DeWalt DW718 TYPE1 Owner’s Manual

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INSTRUCTION MANUAL GUIDE D'UTILISATION

INSTRUCTIVO DE OPERACION, CENTROS DE SERVICIO Y POLIZA DE GARANTiA. ADVERTENCIA: LI2ASE ESTE INSTRUCTIVO ANTES

DE USAR EL PRODUCTO.

MANUAL DE INSTRUCCIONES

DW718 (120 Volt), DW718 (230 Volt) 12" Double Bevel Sliding Compound Miter Saw DW718 (120 Volt), DW718 (230 Volt) Scie coulissante a onglet mixte 305 mm (12 po) DW718 (120 Voltios), DW718 (230 Voltios) Sierra ingletadora compuesta deslizante 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 .......................................................................................................... 5

FAMILIARIZATION ....................................................................................... 5

BENCH MOUNTING .................................................................................... 5

REMOVING THE BLADE ................................................................................................ 5

INSTALLING THE 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 .............................................................................................................. 7

FENCE ADJUSTMENT ............................................................................. 7

AUTOMATIC ELECTRIC BRAKE ................................................................................ 7

GUARD ACTUATION AND VISIBILITY .......................................................... 7

CONTROLS .................................................................................................................... 8

OPERATION ............................................................................................... 8

SWITCH ...................................................................................................................... 8

CUTTING WITH YOUR SAW .................................................................................... 8

CROSSCUTS .............................................................................................................. 8

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

CUTTING BASE MOLDINGS .................................................................................. 10

CUTTING CROWN MOLDING ................................................................................ 11

SPECIAL CUTS ............................................................................................................ 12

REMOVING AND REPLACING THE BELT .................................................................. 13

MAINTENANCE ............................................................................................................ 13

WARRANTY .................................................................................................................. 13

TABLE 1: COMPOUND MITER CUT ............................................................................ 14

TROUBLESHOOTING GUIDE ...................................................................................... 15

KERF PLATE ADJUSTMENT ...................................................................................... 7

RAIL GUIDE ADJUSTMENT ...................................................................................... 7

MITER LOCK ADJUSTMENT .................................................................................... 8

BRUSHES .................................................................................................. 8

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 sys-

tem. 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 with- out concern for maintaining a ground connection.

NOTE: Double insulation does not take the place of normal safety precautions when oper-

ating this tool. The insulation system is for added protection against injury resulting from a possible electrical insulation failure within the tool.

i_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 SAFETYGLASSES. Also use face or dust mask if cutting operation is dusty. Everyday eyeglasses have only impact resistant lenses, they are NOT safety

glasses.

• 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 per- formance. 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 RECOMMENDEDACCESSORIES. Consult the instruction manual for recom- mended accessories. The use of improper accessories may cause risk of injury to per-

sons.

• 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, ff 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 breaker.

• DO - Make certain the blade rotates in the correct direction and that the teeth at the bot- tom of the blade are pointing to the rear of the miter saw.

• 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 against blade. Tighten arbor screw securely.

• 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 offpower, disconnect cord from power source and wait for saw blade to stop before servicing or adjusting tooL

• DO - Support long work with an outboard tool rest.

• 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 orpartial stalling of motor can cause major dam- age. 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 cer-

tain 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.

_CAUTION: 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, or lay

on the skin may promote absorption of harmful chemicals.

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

ous and permanent respiratory or other injury Always use NIOSH/OSHA approved respi- ratory 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:

ALWAYS ADJUST FENCE PROPERLY

BEFORE USE. Clamp small pieces before cutting. See manual

ON GUARD: DANGER- KEEPAWAY

i _ ALWAYS ADJUST FENCE PROPERLYBEFOREUSE.

CLAMP SMALL PIECESBEFORECUTTING.SEEMANUAL

AJUSTE LAGUiA DEBIDAMENTE ANTES DE UTILIZAR LA DERRAMiENTA. ASEGURE LAG PIEZAS PEQUENAS ANTES DE CURTARLAS. CONSULTE ELMANUAL.

TOUJOURG REGLER LEGUIDE AVANT [UTJLiSATJON. FIXER LEG PETiTS ODJETS AVANT DE LESSCiER. CONSULTER LEGUIDE

D'UTiLiSATiON. j

FROM BLADE. ON UPPER GUARD: PROPERLY SECURE BRACKET WITH BOTH

SCREWS BEFORE USE.

K_P AWAY

ON TABLE: (2 PLACES)

ALWAYS TIGHTEN ADJUSTMENT KNOBS BEFORE USE.

F_OMBLAOE

MANIENERSALEJAOO

DE[ABO3A

S'ELOIGNERO£LAi._ta£

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.

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. Ifthis 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 may be hazardous. Dado

sets, molding cutters or abrasive wheels should not be used on your miter saw.

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

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 (see drawing). It is used to make repetitive cuts of the same length from 0 to 42".

Clamp: DW7082 (similar model included)

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.

SAW BLADES: ALWAYS USE 12" SAW BLADES WITH 1" ARBOR HOLES. SPEED RATING MUST BE AT LEAST 4800 RPM. Never use a smaller

diameter blade. It will not be guarded properly.

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

DW7080

END

PLATE

DW7051

LOCKNUTS

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 DW718 miter saw.

2. One DEWALT 12" diameter saw blade.

3. One blade wrench in wrench pocket shown in Figure 4.

4. One DW7053 Dustbag (some models).

5. One material clamp.

DW7082

DW7084

Specifications

CAPACITY OF CUT 50 ° miter right, 60° miter left

48 ° bevel left and right 0° miter

Max. Height 3.7" (94mm) Result Width 12.9" (328mm) Max. Width 13.6" (345mm) Result Height 2.9" (74mm)

45° miter

Max. Height 3.7" (94mm) Result Width 9.1" (231mm) Max. Width 9.5" (241mm) Result Height 2.9" (74mm)

45° bevel - Left

Max. Height 2.4" (61mm) Result Width 12.9" (328mm) Max. Width 13.6" (345mm) Result Height 1.9" (48mm)

45° bevel - Right

Max. Height 1.7" (43mm) Result Width 12.9" (328mm) Max. Width 13.6" (345mm) Result Height 1.1" (28mm)

Your saw is capable of cutting baseboard moldings 0.8"

(20mm) thick by 6.5" (165mm) 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 width 16.1

45° miter height 1.5 width 11.7

DRIVE 120 Volt Motor

1600 Watts In 15 Amp Motor 3600 RPM Cut Helical Gears

Multi-V Belt Roller Bearings Automatic Electric Brake Carbide Blade

Familiarization

Your miter saw is fully FIG. 1 assembled in the carton.

Open the box and lift the saw out by the con-

venient carrying handle, as shown in Figure 1.

Place the saw on a

smooth, flat surface such as a workbench or strong table. FIG.2

Examine the two figures on page 6

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. 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 4 feet to facilitate bench mount- ing, as shown in Figure 4. (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.

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.

_, 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 CAUTION:

• 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

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.

FIG.3A

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), blade (G) and blade adapter (H), if used. The inner

clamp washer (I), may be left on the spindle.

FIG. 3B

NOTE: For blades with a blade hole of 5/8" (15.88mm), the 1" (25.4mm) blade adapter (H) is not used.

RAILLOCK

KNOB

RAIL SET

SCREW

ADJUSTMENT

MOTOR

HOUSING

LIFTING

HANDLE

FIG. 4

OPERATING HANDLE

TRIGGER

SWITCH

BEVEL

LOCK

HANDLE

MOTOR

BEVEL LATCH

LEVER

(one each side)

BEVEL SCALE

(one each

side)

LOCK

BLADE

WRENCH

FENCE

ADJUSTMENT

KNOB

(one each side)

MITER

SCALE

BENCH MOUNTING HOLES

TABLE

MITER LATCH MITER LOCK

OVERRIDE HANDLE

KERF

PLATE

MITER LATCH

BUTTON

BLADE

GUARD

BELT COVER

RAILS

FENCE

GROOVING

STOP

BEVELLATCH

PLATES

DUST SPOUT

HAND

INDENTATION

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) diam-

eter 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.

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.

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

TURN OFF AND UNPLUG THE MITER SAW BEFORE ATTEMPTING TO MOVE IT OR

MAKE ANY ADJUSTMENTS 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 Figure 4.

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)

Placea squareagainstthesaw'sfenceandblade,as shown.(Donottouchthetipsofthebladeteethwiththe square.Todosowillcauseaninaccuratemeasurement.)

Loosenthemiterlockhandleandswingthemiterarmuntil themiterlatchlocksitatthe0 miterposition.Donot

tightenthelockhandle.Ifthesawbladeis notexactly perpendiculartothefence,loosenthefourscrewsthat

holdthemiterscaletothebaseandmovethescaleleft orrightuntilthebladeisperpendicularto thefence,as

measuredwiththesquare.Retightenthefourscrews.Pay

noattentiontothereadingofthemiterpointeratthistime.

MITERPOINTERADJUSTMENT(FIG.6,7)

Loosenthemiterlockhandletomovethemiterarmtothe zeroposition.Withthemiterlockhandlelooseallowthe

miterlatchtosnapintoplaceasyourotatethemiterarm tozero.Observethepointerandmiterscaleshownin

Figure6.If thepointerdoesnotindicateexactlyzero,

loosenthescrewholdingthepointerinplace,reposition thepointerandtightenthescrew.

BEVELSQUARETOTABLEADJUSTMENT(FIG.8) Toalignthebladesquaretothetable,lockthearminthe

downposition.Placeasquareagainstthebladeandtable takingcaretonothavethesquarenottouchabladetooth.

Loosenthebevellockhandleandensurethebevellatch

hasfirmlysnappedintoplaceat0 degrees.Ifthesaw bladeisnotexactlyperpendiculartothetable,loosenthe

nutwhichholdsthe0bevellatchplatetothetable.Adjust thenuttoallowsomedragbetweentheparts.Gentlytap themotororthebeltcovertomovetheupperassembly

untilthebladeissquaretothetable.Tightenthelocknut.

BEVELPOINTER(FIG.8)

Ifthebevelpointersdonotindicatezero,looseneach screwthatholdseachbevelpointerinplaceandmove themasnecessary.

BEVEL STOP 45 ° RIGHT AND LEFT ADJUSTMENT (FIG. 8)

Your saw has two 45 degree bevel adjustments, one for the right, and one for the left. The procedure is the same

for each. To align the 45 degree stops, lock the arm in the down

position. Place a speed square against the blade and table taking care to not have the square not touch a blade tooth.

Loosen the bevel lock lever and ensure the bevel latch has firmly snapped into place at 45 degrees. If the saw blade

is not 45 degrees to the table, loosen the nut which holds the 45 bevel latch plate to the table. Rotate the adjustment screw counterclockwise one or two turns so that the blade

is less than 45 degrees to the table. Turn the adjustment screw clockwise until the blade is 45 degrees to the table. Tighten the lock nut.

FIG. 5

FIG. 7

MITER LATCH

OVERRIDE

FIG. 8

0° BEVEL LATCH RIGHT 45° BEVEL

LEFT 45° BEVEL

LATCH PLATE

LEFT 45° BEVEL

ADJUSTMENT-

SCREW

LEFT 45° BEVEL j

PLATE LOCK NUT

LEFT BEVEL

POINTER

FIG. 6 MITER

MITER LOCK

HANDLE

PLATE LATCH PLATE

0° BEVEL

LOCK NUT

POINTER

MITER LATCH

RIGHT 45 ° BEVEL

ADJUSTMENT

RIGHT 45 ° BEVEL

PLATE LOCK NUT

MITER

SCALE

BUTTON

SCREW

RIGHT BEVEL

POINTER

FENCE ADJUSTMENT (FIG. 9)

Turn Off and Unplug the Miter Saw.

In order that the saw can bevel to a full 48 degrees left or right, one of the fences can be adjusted to provide clear-

ance. To adjust the fences, loosen a plastic knob 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 sup- port, 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.

AUTOMATIC ELECTRIC BRAKE

Your saw is equipped with an automatic electric blade brake which stops the saw blade within 5 seconds of trig- ger 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 DEWALT service center.

Always be sure the blade has stopped before removing it from the kerf. The brake is not a substitute for guards orfor

ensuring your own safety by giving the saw your complete attention.

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 12.

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.

KERF PLATE ADJUSTMENT To adjust the kerf plates, loosen the screws holding the

kerf plates in place. Adjust so that the kerf plates are as close as possible without interfering with the blade's move-

ment.

RAIL GUIDE ADJUSTMENT

Periodically check the rails for any play or clearance. The

right rail can be adjusted with the set screw shown in

Figure 4. To reduce clearance, use a 4mm hex wrench and

rotate the set screw clockwise gradually while sliding the

FIG. 9 FENCE KNOB FIG. 10

(one each side)

BLADE WRENCH ROD

MITER LOCK LOCK NUT

Controls

Your compound miter saw has several main controls, which will be discussed briefly here. For more information

saw head back and forth. Reduce play while maintaining

minimum slide force. MITER LOCK ADJUSTMENT

The miter lock rod should be adjusted if the table of the saw can be moved when the miter lock is locked down.

To adjust the miter lock handle, put the miter lock handle

in the up, unlocked position. Using a 13mm open end

wrench, loosen the lock nut on the miter lock rod (Fig.

10). Using a slotted screwdriver, tighten the miter lock rod by turning it clockwise as shown in Figure 10. Turn

the lock rod until it is snug, then turn counterclockwise one turn. To ensure the miter lock handle is functioning

properly, re-lock the miter lock to a non-detented meas-

urement on the miter scale - for example, 34 degrees -

and ensure the table will not rotate. Tighten lock nut.

Brushes

DISCONNECT PLUG FROM POWER SUPPLY. Inspect carbon brushes regularly by unplugging tool,

removing the motor end cap (Fig. 4), 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 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

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.

on these controls, see the respective sections earlier in the

manual. MITER CONTROL (FIG. 7)

The miter adjustment/lock handle and detent trigger allows you to miter your saw to 60 left and 50 right. To miter the saw, lift the miter adjustment/lock handle, push the miter

latch button and set the set the miter angle desired on the miter scale. Push down on the lock handle to lock the saw

table in place. TRIGGER SWITCH The trigger switch (Fig. 4) turns your saw on and off.A hole

is provided in the trigger for insertion of a padlock to secure

the saw.

MITER LATCH OVERRIDE (FIG. 7)

The miter latch override allows your saw to override the common stop angles. To override the common stop angles, push the miter latch button and flip the miter latch override lever to the vertical position.

BEVEL CONTROL (FIG. 8)

The bevel latch levers and bevel lock handle allow you to bevel the saw to 48 degrees left and right. Your saw has two bevel latch levers, one on either side of the rear sup- port housing. Only one needs to be used to move the bevel to either direction. The bevel lock handle is on top of the

rear support housing. To bevel the saw, loosen the bevel

lock handle. Lift one of the levers to approximately 45 degrees and set the bevel angle desired on the bevel scale. Two bevel scales are provided for convenience.

Lock the bevel lock handle to lock the bevel in place. The bevel latch levers can be lifted vertically to override the common stop angles.

The bevel lock handle is designed to have a limited rota- tion amount. The handle can be reoriented to compensate

for normal wear. The bevel lock handle should be reorient- ed if the bevel of the saw can be moved when the bevel

lock handle is tightened. To adjust the bevel lock handle, remove the screw in the center of the handle. Carefully pry

off the handle using a flat bladed screwdriver. Reorient and

install the handle such that it will hold the bevel when tight-

ened. Install and tighten screw.

RAIL LOCK KNOB (FIG. 4)

The rail lock knob allows you to lock the saw head firmly to

keep it from sliding on the rails. This is necessary when making certain cuts or when transporting the saw.

GROOVING STOP (FIG. 4) The grooving stop allows for groove cutting. Flipping the

lever toward the front of the saw and adjusting the thumb-

screw changes the depth of the groove cut. Flipping the

lever toward the rear of the saw bypasses the grooving

stop.

HEAD DOWNLOCK PIN (FIG. 4) To lock the saw head in the down position, push the head down, push the pin 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

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

If the slide feature is not used, ensure the saw head is pushed back as far as possible and the rail lock knob is tightened. This will prevent the saw from sliding along its

rails as the workpiece is engaged.

NOTE: Although this saw will cut wood and many non- ferrous materials, we will limit our discussion to the cut- ting 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. When the saw comes up to speed (about 1 second) lower the arm smoothly and slow-

ly to cut through the wood. Let the blade come to a full stop before raising arm.

Acrosscutismadebycuttingwoodacrossthegrainatany angle.Astraightcrosscutismadewiththemiterarmatthe zerodegreeposition.Setandlockthemiterarmatzero,

holdthewoodfirmlyonthetableandagainstthefence. Withtheraillockknobtightened,turnonthesawby squeezingthetriggerswitchshowninFigure4.

Whenthesawcomesuptospeed(about1second)lower thearmsmoothlyandslowlytocutthroughthewood.Let thebladecometoafullstopbeforeraisingarm.

Whencuttinganythinglargerthana2 x8 (2x 6at45 degreemiter)useanout-down-backmotionwiththerail

lockknobloosened.Pullthesawout,towardyou,lowerthe sawheaddowntowardtheworkpiece,andslowlypushthe sawbacktocompletethecut.Donotallowthesawto contactthetopoftheworkpiecewhilepullingout.Thesaw

mayruntowardyou,possiblycausingpersonalinjuryor damagetotheworkpiece.

NOTE:Toprovidegreatercrosscutcapacitywithreduced strokethebladeontheDW718extendsdeeperintothe table.Asaresultagreaterliftingforceontheworkpiece

maybeexperiencedduringthecut.

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

NOTE: The rail lock knob shown in Figure 4 must be loose

to allow the saw to slide along its rails.

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. Make the cut as described above.

When cutting wider workpieces wider than a 2 x 6 that are shorter in length, always place the longer side against the

fence (Fig. 12).

BEVEL CUTS

A bevel cut is a crosscut made with the saw blade at an angle to the wood. In order to set the bevel, loosen the

bevel lock handle, lift the bevel latch lever, Figure 4, and

move the sawto the left or right as desired. (It is necessary

to move the fence to allow clearance). Once the desired bevel angle has been set, tighten the bevel clamp handle

firmly.

Bevel angles can be set from 48 degrees right to

48 degrees left and can be cut with the miter arm set between 50 degrees right or 60 degrees 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 Fence Adjustment Knob 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.

FIG. 11

FIG. 12

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).

FIG. 13A

PROPER CUT

FIG. 13B

IMPROPER CUT

BODY AND HAND POSITION (FIG. 13A)

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 13B.

Keep both feet firmly on the floor and maintain proper bal- ance. As you move the miter arm left and right, follow it and

standslightlytothesideofthesawblade.Sightthrough theguardlouverswhenfollowingapencilline.

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. Another type of clamp may be supplied with your

DW718. To purchase the DW7082 contact your local retail-

er or DEWALT service center. Other aids such as spring clamps, bar clamps or C-clamps

may be appropriate for certain sizes and shapes of mate- rial. 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

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 180 degrees 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 (UNPOW-

ERED) BEFORE FINISH CUTS TO CHECK THE PATH

OF THE BLADE. ENSURE THE CLAMP DOES NOT

INTERFERE WITH THE ACTION OF THE SAW OR

GUARDS.

A 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.

A 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.

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.

FIG. 14 FIG. 15

FIG. 16

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 15 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 14 shows a joint made by setting the

miter arm at 45 degrees to miter the two boards to form a

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 11 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 16.

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 14 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 16) 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 devel- op a feel for this procedure and feel comfortable with it.

Example: To make a 4 sided box with 26 degree 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.

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 11.Turn on the saw, allow the blade to reach full speed and lower the arm smoothly through the cut.

CUTTING BASE MOLDING UP TO 6.5" (165MM) HIGH VERTICALLY AGAINST THE FENCE

Position material as shown in Figure 11. All cuts made with the back of the molding against the

fence and bottom of the molding against the base.

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 6.5" (159mm) 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 pre-

cisely 90 degrees, you will have to fine tune your settings anyway.

INSTRUCTIONS FOR CUTTING CROWN MOLDING LAYING FLAT AND USING THE COMPOUND FEATURES

PRETESTING WITH SCRAP MATERIAL

IS EXTREMELY IMPORTANT!

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

33.85 ° Left

LEFT SIDE, INSIDE CORNER:

1. Top of molding against fence

2. Miter table set right 31.62 °

3. Save left end of cut

TYPE OF CUT

FIG. 17

FENCE

TABLE

CROWN MOLDING FLAT ON TABLE

AND AGAINST FENCE

FIG. 18

BOTTOM SIDE

OF MOLDING

CROWN MOLDING BETWEEN FENCE AND TABLE

RIGHT SIDE, INSIDE CORNER:

33.85 ° Right 1. Top of molding against fence.

2. Miter table set at left 31.62 °

3. Save right end of cut LEFT SIDE, OUTSIDE CORNER:

33.85 ° Right 1. Top of molding against fence.

2. Miter table set at left 31.62 °

3. Save left end of cut RIGHT SIDE, OUTSIDE CORNER:

33.85 ° Left 1. Top of molding against fence

2. Miter 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 exact-

ly square corners, all settings should be tested on

scrap molding.

DW 7084 CROWN MOLDING FENCE

TABLE

FIG. 19

BLADE

FENCE

FIG. 20

FENCE

PRETESTING WITH SCRAP MATERIAL IS

ALTERNATIVE METHOD FOR CUTTING CROWN MOLDING

Place the molding on the table at an angle between the fence and the saw table, as shown inFigure 18. 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 avail- able for purchase from your local dealer.

The advantage to cutting crown molding using this method

isthat 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 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.

RIGHT

EXTREMELY IMPORTANT!

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 18.

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

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

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 20 illustrates the wrong way to cut these extrusions. Use a stick wax cutting lubricant when cutting aluminum. Apply the stick wax cutting lubricant 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 page 4 for correct saw blade.

BOWED MATERIAL

When cutting bowed material always position it as shown

in Figure 21 and never like that shown in Figure 22.

Positioning the material incorrectly will cause it to pinch the blade near the completion of the cut.

FIG. 21

FIG. 22

FIG. 23

RIGHT

WRONG

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 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 23. 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. SPECIAL SET-UP FOR WIDE CROSSCUTS

Your saw can cut very wide [up to 16 inch (406mm)] work- pieces when aspecial 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

knobs several turns and slide each fence outward.

Adjust and lock the miter control so that it is at 0

degrees miter.

2. Make a platform using a piece of 1.5 inch (38mm) thick particleboard or similar flat strong 1.5 inch thick wood

to the dimensions: 14.5" x 26" (368 x 660mm). The

platform must be flat otherwise the material could move during cutting and cause injury.

3. Mount the 14.5" x 26" platform to the saw using 4

three-inch long wood screws through the holes in the

base fence (Fig. 24). 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. 25).

5. Secure the material before cutting. Cut slowly through

the material using a out-down-and-back motion.

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.

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 26. 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 adjustments should be performed by a DEWALT factory service center, a DEWALT authorized

service center or other qualified service personnel. Always

use 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.

FIG. 24

(two each side)

FIG. 25

FIG. 26

SCREWS

SCREWS_

BACK FENCE

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.

90 DAY MONEY BACK GUARANTEE

Ifyou are not completely satisfied with the performance 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 product 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:

6,823,765 6,101,914 5,907,987 5,375,495 6,810,780 6,035,754 5,862,734 5,285,708 6,520,059, 6,032,563 5,582,089 5,199,343

Other patents may be pending.

SET SCREW

TABLE 1 COMPOUND MITER CUT (Position wood with broad flat side on the table and the narrow edge against the fence.)

45-

40-

35-

30-

o0 Z

25-

W t-,-

(,9

20-

t-- t--

(.,9

10 15 20 25 30 35 40 45

- 45

- 40

15-

10-

10 45

15 20 25

30 35 4O

SET THIS BEVEL ANGLE ON SAW

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 UP TO 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. Blade is not square to fence

3. Blade is not perpendicular to table

4. Workpiece moving

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 5.

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 5.

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.

TROUBLE! MATERIAL PINCHES BLADE WHAT'S WRONG?

1. Cutting bowed material

WHAT TO DO...

1. Position bowed material as shown on page 12.

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