right miter.
For settings that require partial degrees (1/4, 1/2,
3/4 degrees) align the desired vernier mark with the
CLOSEST degree mark on the miter scale, as described
below (The plastic vernier plate is inscribed with marks for
1/4, 1/2, 3/4 and 1 degrees. Only the 1/2 degree and the
1 degree are numerically labeled.)
WHEN MITERING TO THE RIGHT
To increase the miter angle when mitering to the right,
move the arm to align the appropriate vernier mark with the
closest mark on the miter scale to the right. To decrease
the miter angle when mitering to the right, move the arm to
align the appropriate vernier mark with the closest mark on
the miter scale to the left.
WHEN MITERING TO THE LEFT
To increase the miter angle when mitering to the left, move
the arm to align the appropriate vernier mark with the
closest mark on the miter scale to the left. To decrease the
miter angle when mitering to the left, move the arm to align
the appropriate vernier mark with the closest mark on the
miter scale to the right.
CUTTING BASE MOLDING
ALWAYS MAKE A DRY RUN WITHOUT POWER
BEFORE MAKING ANY CUTS.
Straight 90 degree cuts:
Position the wood against the fence and hold it in place
as shown in Figure 16.Turn on the saw, allow the blade
to reach full speed and lower the arm smoothly through
the cut.
CUTTING BASE MOLDING UP TO 6" (152.4mm)
VERTICALLY AGAINST THE FENCE
Position material as shown in Figure 16.
All cuts made with the back of the molding against the
fence and bottom of the molding against the base.
FIG, 16
FENCE
CROWN MOLDING FLAT ON TABLE AND
AGAINST FENCE
BOTTOM SIDE
OF MOLDING
FIG, 17
TABLE
FIG. 17A
DW 7O84 CROWN
MOLDING FENCE
TABLE
INSIDE CORNER:
Left side
1. Miter left 45°
2. Save left side of cut
Right side
1. Miter Right 45°
2. Save right side of cut
OUTSIDE CORNER:
Left side
1. Miter right at 45°
2. Save left side of cut
Right side
1. Miter left at 45°
2. Save right side of cut
Material up to 6" can be cut as described above.
CUTTING CROWN MOLDING
Your miter saw is better suited to the task of cutting
crown molding than any tool made. In order to fit properly,
crown molding must be compound mitered with extreme
accuracy.
The two flat surfaces on a given piece of crown molding
are at angles that, when added together, equal exactly 90
degrees. Most, but not all, crown molding has a top rear
angle (the section that fits flat against the ceiling) of 52
degrees and a bottom rear angle (the part that fits flat
against the wall) of 38 degrees.
Your miter saw has special pre-set miter latch points at
31.62 degrees left and right for cutting crown molding at the
proper angle and bevel stop pawls at 33.85° left and right.
There is also a mark on the bevel scale at 33.85 degrees.
The chart below gives the proper settings for cutting crown
molding. (The numbers for the miter and bevel settings are
very precise and are not easy to accurately set on your
saw.) Since most rooms do not have angles of precisely 90
degrees, you will have to fine tune your settings anyway.
PRETESTING WITH SCRAP MATERIAL IS
EXTREMELY IMPORTANT!
INSTRUCTIONS FOR CUTTING CROWN MOLDING
LAYING FLAT AND USING THE COMPOUND FEATURES:
1. Molding laying with broad back surface down flat on
saw table (Figure 17).
2. The settings below are for All Standard (U.S.) crown
molding with 52° and 38° angles.
BEVEL SETTING
TYPE OF CUT
LEFT SIDE, INSIDE CORNER:
33.85 ° Left
1. Top of molding against fence
2. Miter table set right 31.62 °
3. Save left end of cut
CROWN MOLDING BETWEEN FENCE AND TABLE
11
RIGHTSIDE,INSIDECORNER:
33.85°Right 1.Topofmoldingagainstfence.
2.Mitertablesetatleft31.62°
3.Saverightendofcut
LEFTSIDE,OUTSIDECORNER:
33.85°Right 1.Topofmoldingagainstfence.
2.Mitertablesetatleft31.62°
3.Saveleftendofcut
RIGHTSIDE,OUTSIDECORNER:
33.85°Left 1.Topofmoldingagainstfence
2.Mitertablesetright31.62°
3.Saverightendofcut
Whensettingbevelandmiteranglesforallcompound
miters,rememberthat:
Theanglespresentedforcrownmoldingsarevery
preciseanddifficulttosetexactly.Sincetheycan
easilyshiftslightlyandveryfewroomshaveexactly
squarecorners,allsettingsshouldbetestedon
scrapmolding.
PRETESTINGWITHSCRAPMATERIALIS
EXTREMELY IMPORTANT!
ALTERNATIVE METHOD FOR CUTTING CROWN
MOLDING
Place the molding on the table at an angle between the
fence and the saw table, as shown in Figure 17A. Use of
the crown molding fence accessory (DW7084) is highly
recommended because of its degree of accuracy and con-
venience. The crown molding fence accessory is available
for purchase from your local dealer.
The advantage to cutting crown molding using this method
isthat no bevel cut is required. Minute changes inthe miter
angle can be made without affecting the bevel angle. This
way, when corners other than 90 degrees are encountered,
the saw can be quickly and easily adjusted for them. Use
the crown molding fence accessory to maintain the angle
at which the molding will be on the wall.
INSTRUCTIONS FOR CUTTING CROWN MOLDING
ANGLED BETWEEN THE FENCE AND BASE OF
THE SAW FOR ALL CUTS:
1. Angle the molding so the bottom of the molding (part
which goes against the wall when installed) is against
the fence and the top of the molding is resting on the
base of the saw, as shown in Figure 17A.
2. The angled "flats" on the back of the molding must rest
squarely on the fence and base of the saw.
INSIDE CORNER:
Left side
1. Miter right at 45°
2. Save the right side of cut
FIG. 18
\
FENCE
FIG. 18A
FENCE
Right side
1. Miter left at 45°
2. Save left side of cut
OUTSIDE CORNER:
Left side
1. Miter left at 45°
2. Save right side of cut
Right side
1. Miter right at 45°
2. Save left side of cut
FIG. 19
BLADE
RIGHT
RIGHT
FIG. 19A
WRONG
Special Cuts
NEVER MAKE ANY CUT UNLESS THE MATERIAL IS
SECURED ON THE TABLE AND AGAINST THE FENCE.
ALUMINUM CUTTING
ALWAYS USE THE APPROPRIATE SAW BLADE MADE
ESPECIALLY FOR CUTTING ALUMINUM. These are
available at your local DEWALT retailer or DEWALT
service center. Certain workpieces, due to their size,
shape or surface finish, may require the use of a clamp or
fixture to prevent movement during the cut. Position the
material so that you will be cutting the thinnest cross
section, as shown in Figure 18. Figure 18A illustrates the
wrong way to cut these extrusions. Use astick wax cutting
lubricant when cutting aluminum. Apply the stick wax
directly to the saw blade before cutting. Never apply stick
wax to a moving blade.
12
Thewax,availableatmosthardwarestoresandindustrial
millsupplyhouses,providesproperlubricationandkeeps
chipsfromadheringtotheblade.
Besuretoproperlysecureworkpiece.Refertopage4for
correctsawblade.
BOWEDMATERIAL
Whencuttingbowedmaterialalwayspositionitasshown
inFigure19andneverlikethatshowninFigure19A.
Positioningthematerialincorrectlywillcauseittopinchthe
bladenearthecompletionofthecut.
CUTTINGPLASTICPIPEOROTHERROUND
MATERIAL
Plasticpipecanbeeasilycutwithyoursaw.Itshouldbe
cutjustlikewoodandCLAMPEDORHELDFIRMLYTO
THEFENCETOKEEPIT FROMROLLING.Thisis
extremelyimportantwhenmakinganglecuts.
CUTTINGLARGEMATERIAL
Occasionallyyouwillencounterapieceofwoodalittletoo
largetofitbeneaththebladeguard.Ifthisoccurs,simply
placeyourrightthumbontheuppersideoftheguardand
rolltheguardupjustenoughtocleartheworkpiece,as
showninFigure20.Avoiddoingthisasmuchaspossible,
butifneedbe,thesawwilloperateproperlyandmakethe
biggercut.NEVERTIE,TAPE,OROTHERWISEHOLD
THEGUARDOPENWHENOPERATINGTHISSAW.
SPECIALSET-UPFORWIDECROSSCUTS
Yoursawcancutverywide[upto 10"(406mm)]work-
pieceswhenaspecialsetupisused.Tosetthesawupfor
theseworkpieces,followthesesteps:
1.Removebothleftandrightslidingfencesfromthesaw
andsetaside.Toremovethem,unscrewthefence
knobsseveralturnsandslideeachfenceoutward.
Adjustandlockthemitercontrolso thatit is at
0degreesmiter.
2.Makeaplatformusingapieceof1.5inch(38mm)thick
particleboardorsimilarflatstrong1.5inchthickwood
tothedimensions:10"x 24"(254x 610mm).The
platformmustbeflat otherwisethematerialcould
moveduringcuttingandcauseinjury.
3.Mountthe10"x24"(254x610mm)platformtothesaw
using4three-inchlongwoodscrewsthroughtheholes
inthebasefence(Fig.9).Fourscrewsmustbeused
toproperlysecurethematerial.Whenthespecialset
upisused,theplatformwillbecutintotwopieces.
Ensurethescrewsaretightenedproperlyotherwise
materialcouldloosenandcauseinjury.Ensurethe
platformisfirmlyflatonthetable,againstthefence,
andcenteredevenlyfromlefttoright.
_,WARNING: Ensure the saw is mounted firmly to a
stable flat surface. Failure to do so could cause the saw
to be unstable and fall causing personal injury.
4. Place the workpiece to be cut on top of the platform
mounted to the table. Ensure the workpiece is firmly
against the backfence (Fig. 9).
FIG. 20
FIG. 21 SET SCREW
5. Secure the material before cutting. Cut slowly through
the material. Failure to clamp securely or cut slowly
could result in the material coming loose and causing
injury.
After several cuts are made at various miter angles other
than 0°, the platform may weaken and not properly support
the work. Install a new, unused platform to the saw after
presetting the desired miter angle.
CAUTION: Continued use of a platform with several
kerfs may cause loss of material control and possible
injurjz.
SCREWS
Removing and Replacing Belt
The belt is designed to last the life of the tool. However,
abuse of the tool could cause the belt to fail.
If the blade does not turn when the motor is running, the
belt has failed. To inspect or replace the belt, remove the
belt cover screws. Remove the belt cover. Inspect the ribs
of the belt for wear or failure. Check belt tension by squeez-
ing the belt as shown in Figure 21. The belt halves should
almost touch when squeezing firmly with the thumb and
index finger.
To adjust the tension, loosen, but do not remove, the four
Phillips head screws shown. Then rotate the set screw on
the top of the motor plate casting until the proper tension
is achieved. Tighten the four screws securely and replace
the belt cover.
NOTE: Over tightening the belt will cause premature motor
failure.
Maintenance
1. All bearings are sealed. They are lubricatedfor life and
need no further maintenance.
2. Periodically clean all dust and wood chips from around
AND UNDER the base and the rotary table. Even
though slots are provided to allow debris to pass
through, some dust will accumulate.
3. The brushes are designed to give you several years
of use. If they ever need replacement follow the
instructions on page 8 or return the tool to the nearest
service center for repair. Service center locations are
packed with your tool.
Repairs
To assure product SAFETY and RELIABILITY, repairs,
maintenance and adjustment (including brush inspection
and replacement) should be performed by authorized serv-
ice 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. This warranty does not cover part failure
due to normal wear or tool abuse. For further detail of war-
ranty coverage and warranty repair information, visit
www.dewalt.com or call 1-800-4-DEWALT (1-800-433-
9258). 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:
1 YEAR FREE SERVICE
DEWALT will maintain the tool and replace worn parts
caused by normal use, for free, any time during the first
year after purchase.
13
90 DAY MONEY BACK GUARANTEE
If you are not completely satisfied with the perform-
ance of your DEWALT Power Tool, Laser, or Nailer for
any reason, you can return it within 90 days from the
date of purchase with a receipt for a full refund - no
questions asked.
RECONDITIONED PRODUCT: Reconditioned prod-
uct is covered under the 1 Year Free Service Warranty.
The 90 Day Money Back Guarantee and the Three
Year Limited Warranty do not apply to reconditioned
product.
FREE WARNING LABEL REPLACEMENT: If your
warning labels become illegible or are missing, call
1-800-4-DEWALT for a free replacement.
Patent Notification
Manufactured under one or more of
the following U.S. patents:
6,431,040 5,582,089
6,427,570 5,375,495
D454,577 5,285,708
5,819,619 5,199,343
Other patents pending.
Troubleshooting Guide
BE SURE TO FOLLOW SAFETY RULES AND INSTRUCTIONS
TROUBLE! SAW WILL NOT START
WHAT'S WRONG?
1. Saw not plugged in
2. Fuse blown or circuit breaker tripped
3. Cord damaged
4. Brushes worn out
TROUBLE! SAW MAKES UNSATISFACTORY CUTS
WHAT'S WRONG?
1. Dull blade
2. Blade mounted backwards
3. Gum or pitch on blade
4. Incorrect blade for work being done
TROUBLE! BLADE DOES NOT COME UPTO SPEED
WHAT'S WRONG?
1. Extension cord too light or too long
2. Low house current
TROUBLE! MACHINE VIBRATES EXCESSIVELY
WHAT'S WRONG?
1. Saw not mounted securely to stand or work bench
2. Stand or bench on uneven floor
3. Damaged saw blade
TROUBLE! DOES NOT MAKE ACCURATE MITER CUTS
WHAT'S WRONG?
1. Miter scale not adjusted correctly
2. Miter pointer not adjusted correctly
3. Workpiece is not perpendicular to table
4. Workpiece moving
TROUBLE! MATERIAL PINCHES BLADE
WHAT'S WRONG?
1. Cutting bowed material
WHAT TO DO...
1. Plug in saw.
2. Replace fuse or reset circuit breaker
3. Have cord replaced by authorized service center
4. Have brushes replaced by authorized service center
or replace them yourself as instructed on page 8.
WHAT TO DO...
1. Replace blade. See page 6.
2. Turn blade around. See page 6.
3. Remove blade and clean with turpentine and
coarse steel wool or household oven cleaner.
4. Change the blade type. See page 4.
WHAT TO DO...
1. Replace with adequate size cord. See page 2.
2. Contact your electric company
WHAT TO DO...
1. Tighten all mounting hardware. See page 5.
2. Reposition on flat level surface. See page 5.
3. Replace blade. See page 6.
WHAT TO DO...
1. Check and adjust. See page 7.
2. Check and adjust. See page 7.
3. Check and adjust fence. See page 7.
4. Clamp workpiece to fence or glue 120 grit
sandpaper to fence with rubber cement.
WHAT TO DO...
1. Position bowed material as shown on page 13.
14
TABLE 1
0
45-
COMPOUND MITER CUT (position wood with broad flat side on the table and the narrow edge against the fence)
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