DeWalt DW716XPS User Manual

Before returning this product call

1-800-4-DEWAL T

Questions? Visit us at www.dewalt.com

Des questions ? Rendez nous visite à www.dewalt.com

¿Tiene preguntas? Visítenos en www.dewalt.com

IF YOU SHOULD EXPERIENCE A PROBLEM WITH YOUR DEWALT PURCHASE,

IN MOST CASES, A DEWALT REPRESENTATIVE CAN RESOLVE

IF YOU HAVE A SUGGESTION OR COMMENT, GIVE US A CALL.

YOUR FEEDBACK IS VITAL TO THE SUCCESS OF D

CALL 1-800-4-DEWALT

YOUR PROBLEM OVER THE PHONE.

WALT’S QUALITY

IMPROVEMENT PROGRAM.

INSTRUCTION MANUAL GUIDE D’UTILISATION MANUAL DE INSTRUCCIONES

INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y PÓLIZA DE GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUCTIVO ANTES DE USAR EL PRODUCTO.

DW716, DW716XPS 12" (305 mm) Double Bevel Compound Miter Saw Scie coulissante à onglets mixtes, 305 mm (12 po)

Sierra ingletadora compuesta de doble bisel de 305 mm (12")

Deﬁ nitions: Safety Guidelines

The definitions below describe the level of severity for each signal word. Please read the manual and pay attention to these symbols.

DANGER: Indicates an imminently hazardous situation which, if not avoided, will

result in death or serious injury.

WARNING: Indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury.

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may

result in minor or moderate injury.

NOTICE: Indicates a practice not related to personal injury which, if not avoided, may result in property damage.

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL, CALL US TOLL FREE AT: 1-800-4-D

EWALT (1-800-433-9258).

IMPORTANT SAFETY INSTRUCTIONS

WARNING: When using electric tools, basic safety precautions should always be followed to reduce risk of fire, electric shock, and personal injury, including the following:

SAVE ALL WARNINGS AND INSTRUCTIONS

FOR FUTURE REFERENCE

Double Insulation

Double insulated tools are constructed throughout with two separate layers of electrical insulation or one single layer of reinforced 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 secondary insulation system is for protection against injury resulting from a possible failure of the primary insulation 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

WARNING: To reduce the risk of eye injury, ALWAYS use eye protection when

operating the miter saw.

• 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. Tools, scrap pieces, and other debris can be thrown at high speed, causing injury.

• KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents.

• DO NOT USE THE MACHINE IN A DANGEROUS ENVIRONMENT. The use of power

tools in damp or wet locations or in rain can cause shock or electrocution. Keep your work area well-lit to avoid tripping or placing arms, hands, and fingers in danger.

• KEEP CHILDREN AWAY. All visitors should be kept at a safe distance from work area.

Your shop is a potentially dangerous environment.

• MAKE WORKSHOP CHILDPROOF with padlocks, master switches, or by removing

starter keys. The unauthorized start-up of a machine by a child or visitor may result in injury.

• DON’T FORCE 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. Using the incorrect tool or attachment may result in personal injury.

• 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 USE SAFETY GLASSES. Everyday eyeglasses are NOT safety glasses. Also use face or dust mask if cutting operation is dusty. ALWAYS WEAR CERTIFIED SAFETY

EQUIPMENT:

• ANSI Z87.1 eye protection (CAN/CSA Z94.3)

• ANSI S12.6 (S3.19) hearing protection

• NIOSH/OSHA/MSHA respiratory protection

• SECURE THE WORKPIECE. Use clamps or a vise to hold the workpiece on the table and against the fence or when your hand will be dangerously close to the blade within 6" (152mm). It is safer than using your hand and it frees both hands to operate tool.

• DON’T OVERREACH. Keep proper footing and balance at all times. Loss of balance may cause personal injury.

• MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories. Poorly maintained tools and machines can further damage the tool or machine and/or cause injury.

• TURN THE MACHINE “OFF”, AND DISCONNECT THE MACHINE FROM THE POWER SOURCE before installing or removing accessories, before adjusting or changing set-ups, when making repairs or changing locations. An accidental start-up can cause injury. Do not touch the plug’s metal prongs when unplugging or plugging in the cord.

• REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure that the switch is in the “OFF” position before plugging in the power cord.

• USE PROPER EXTENSION CORD. 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 gauge. The smaller the gauge number, the heavier the cord.

Minimum Gauge for Cord Sets

Volts Total Length of Cord in Feet (meters)

Ampere Rating

More Than Not More Than AWG

0 6 18 16 16 14

610 18161412 10 12 16 16 14 12 12 16 14 12 Not Recommended

120 V 25

(7.6)

240 V 50

(15.2)

100

(30.5)

100

(30.5)

200

(61.0)

150

(45.7)

300

(91.4)

English

• CHECK FOR 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. Do not use tool if switch does not turn it on and off.

• USE RECOMMENDED ACCESSORIES. Use only accessories that are recommended

English

by the manufacturer for your model. Accessories that may be suitable for one tool may be hazardous when used on another tool. 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.

• NEVER LEAVE TOOL RUNNING UNATTENDED. TURN POWER OFF. Don’t leave

tool until it comes to a complete stop. Serious injury can result.

• DO NOT OPERATE ELECTRIC TOOLS NEAR FLAMMABLE LIQUIDS OR IN

GASEOUS OR EXPLOSIVE ATMOSPHERES.

ignite fumes.

• STAY ALERT, WATCH WHAT YOU ARE DOING, AND USE COMMON SENSE. DO

NOT USE THE MACHINE WHEN YOU ARE TIRED OR UNDER THE INFLUENCE OF DRUGS or ALCOHOL. A moment of inattention while operating power tools may

result in injury.

Motors in these tools may spark and

Additional Safety Rules For Miter Saws

WARNING: Do not allow familiarity (gained from frequent use of your saw) to replace safety

rules. Always remember that a careless fraction of a second is sufficient to inflict severe injury.

• DO NOT OPERATE THIS MACHINE until it is completely assembled and installed

according to the instructions. A machine incorrectly assembled can cause serious injury.

• OBTAIN ADVICE from your supervisor, instructor, or another qualified person if you are

not thoroughly familiar with the operation of this machine. Knowledge is safety.

• STABILITY. Make sure the miter saw is placed on a secure supporting surface and does

not slip or move during use.

• FOLLOW ALL WIRING CODES and recommended electrical connections to prevent

shock or electrocution. Protect electric supply line with at least a 15 ampere time-delay fuse or a circuit breaker.”

• MAKE CERTAIN the blade rotates in the correct direction. The teeth on the blade should

point in the direction of rotation as marked on the saw.

• TIGHTEN ALL CLAMP HANDLES, knobs and levers prior to operation. Loose clamps

can cause parts or the workpiece to be thrown at high speeds.

• BE SURE all blade and blade clamps are clean, recessed sides of blade clamps are

against blade and arbor screw is tightened securely. Loose or improper blade clamping may result in damage to the saw and possible personal injury.

• ALWAYS USE A SHARP BLADE. Check the blade to see if it runs true and is free from

vibration. A dull or a vibrating blade can cause damage to the machine and/or serious injury.”

• DO NOT OPERATE ON ANYTHING OTHER THAN THE DESIGNATED VOLTAGE for

the saw. Overheating, damage to the tool and personal injury may occur.

• DO NOT WEDGE ANYTHING AGAINST THE FAN to hold the motor shaft. Damage to

tool and possible personal injury may occur.

• DO NOT force cutting action. Stalling or partial stalling of motor can cause damage. To

the machine or blade and/or serious injury.

• ALLOW THE MOTOR TO COME TO FULL SPEED prior to starting cut. Starting the cut

too soon may cause damage to the machine or blade and/or serious injury.”

• NEVER CUT FERROUS METALS (Those with any iron or steel content) or masonry.

Either of these can cause the carbide tips to fly off the blade at high speeds causing serious injury.

• DO NOT USE ABRASIVE WHEELS. The excessive heat and abrasive particles generated

by them may damage the saw and cause personal injury.

• NEVER have any part of your body in line with the path of the saw blade. Personal injury

will occur.

• NEVER apply blade lubricant to a running blade. Applying lubricant could cause your hand

to move into the blade resulting in serious injury.

• DO NOT place either hand in the blade area when the saw is connected to the power

source. Inadvertent blade activation may result in serious injury.

• DO NOT PERFORM FREE-HAND OPERATIONS (workpiece not supported by table

and fence). Hold the work firmly against the fence and table. Free-hand operations on a miter saw could cause the workpiece to be thrown at high speeds, causing serious injury.

• NEVER REACH AROUND or behind the saw blade. A blade can cause serious injury.

• DO NOT reach underneath the saw unless it is unplugged and turned off. Contact with

saw blade may cause personal injury.

• SECURE THE MACHINE TO A STABLE SUPPORTING SURFACE. Vibration can

possibly cause the machine to slide, walk, or tip over, causing serious injury.

• USE ONLY CROSSCUT SAW BLADES recommended for miter saws. For best results,

do not use carbide tipped blades with hook angles in excess of 7 degrees. Do not use blades with deep gullets. These can deflect and contact the guard, and can cause damage to the machine and/or serious injury.

• USE ONLY BLADES OF THE CORRECT SIZE AND TYPE specified for this tool to

prevent damage to the machine and/or serious injury.

• INSPECT BLADE FOR CRACKS or other damage prior to operation. A cracked or

damaged blade can come apart and pieces can be thrown at high speeds, causing serious injury. Replace cracked or damaged blades immediately.

• CLEAN THE BLADE AND BLADE CLAMPS prior to operation. Cleaning the blade

and blade clamps allows you to check for any damage to the blade or blade clamps. A cracked or damaged blade or blade clamp can come apart and pieces can be thrown at high speeds, causing serious injury.

• 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.

• ALWAYS USE THE KERF PLATE AND REPLACE THIS PLATE WHEN DAMAGED.

Small chip accumulation under the saw may interfere with the saw blade or may cause instability of workpiece when cutting.

• USE ONLY BLADE CLAMPS specified for this tool to prevent damage to the machine

and/or serious injury.

• CLEAN THE MOTOR AIR SLOTS of chips and sawdust. Clogged motor air slots can

cause the machine to overheat, damaging the machine and possibly causing a short which could cause serious injury.

• KEEP ARMS, HANDS, AND FINGERS away from the blade to prevent severe cuts.

Clamp all workpieces that would cause your hand to be within 6" (152 mm) of the saw blade.

• NEVER LOCK THE SWITCH IN THE “ON” position. Severe personal injury may result.

• TURN OFF THE MACHINE and allow the blade to come to a complete stop before

raising the arm and prior to cleaning the blade area, removing debris in the path of the blade, before servicing or adjusting tool. A moving blade can cause serious injury.

• PROPERLY SUPPORT LONG OR WIDE WORKPIECES. Loss of control of the

workpiece can cause injury.

• NEVER cross arms in front of blade while using tool. Always make a dry run

(unpowered) before making a finish cut so that you can check the path of the blade or severe personal injury may result.

• ADDITIONAL INFORMATION regarding the safe and proper operation of power tools

(i.e. a safety video) is available from the Power Tool Institute, 1300 Sumner Avenue, Cleveland, OH 44115-2851 (www.powertoolinstitute.com). Information is also available from the National Safety Council, 1121 Spring Lake Drive, Itasca, IL 60143-3201. Please refer to the American National Standards Institute ANSI 01.1 Safety Requirements for Woodworking Machines and the U.S. Department of Labor OSHA 1910.213 Regulations.

WARNING: Do not connect unit to electrical power source until complete instructions are

read and understood.

WARNING: Always wear proper personal hearing protection that conforms to

ANSI S12.6 (S3.19) during use. Under some conditions and duration of use, noise from

this product may contribute to hearing loss.

WARNING: NEVER MAKE ANY CUT UNLESS THE MATERIAL IS SECURED ON THE

TABLE AND AGAINST THE FENCE.

WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other

construction activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

• lead from lead-based paints,

• crystalline silica from bricks and cement and other masonry products, and

• arsenic and chromium from chemically-treated lumber.

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as dust masks that are specially designed to filter out microscopic particles.

• Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling, and other construction activities. Wear protective clothing and wash exposed areas with soap and water. Allowing dust to get into your mouth, eyes, or lay on the skin may promote absorption of harmful chemicals.

WARNING: Use of this tool can generate and/or disburse dust, which may cause serious

and permanent respiratory or other injury. Always use NIOSH/OSHA approved respiratory protection appropriate for the dust exposure. Direct particles away from face and body.

For your convenience and safety, the following warning labels are on your miter saw.

ON MOTOR HOUSING:

WARNING: TO REDUCE THE RISK OF INJURY, USER MUST READ

INSTRUCTION MANUAL BEFORE OPERATING MITER SAW. WHEN SERVICING, USE ONLY IDENTICAL RE PLACE MENT PARTS. DO NOT EXPOSE TO RAIN OR USE IN DAMP LOCATIONS. ALWAYS USE PROPER EYE AND RESPIRATORY PROTECTION.

ON MOVING FENCES:

ON GUARD: DANGER --KEEP AWAY FROM BLADE.

ON UPPER GUARD: PROPERLY SECURE BRACKET WITH BOTH SCREWS

BEFORE USE.

ON TABLE: (2 PLACES) WARNING: FOR YOUR OWN SAFETY, READ INSTRUCTION

MANUAL BEFORE OPERATING MITER SAW. KEEP HANDS OUT OF PATH OF SAW BLADE. DO NOT OPERATE SAW WITHOUT GUARDS IN PLACE. CHECK LOWER GUARD FOR PROPER CLOSING BEFORE EACH USE. ALWAYS TIGHTEN ADJUSTMENT KNOBS BEFORE USE. DO NOT PERFORM ANY OPERATION FREEHAND. NEVER REACH IN BACK OF SAW BLADE. NEVER CROSS ARMS IN FRONT OF BLADE. TURN OFF TOOL AND WAIT FOR SAW BLADE TO STOP BEFORE MOVING WORKPIECE, CHANGING SETTINGS OR MOVING HANDS. DISCONNECT POWER BEFORE CHANGING BLADE OR SERVICING. TO REDUCE THE RISK OF INJURY, RETURN CARRIAGE TO THE FULL REAR POSITION AFTER EACH CROSSCUT OPERATION. THINK! YOU CAN PREVENT ACCIDENTS.

ON BASE: (2 PLACES)

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 susceptible to failure if direct current is used. A voltage decrease of 10 percent or more will cause a loss of power and overheating. All D

EWALT tools are factory tested. If this tool does not operate, check the power supply.

Accessories

WARNING: Since accessories, other than those offered by DEWALT, have not been tested

with this product, use of such accessories with this tool could be hazardous. To reduce the risk of injury, only D

Recommended accessories for use with your tool are available for purchase from your local dealer or authorized service center. If you need assistance in locating any accessory for your tool, please contact D call 1-800-4-D

EWALT, recommended accessories should be used with this product.

EWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286,

EWALT (1-800-433-9258) or visit our website www.dewalt.com.

English

ALWAYS ADJUST FENCE PROPERLY BEFORE USE. CLAMP SMALL PIECES

BEFORE CUTTING. SEE MANUAL.

FIG. 1

English

DW7051

KNOBS

TOP HOLE

(USE FOR

DW716)

BRACKET

DW7082

DW7080

Clamp: DW7082

Used for firmly clamping workpiece to the saw table for precision cutting.

Dust Bag: DW7053 (Included with some models)

Equipped with a zipper for easy emptying, the dust bag will capture the majority of the sawdust produced (not shown).

Crown Molding Fence: DW7084

Used for precision cutting of crown molding.

Kerf Plate Blank: DW7055 (not shown)

Used to limit back side tear out of material or as a replacement kerf plate.

Miter Saw Stands: DWX723, DWX724, DWX725B (not shown)

Provides stable and accurate work platform for miter saws. SAW BLADES: ALWAYS USE 12" (305 mm) SAW BLADES WITH 1" (25.4 mm) ARBOR

HOLES. SPEED RATING MUST BE AT LEAST 4800 RPM. Never use a smaller diameter blade. It will not be guarded properly. Use crosscut blades only! Do not use blades designed for ripping, combination blades or blades with hook angles in excess of 7 degrees..

BLADE DESCRIPTIONS APPLICATION DIAMETER TEETH Construction Saw Blades (thin kerf with anti-stick rim)

General Purpose 12" (305 mm) 40 Fine Crosscuts 12" (305 mm) 60

Woodworking Saw Blades (provide smooth, clean cuts)

Fine crosscuts 12" (305 mm) 80 Non-ferrous metals 12" (305 mm) 96 NOTE: For cutting non-ferrous metals, use only saw blades with TCG teeth designed for this purpose.

END

DW7084

PLATE

LOCKNUTS

Optional Accessories (Fig. 1)

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.

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. It is used to make repetitive cuts of the same length from 0 to 42" (0–107 cm).

IMPORTANT SAFETY INSTRUCTIONS

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 or DW716XPS miter saw.

2. One D

EWALT 12" (305 mm) dia. saw blade

3. One blade wrench in wrench pocket shown in Figure 2.

4. One DW7053 dustbag (some models).

Speciﬁ cations

CAPACITY OF CUT

50º miter left and right 48º bevel left and right

0º miter Max. Height 3.6" (91.5 mm) Result Width 7.2" (183 mm) Max. Width 7.9:" (200.7 mm) Result Height 2.9" (73.7mm)

45º miter Max. Height 3.6" (91.5 mm) Result Width 4.9" (125 mm) Max. Width 5.5” (140 mm) Result Height 2.9" (73.7 mm)

45º bevel - Left Max. Height 2.3" (58.4 mm) Result Width 7.4" (188 mm) Max. Width 7.9" (200.7 mm) Result Height 1.9" (48.3 mm)

45º bevel - Right Max. Width 7.9" (200.7 mm) Result Height 1.1" (28 mm) Max. Height 1.6" (40.6 mm) Result Width 7.1" (180.3 mm) Your saw is capable of cutting baseboard moldings 0.9" (22.9 mm) thick by 6" (152mm) tall on a 45º right or left miter. NOTE: Your saw is capable of cutting the following once a special set-up procedure is followed (see Special Cuts). 0º miter height 1.5" (38.1 mm)

width 10" (255 mm) 45º miter height 1.5" (38.1 mm)

width 7.5" (190.5 mm)

DRIVE 120 Volt Motor

1675 Watts (max in) 15 Amp Motor

3800 RPM Cut Helical Gears Multi-V Belt Roller Bearings Automatic Electric Brake Carbide Blade

FIG. 2

OPERATING

HANDLE

Familiarization

Your miter saw is fully assembled in the car ton. Open the box and lift the saw out by the con venient carry ing handle, as shown in Figure 1A. Place the saw on a smooth, flat surface such as a workbench, strong table or D to become familiar with the saw and its various parts. The section on adjus tments will refer to these terms and you must know what and where the parts are.

CAUTION: Pinch Hazard. To reduce the risk of

injury, keep thumb underneath the handle when pulling the handle down. The lower guard will move up as the handle is pulled down which could cause pinching. The handle is placed close to the guard for special cuts.

DW716

EWALT miter saw stand. Examine Figure 2

TRIGGER

SWITCH

OPERATING

HANDLE

FIG. 1A

English

LOCK DOWN

0º BEVEL STOP

ADJUSTMENT

SCREW

BENCH MOUNTING

HOLES

MITER SCALE

GUARD

BEVEL SCALE

MITER

LOCK LEVER

RIGHT SIDE

FENCE

KERF

PLATE

CARRY HANDLE

MOTOR END CAP

MOTOR

HOUSING

FENCE LOCK

KNOB

DUST

SPOUT

BEVEL LOCK

KNOB

0º BEVEL

OVERRIDE KNOB

45º BEVEL OVERRIDE

LEVERS

LOCK DOWN

45º

BEVEL STOP

ADJUSTMENT

SCREW

BEVEL STOP

33.9º PAWLS

XPSTM ON/OFF SWITCH

(DW716XPS ONLY)

LEFT SIDE

FENCE

FENCE LOCK

KNOB

HAND

INDENTATIONS

BLADE

WRENCH

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 and 4.

ASSEMBLY AND ADJUSTMENTS

WARNING: To reduce the risk of injury, turn unit off and disconnect it from power

source before installing and removing accessories, before adjusting or when

English

making repairs. An accidental start-up can cause injury.

Bench Mounting

Holes are provided in all four feet to facilitate bench mounting, 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" (12.7 mm) or thicker plywood which can then be clamped to your work support or moved to other job sites and reclamped.

NOTE: If you elect to mount your saw to a piece of plywood, 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 surface, clamp only on the clamping bosses where the mounting screw holes are located. Clamping at any other point will surely interfere with the proper operation of the saw.

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 material under one saw foot until the saw sits firmly on the mounting surface.

Changing or Installing a New Saw Blade (Fig. 3)

CAUTION:

• Never depress the spindle lock button 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

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.

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 blade clamp (F), and blade (G). The inner blade clamp (I), and if used, the 1" (25.4 mm) blade adapter (H), may be left on the spindle.

NOTE: For blades with a blade hole of 5/8" (15.88mm), the 1" (25.4mm) blade adapter

is not used.

FIG. 3A

FIG. 3B

Installing a Blade

1. Unplug the saw.

2. With the arm raised, the lower guard held open and the guard bracket raised, place the blade on the spindle, onto the blade adapter [if using a blade with a 1" (25.4mm)

diameter blade hole] and against the inner blade clamp with the teeth at the bottom of the blade pointing toward the back of the saw.

3. Assemble the outer blade clamp onto the spindle.

4. Install the blade screw (E) 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" (15.88 mm) 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 (B) to hold bracket in place.

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

resulting in damage to the saw and severe personal injury.

Transporting the Saw (Fig. 2, 4)

WARNING: To reduce the risk of serious

personal injury, ALWAYS lock the miter lock

handle, bevel lock knob, fence adjustment knobs,

FIG. 4

and secure the arm down using the lock down pin before transporting saw.

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.

Adjustments

WARNING: To reduce the risk of injury, turn unit off and disconnect it from power source before installing and removing accessories, before adjusting or when making repairs. An

accidental start-up can cause injury.

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. Once made, these adjustments should remain accurate. Take a little time now to follow these directions carefully to maintain the accuracy of which your saw is capable.

MITER SCALE ADJUSTMENT (FIG. 5)

Place a square against the saw’s fence and blade. (Do not touch the tips of the blade teeth with the square. To do so will cause an inaccurate measure ment.) Unlock miter lock lever (J) and swing the miter arm until the miter latch locks it at the 0 miter position. Do not lock miter lock lever (J). If the saw blade is not exactly perpendicular to the fence, loosen the three screws that hold the miter scale to the base and move the scale left or right until the blade is perpendicular to the fence, as measured with the square. Retighten the three screws. Pay no attention to the reading of the miter pointer at this time.

FIG. 6

POINTER

MITER

SCALE

POINTER

ADJUSTMENT

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 0º bevel stop. Move the 0º bevel stop adjusting screw (T) as necessary so that the blade is at 0º 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 necessary. 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.

FIG. 7

English

FIG. 5

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. If the pointer does not indicate exactly zero, loosen the screw holding the pointer in place, reposition the pointer and tighten the screw.

ADJUSTING THE BEVEL STOP TO 45º LEFT OR RIGHT (FIG. 8) NOTE: Adjust the 45º bevel angles only after performing the 0º bevel angle and pointer

adjustment. Ensure the 45º bevel override levers (N) are pushed inward to obtain an accurate adjustment.

To adjust the right 45º bevel angle, loosen the bevel lock knob (L) and pull the bevel stop override knob (S) to override the 0º bevel stop. When the saw is fully to the right, if the pointer does not indicate exactly 45º, turn the right bevel stop screw (O) until the pointer indicates 45º.

To adjust the left 45º bevel stop, first loosen the bevel lock knob (L) and tilt the head to the left. If the pointer does not indicate exactly 45º, turn the left bevel stop screw until the pointer reads 45º.

FIG. 8

English

ADJUSTING THE BEVEL STOP TO 33.9º (FIG. 8) NOTE: Adjust the 33.9º bevel angles only after performing the 0º bevel angle and pointer

adjustment. To set the 33.9º 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 33.9º, turn the screw contacting the pawl until the pointer reads 33.9º.

To adjust the right 33.9º bevel angle, flip out the stop pawl. Loosen the bevel lock knob (L) and pull the bevel stop override button (S) to override the 0º bevel stop. When the saw is fully to the right, if the pointer does not indicate exactly 33.9º, turn the screw contacting the pawl until the pointer indicates 33.9º.

FENCE ADJUSTMENT (FIG. 8)

In order that the saw can bevel to a full 48° 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 max imum 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 the guide groove becomes clogged, use a stick, low pressure air or a vacuum to clear.

AUTOMATIC ELECTRIC BRAKE (FIG. 2)

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 5 times. If the condition persists, have the tool serviced by an authorized D

Always be sure the blade has stopped before removing it from the kerf plate. The brake is not a substitute for guards. Ensure your own safety by giving the saw your complete attention.

GUARD ACTUATION AND VISIBILITY

CAUTION: Pinch Hazard. To reduce the risk of injury, keep thumb underneath the handle when pulling the handle down. The lower guard will move up as the handle is pulled down which could cause pinching.

EWALT service center.

The blade guard on your saw has been designed to automatically 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 removing saw blades or for inspection of the saw. NEVER RAISE THE BLADE GUARD MANUALLY UN LESS THE SAW IS TURNED

OFF. NOTE: Certain special cuts of large material will require that you manually raise the guard.

Refer to Cutting Large Material under Special Cuts. The front section of the guard is louvered 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.

MITER LOCK ADJUSTMENT (FIG. 9)

The miter lock rod should be adjusted if the table of the saw can be moved when the miter lock handle is locked down. To adjust, put the miter lock handle in the up position. 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 properly, re-lock miter lock handle to a non-detent miter angle.

FIG. 9

Brushes (Fig. 2)

Inspect carbon brushes regularly by unplugging the tool, removing the motor end cap (Fig. 2) and removing the brush cap that holds the spring-loaded 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 approximately 1/2" (12.7 mm), the spring will no longer exert pressure and they must be replaced. Use only identical D for proper operation of electric brake. New brush assemblies are available at D

EWALT brushes. Use of the correct grade of brush is essential

EWALT

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 OTHER WISE LOCK THE TRIGGER SWITCH ON. HOLD BY HAND ONLY.

Controls

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, 10)

The miter lock lever (J) and miter latch (K) 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).

FIG. 10

TRIGGER SWITCH (FIG. 2)

The trigger switch turns your saw on and off. A hole is provided in the trigger for insertion of a padlock to secure the saw.

USE OF XPS

LED WORKLIGHT SYSTEM (FIG. 2) DW716XPS ONLY NOTE: The miter saw must be connected to a power

source. The XPS

OFF switch (Fig. 2). The XPS

LED Worklight System is equipped with an ON/

LED Worklight System is

independent of the miter saw’s trigger switch. The light does not need to be on in order to operate the saw. To cut through an existing pencil line on a piece of wood,

turn on the XPS

system, then pull down on the operating handle to bring the saw blade close to the wood. The shadow of the blade will appear on the wood. This shadow line represents the material that the blade will remove when performing a cut. To correctly locate your cut to the pencil line, align the pencil line with the edge of the blade’s shadow. Keep in mind that you may have to adjust the miter or bevel angles in order to match the pencil line exactly.

BEVEL LOCK (FIG. 7, 8)

The bevel lock knob (L) allows you to bevel the saw 48º left or right. To loosen the handle and adjust the bevel setting, turn the handle counter clock wise, the saw head bevels easily to the left or to the right once the 0º 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).

0º BEVEL OVERRIDE (FIG. 8)

The bevel stop override (S) allows you to bevel the saw to the right past the 0º mark.

The saw will automatically stop at 0º when brought up from the left. To move past 0º to the right, pull the bevel stop knob. The stop knob can be locked out by pulling the knob out and rotating it 180º.

45º BEVEL STOP OVERRIDES (FIG. 8)

The bevel stop overrides (N) are held secure with their attachment screw to prevent inadvertent movement. Use the bit on the blade wrench to loosen the attachment screw. This allows the slides, to be pulled outward and the saw head to pivot past the 45º mark. Be sure to retighten the attachment screw when finished.

33.9º BEVEL STOPS (FIG. 8)

The two pawls (P) are used to stop the saw head bevel setting at 33.9º. This setting is used primarily for cutting crown moldings laid flat on the table.

HEAD LOCK DOWN PIN (FIG. 8)

WARNING: The lock down pin should be used ONLY

when carrying or storing the saw. NEVER use the lock

down pin for any cutting operation.

To lock the saw head in the down position, push the head down, push the pin (U) in and release the saw head. This will hold the saw head safely down for moving the saw from place to place. To release, press the saw head down and pull the pin out.

OPERATION

WARNING: To reduce the risk of injury, turn unit off and disconnect it from power source before installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

WARNING: Always use eye protection. All users and

bystanders must wear eye protection that conforms to ANSI Z87.1 (CAN/CSA Z94.3).

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 materials. 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.

CAUTION: Always use a work clamp to maintain control

and reduce the risk of workpiece damage and personal injury.

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° for making corners, but can be set anywhere from zero to 50° left or right. After selecting the desired miter angle, be sure to lock miter lock lever. Make the cut as described above.

To cut through an existing pencil line on a piece of wood, match the angle as close as possible. Cut the wood a little too long and measure from the pencil line to the cut edge to determine which direction to adjust the miter angle and recut. This will take some practice, but it is a commonly used technique.

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° right to 48° left and can be cut with the miter arm set between zero and 50° 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 of any 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 of the 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 workpiece, 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 recommended saw blades for your saw and select the one that best fits your needs. Refer to Saw Blades under Optional Accessories.

English

BODY AND HAND POSITION (FIG. 11)

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" (152 mm) from the blade. Hold the workpiece tightly 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 ARMS, AS SHOWN IN FIGURE11.

English

Keep both feet firmly on the floor and maintain proper balance. 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.

CLAMPING THE WORKPIECE

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 workbench. When making a cut that may become unbalanced, properly support the workpiece and ensure the saw is firmly bolted to a stable surface. Personal injury may occur.

WARNING: The clamp foot must remain clamped above the base of the saw whenever the clamp is used. Always clamp the workpiece to the base of the saw–not to any other part of the work area. Ensure the clamp foot is not clamped on the edge of the base of the saw.

CAUTION: Always use a work clamp to maintain control and reduce the risk of workpiece

damage and personal injury.

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" (152mm) 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 D

EWALT service center.

Other aids such as spring clamps, bar clamps or C-clamps may be appropriate for certain sizes and shapes of material. 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.

TO INSTALL CLAMP (SOLD SEPARATELY)

1. Insert it into the hole behind the fence. The clamp should be facing toward the back of the

miter saw. The groove on the clamp rod should be fully inserted into the base. Ensure this groove is fully inserted into the base of the miter saw. If the groove is visible, the clamp will not be secure.

2. Rotate the clamp 180º toward the front of the miter saw.

3. Loosen the knob to adjust the clamp up or down, then use the fine adjust knob to firmly

clamp the workpiece.

NOTE: Place the clamp on the opposite side of the base when beveling. ALWAYS MAKE DRY RUNS (UNPOWERED) BEFORE FINISH CUTS TO CHECK THE PATH OF THE BLADE. ENSURE THE CLAMP DOES NOT INTERFERE WITH THE ACTION OF THE SAW OR GUARDS.

SUPPORT FOR LONG PIECES

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 or the DWX723, DWX724 or DWX725B miter saw stand to extend the table width of your saw. These are available from your dealer at extra cost.

FIG. 11

PROPER CUT

IMPROPER CUT

FIG. 12

IMPROPER CUT

PROPER CUT

IMPROPER CUT

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 13. Sketch A in Figure 12 shows a joint made by using the bevel adjustment to bevel the edges of the two boards at 45° each to produce a 90° corner. For this joint the miter arm was locked in the zero position and the bevel adjustment was locked at 45°. 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.

FIG. 13

FIG. 14

ANGLE “A”

CUTTING TRIM MOLDING AND OTHER FRAMES

Sketch B in Figure 12 shows a joint made by setting the miter arm at 45° to miter the two boards to form a 90° corner. To make this type of joint, set the bevel adjustment to zero and the miter arm to 45°. 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 12 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 variety of shapes.

- EXAMPLES -

NO. SIDES ANGLE MITER OR BEVEL

4 45° 5 36° 6 30° 7 25.7° 8 22.5° 9 20°

10 18°

(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° 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).

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14.

NOTE: If the cutting angle varies from cut to cut, check that the bevel clamp knob and the miter lock knob are securely tightened. These knobs must be tightened after making any changes in bevel or miter.

The chart (Table 1) will assist you in selecting the proper bevel and miter settings for common compound miter cuts. To use the chart, select the desired angle “A” (Figure 14) 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 14), 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 precision. The vernier scale allows you to accurately set miter angles to the nearest 1/4°. 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° 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 15, with the whole degree number etched in the miter scale. Examine Figure 16 closely; the setting shown is 24° right miter.

FIG. 15

CENTER MARK ON VERNIER SCALE

ALIGNS WITH DESIRED WHOLE ANGLE

ON MITER SCALE (24° RIGHT MITER)

KERF PLATE

MITER

ANGLE

FIG. 16

1/4° VERNIER MARK ALIGNS WITH

CLOSEST WHOLE DEGREE MARK ON

MITER SCALE (24-1/4° RIGHT MITER)

3. To set the additional 1/4°, squeeze the miter arm lock and carefully move the arm to the RIGHT until the 1/4° 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°. Figure 16 shows a setting of 24-1/4° right miter.

For settings that require partial degrees (1/4, 1/2, 3/4°) 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°. Only the 1/2° and the 1° 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

English

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

English

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° cuts:

Position the wood against the fence and hold it in place as shown in Figure 17. 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MM) VERTICALLY AGAINST THE FENCE

Position material as shown in Figure 17. All cuts made with the back of the molding against the fence

and bottom of the molding against the base.

INSIDE CORNER: OUTSIDE CORNER: Left side Left side

1. Miter left 45 1. Miter right at 45°

2. Save left side of cut 2. Save left side of cut Right side Right side

1. Miter Right 45° 1. Miter left at 45°

2. Save right side of cut 2. Save right side of cut

Material up to 6"(152mm) 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°. Most, but not all, crown molding has a top rear angle (the section that fits flat against the ceiling) of 52° and a bottom rear angle (the part that fits flat against the wall) of38°.

Your miter saw has special pre-set miter latch points at

31.62° left and right for cutting crown molding at the proper angle and bevel stop pawls at 33.9º left and right. There is also a mark on the bevel scale at 33.9°.

The Bevel Setting/Type of Cut chart 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°, 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 18).

2. The settings below are for All Standard (U.S.) crown molding with 52° and 38° angles.

BEVEL SETTING TYPE OF CUT

33.9° Left LEFT SIDE, INSIDE CORNER

1. Top of molding against fence

2. Mitre table set right 31.62°

3. Save left end of cut

33.9° Right RIGHT SIDE, INSIDE CORNER

1. Top of molding against fence

2. Miter table set right 31.62°

3. Save right end of cut

33.9° Right LEFT SIDE, OUTSIDE CORNER

1. Top of molding against fence

2. Miter table set at left 31.62°

3. Save left end of cut

33.9° Left RIGHT SIDE, OUTSIDE CORNER

1. Top of molding against fence

2. Mitre table set right 31.62

3. Save right end of cut°

When setting bevel and miter angles for all compound miters, remember that:

The angles presented for crown moldings are very precise and difficult to set exactly. Since they can easily shift slightly and very few rooms have exactly square corners, all settings should be tested on scrap molding.

PRETESTING WITH SCRAP MATERIAL IS

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 18A. Use of the crown molding fence accessory (DW7084) is highly recommended because of its degree of accuracy and convenience. The crown molding fence accessory is available for purchase from your local dealer.

The advantage to cutting crown molding using this method is that no bevel cut is required. Minute changes in the miter angle can be made without affecting the bevel angle. This way, when corners other than 90° are encountered, the saw can be quickly and easily adjusted for them. Use the crown

FIG. 17

FIG. 18

FENCE

CROWN MOLDING FLAT ON TABLE AND

AGAINST FENCE

FIG. 18A

BOTTOM SIDE

OF MOLDING

TOP SIDE

OF MOLDING

FENCE

CROWN MOLDING BETWEEN FENCE

AND TABLE

TABLE

DW7084

CROWN

MOLDING

FENCE

TABLE

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 18A.

2. The angled “flats” on the back of the molding must rest squarely on the fence and base of the saw.

INSIDE CORNER: OUTSIDE CORNER: Left side Left side

1. Miter right 45 1. Miter left at 45°

2. Save right side of cut 2. Save right side of cut Right side Right side

1. Miter left 45° 1. Miter right at 45°

2. Save left side of cut 2. Save left side of cut

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 19. Figure 19A illustrates the wrong way to cut these extrusions. Use a stick 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.

The wax, available at most hardware stores and industrial mill supply houses, provides proper lubrication and keeps chips from adhering to the blade.

Be sure to properly secure workpiece. Refer to Saw Blades under Optional Accessories for

correct saw blade.

BOWED MATERIAL

When cutting bowed material always position it as shown in Figure 20 and never like that shown in Figure 20A. Positioning the material incorrectly will cause it to pinch the blade near the completion of the cut.

CUTTING PLASTIC PIPE OR OTHER ROUND MATERIAL

Plastic pipe can be easily cut with your saw. It should be cut just like wood and CLAMPED OR HELD FIRMLY TO THE

FIG. 19

BLADE

FENCE

FIG. 19A

FENCE

RIGHT

BLADE

WRONG

FENCE TO KEEP IT FROM ROLLING. This is extremely important when making angle cuts.

CUTTING LARGE MATERIAL

Occasionally you will encounter a piece of wood a little too large to fit beneath the blade guard. If this occurs, simply place your right thumb on the upper side of the guard and roll the guard up just enough to clear the workpiece, as shown in Figure 21. Release the lower blade guard before turning the saw on and beginning the cut. Avoid doing this as much as possible, but if need be, the saw will operate properly and make the bigger cut. NEVER TIE, TAPE, OR OTHERWISE HOLD THE GUARD OPEN WHEN OPERATING THIS SAW. NEVER RAISE THE LOWER GUARD ASSEMBLY MANUALLY UNLESS THE BLADE IS STOPPED.

SPECIAL SET-UP FOR WIDE CROSSCUTS

Your saw can cut very wide [up to 10" (406mm)] workpieces when a special set up is used. To set the saw up for these workpieces, follow these steps:

1. Remove both left and right sliding fences from the saw and set aside. To remove them, unscrew the fence

FIG. 20

English

CORRECT

FIG. 20A

INCORRECT

knobs several turns and slide each fence outward. Adjust and lock the miter control so that it is at 0° miter.

2. Make a platform using a piece of 1.5 inch (38mm) thick particleboard or similar flat strong 1.5" (38 mm) thick wood to the dimensions: 10" x 24" (254 x 610mm). The platform must be flat otherwise the material could move during cutting and cause injury.

3. Mount the 10" x 24" (254 x 610mm) platform to the saw using 4 three-inch (76 mm) long wood screws through the holes in the base fence (Fig. 22). Four screws must be used to properly secure the material. When the special set up is used, the platform will be cut into two pieces. Ensure the screws are tightened properly otherwise material could loosen and cause injury. Ensure the platform is firmly flat on the table, against the fence, and centered evenly from left to right.

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. 22).

5. Secure the material before cutting. Cut slowly through

English

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 0º, 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 injury.

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 squeezing the belt as shown in Figure 23. 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

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.

1. All bearings are sealed. They are lubricated for 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 under Brushes or return the tool to the nearest service center for repair.

FIG. 21

FIG. 22

SCREWS (two each

side)

FIG. 23

SCREWS

SET

SCREW

Worklight Cleaning

For the best worklight performance, perform the following maintenance regularly.

• Carefully clean sawdust and debris from worklight lens with a cotton swab.

• DO NOT use solvents of any kind, they may damage the lens.

• Dust build-up can block the worklight and prevent it from accurately indicating the line of cut.

• Follow miter saw’s instruction manual to remove and install blade.

• With blade removed from saw, clean pitch and buildup from blade. Pitch and debris can interfere with the worklight and prevent it from accurately indicating the line of cut.

Service Information

Please have the following information available for all service calls:

Model Number _________________________ Type ______ Serial Number ______________________________________ Date and Place of Purchase __________________________

Repairs

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

Thank you for your purchase. Register your product now for:

• WARRANTY SERVICE: Registering your product will help you obtain more efficient warranty service in case there is a problem with your product.

• CONFIRMATION OF OWNERSHIP: In case of an insurance loss, such as fire, flood or theft, your registration of ownership will serve as your proof of purchase.

• FOR YOUR SAFETY: Registering your product will allow us to contact you in the unlikely event a safety notification is required under the Federal Consumer Safety Act.

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 warranty coverage and warranty repair information, visit www.dewalt. com or call 1-800-4-D warranty does not apply to accessories or damage caused where repairs have been made or attempted by others. This

EWALT (1-800-433-9258). 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, D

EWALT tools are covered by our:

1 YEAR FREE SERVICE

EWALT will maintain the tool and replace worn parts

caused by normal use, for free, any time during the first year after purchase.

If you are not completely satisfied with the performance of your D you can return it within 90 days from the date of purchase with a receipt for a full refund – no questions asked.

LATIN AMERICA: This warranty does not apply to products sold in Latin America. For products sold in Latin America, see country specific warranty information contained in

90 DAY MONEY BACK GUARANTEE

EWALT Power Tool, Laser, or Nailer for any reason,

the packaging, call the local company or see website for warranty information.

FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are missing, call 1-800-4-D

EWALT

(1-800-433-9258) for a free replacement. Please refer to the beginning of the manual for labels.

Troubleshooting Guide

BE SURE TO FOLLOW SAFETY RULES AND INSTRUCTIONS

TROUBLE! WHAT’S WRONG? WHAT TO DO

Saw will not start 1. Saw not plugged in 1. Plug in saw.

2. Fuse blown or circuit breaker tripped 2. Replace fuse or reset circuit breaker.

3. Cord damaged 3. Have cord replaced by authorized service center.

4. Brushes worn out 4. Have brushes replaced by authorized service center or replace them yourself. Refer to Brushes.

Saw makes unsatisfactory cuts

Blade does not come up to speed

Machine vibrates excessively 1. Saw not mounted securely to stand or

Does not make accurate miter cuts

Material pinches blade 1. Cutting bowed material 1. Refer to Bowed Material under Special Cuts.

1. Dull blade 1. Replace blade. Refer to Changing or Installing a New Saw Blade.

2. Blade mounted backwards 2. Turn blade around. Refer to Changing or Installing a New Saw Blade.

3. Gum or pitch on blade 3. Remove blade and clean with turpentine and coarse steel wool or household oven cleaner.

4. Incorrect blade for work being done 4. Change the blade type. Refer to Saw Blades under Accessories.

1. Extension cord too light or too long 1. Replace with adequate size cord. Refer to Use Proper Extension Cord under Important Safety

Instructions.

2. Low house current 2. Contact your electric company.

1. Tighten all mounting hardware. Refer to Bench Mounting.

work bench

2. Stand or bench on uneven floor 2. Reposition on flat level surface. Refer to Familiarization.

3. Damaged saw blade 3. Replace blade. Refer to Changing or Installing a New Saw Blade.

1. Miter scale not adjusted correctly 1. Check and adjust. Refer to Miter Scale Adjustment under Adjustments.

2. Miter pointer not adjusted correctly 2. Check and adjust. Refer to Miter Pointer Adjustment under Adjustments.

3. Workpiece is not perpendicular to table 3. Check and adjust fence. Refer to Fence Adjustment under Adjustments.

4. Workpiece moving 4. Clamp workpiece securely to fence or glue 120 grit sandpaper to fence with rubber cement.

English

+ 39 hidden pages