DeWalt DW744S TYPE 2 Owner’s Manual

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iNSTRUCTiON MANUAL

GUIDE D'UTILISATION MANUAL DE INSTRUCCIONES

DW744

Table Saw

INSTRUCTIVO DE OPERACION, CENTROS DE SERVICIO Y POLIZA DE GARANTIA. ADVERTENClA: LEASE ESTE INSTRUCTIVO ANTES DE

USAR EL PRODUCTO. Sl TIENE DUDAS, POR FAVOR LLAME.

Scies circulaires _ table Sierra de banco

AWARNING: FOR YOUR OWN SAFETY, READ INSTRUCTION MANUAL BEFORE OPERATING SAW • ALWAYS WEAR EYE PROTECTION • DO NOT WEAR

GLOVES, NECKTIES, JEWELRY OR LOOSE CLOTHING • CONTAIN LONG HAIR * KEEP HANDS AND FINGERS OUT OF THE SAW BLADE PATH -- USE EXTRA CAUTION WHEN BEVELING • ALWAYS USE BLADE GUARD AND SPREADER FOR EVERY OPERATION FOR WHICH IT CAN BE USED, INCLUDING THROUGH

SAWING • USE A "PUSH STICK" WHEN REQUIRED • KNOW HOW TO AVOID KICKBACKS -- SEE MANUAL • ALWAYS SUPPORT WORK WITH TABLE AND

FENCE OR MITER GAUGE • NEVER USE FENCE AND MITER GAUGE TOGETHER • NEVER REACH AROUND OR OVER SAW BLADE • SECURELY MOUNT SAW BLADE BEFORE OPERATING • NEVER REMOVE JAMMED OR CUT-OFF PIECES UNTIL POWER IS OFF AND BLADE HAS STOPPED • DO NOT EXPOSE TO RAIN OR USE IN DAMP LOCATIONS • SECURE TOOL PROPERLY TO PREVENT UNEXPECTED MOVEMENT • DO NOT OPERATE THIS MACHINE WHILE

UNDER THE INFLUENCE OF ALCOHOL OR DRUGS • FAILURE TO COMPLY WITH THESE WARNINGS MAY RESULT IN SERIOUS PERSONAL INJURY.

DEW,tU.T... BUILT JOBSITE TOUGH

DEWALThighperformance industrialtools are madefor America'stough- est industrialandconstructionapplications.The designof everytool inthe

line - from drills to sanders to grinders- is the result of rigorous use on jobsites and throughout industry. Each tool is producedwith painstaking precision using advanced manufacturing systems and intense quality control. Every tool is checked before it leaves the factory to make sure that it meetsyour standards for durability, reliabilityand power.

DEWALT Built Jobsite Tough...WE GUARANTEE IT.

i_, WARNING: For your own safety read instruction manual before operating table saw.

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:

Double lnsulatien

Double insulated tools are constructed throughout with two separate layers of electrical insu-

lation or one double thickness of insulation between you and the tool's electrical system.

Tools built with this insulation system are not intended to be grounded. As a result, your tool

is equipped with a two prong plug which permits you to use extension cords without concern

for maintaining a ground connection.

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

ing this tool. The insulation system is for added protection against injury resulting from a pos-

sible electrical insulation failure within the tool.

CAUTION: WHEN SERVICING USE ONLY IDENTICAL REPLACEMENT PARTS. Repair

or replace damaged cords.

Polarized Plugs

To reduce the risk of electric shock, this equipment has a polarized plug (one blade is wider

than the other). This plug will fit in a polarized outlet only one way. If the plug does not fit fully

into the outlet, reverse the plug. If it still does not fit, contact a quafified electrician to install the proper outlet. Do not change the plug in any way.

Important Safety Instructions

, KEEP GUARDS 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 tool before turning it on. , KEEP WORK AREA CLEAN. Cluttered areas and benches invite injuries. , DON'T USE IN DANGEROUS ENVIRONMENT. Don't use power tools in damp or wet

locations, or expose them to rain. Keep work area weft lighted. , KEEP CHILDREN A WAY. All visitors should be kept 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 safer at the rate for which it was designed. , USE RIGHT TOOL. Don't force tool or attachment to do a job for which it was not designed. , USE PROPER EXTENSION CORD. Make sure your extension cord is in good condition.

When using 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 indoubt, use the next heavier gage. The smaller the

gage number, the heavier the cord.

Minimum Gage for Cord Sets

Volts Total Length of Cord in Feet

120V 0-25 26-50 51-100 101-150

240V 0-50 51-100 101-200 201-300 Ampere Rating

More Not more AWG

Than Than 0 6 18 16 16 14 6 10 18 16 14 12

10 12 16 16 14 12 12 16 14 12 Not Recommended

WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties, rings, bracelets,

or other jewelry which may get caught in moving parts. IVonslip footwear is recommended.

Wear protective hair covering to contain long hair. Air vents often cover moving parts and

should also beavoided.

, AL WAYS USE SAFETY GLASSES. Also use face ordust mask ffcutting operation isdusty.

Everyday eyeglasses only have impact resistant lenses, they are not safety glasses.

, SECURE WORK. Use clamps or a vise to hold work when practical It's safer than using

your hand and it frees both hands to operate tool.

, DON'T OVERREACH. Keep proper footing and balance at all times. , MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best and safest

performance. Follow instructions for lubricating and changing accessories.

, DISCONNECT TOOLS before servicing; when changing accessories, such as blades, bits,

cutters, and the like.

, REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure switch is in off position

before plugging in.

, USERECOMMENDEDACCESSORIES. Consulttheinstructionmanualforrecommended

accessories. The use of improper accessories may cause risk of injury to persons.

, NEVER STAND ON TOOL. Serious injury could occur ff the tool is tipped or ff the cutting tool

is unintentionally contacted.

, CHECK DAMAGED PARTS. Before further use of the tool, a guard or other part that is

damaged should be carefully checked to determine that it will operate properly and perform its intended function-check for alignment of moving parts, binding of moving parts, breakage of parts, mounting, and any other conditions that may affect its operation. A guard or other

part that is damaged should be properly repaired or replaced.

, DIRECTION OF FEED. Feed work into a blade or cutter against the direction of rotation of

the blade or cutter only.

, NEVER LEAVE TOOL RUNNING UNATTENDED. TURN POWER OFF. Don't leave tool

until it comes to a complete stop.

, REPLACEMENT PARTS. When servicing, use only identical replacement parts.

Additiena# Safety Ru#es for Tab#e Saw

,_, WARNING: For your own safety, do not operate your saw until it is completely assembled

and installed according to the instructions and until you have read and understood the following: * All Safety Rules * Adjustment Procedures * Assembly Procedures * Basic Operations * Operating Controls

• KEEP GUARDS in place and in working order.

• STABILITY. Make sure table saw is firmly mounted before use.

• MINIMIZE ACCIDENT POTENTIAL. Most accidents are caused by failure to follow setup and operating instructions.

• AVOID awkward handpositions, where a sudden slip could cause a hand to move into a saw blade or other cutting tool. Never reach in back of, or around, the cutting tool with either hand to hold down the workpiece. DO NOT PLACE FINGERS OR HANDS IN THE

PATH OF THE SAW BLADE.

• NEVER reach under your machine when operating or make any adjustments when it is running.

• SHUT OFF the saw and disconnect the power cord when removing the table insert, chang- ing the cutting tool, removing or replacing the blade guard, or making adjustments.

• AL WAYS maintain control of the workpiece. DO NOT let go of the workpiece until it is well clear of the cutting tool

• WHEN REMOVING short workpieces, or cleaning up around the table, be sure the saw is in the OFF position and blade has stopped turning.

• NEVER turn the saw ON before clearing the table of all tools, wood scraps, etc., except the workpiece and related feed or support devices for the operation planned.

• WHEN changing saw location, disconnect power.

• USE extra caution when the guard assembly is removed for resawing, dadoing, rabbeting, or molding. Replace the guard as soon as that operation is completed.

* NEVERholdontoortouchthe'_reeend"oftheworkpiece

ora'_reepiece"thatiscutoff,whilepowerisONand/or thesawbladeisrotating.

* IF YOU STALL OR JAM the saw blade in the workpiece,

tum saw OFF, remove the workpiece from the saw blade, and check to see ff the saw blade is parallel to the miter

gauge slots or grooves and if the splitter is in proper

alignment with the saw blade. If ripping at the time, check to see ff the rip fence is paraflel with the saw blade. Readjust as indicated.

_ WARNING: Do not allow familiarity (gained from frequent

use of your saw) to replace following safety rules. Always

remember that a careless fraction of a second is sufficient

to inflict severe injury.

* MAKE SURE your fingers do not contact the terminals of

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

* KICKBACKS - Kickbacks can cause serious injury. A

kickback occurs when a part of the workpiece binds between the saw blade and the rip fence, or other fixed object, and rises from the table and is thrown toward the

operator. Kickbacks can be avoided by attention to the following conditions:

KICKBACKS--HOW TO AVOID THEM AND PROTECT YOURSELF FROM POSSIBLE INJURY.

a) Be certain that the saw blade is parallel to the rip fence.

Adjust fence ff not parallel

b) Do not rip by applying the feed force to the section of the

workpiece that will become the cut-off (free) piece. Feed force when ripping should always be applied between the saw blade and the fence.., use apush stick for short

work, 6" (152mm) wide or less. For less than 2" (51mm)

wide, you must use a special fixture.

c) Keep saw blade guard, spfitter and anti-kickback teeth

in place and operating properly. Keep teeth sharp, ff teeth are not operational, return your unit to the nearest DEWAL T Service Center for repair. The spfitter must be in alignment with the saw blade and the teeth must stop a kickback once it has started. Check their action before ripping by pushing the wood under the anti-kickback teeth. The teeth must prevent the

wood from being pulled toward the front of the saw.

d) Plastic and composition (like hardboard) materials may

be cut on your saw. However, since these are usually quite hard and slippery, the anti-kickback teeth may not

stop a kickback. Therefore, be especially attentive to following proper set up and cutting procedures for

ripping.

e) Use saw blade guard and spfitter for every operation for

which it can be used, including all through sawing.

* DO NOT leave a long board (or other workpiece)

unsupported so the spring of the board causes it to shift on the table. Provide proper support for the workpiece, based on its size and the type of operation to be performed. Hold the work firmly against the fence and down against the

table surface.

• NEVER use a length stop on the free endofthe workpiece when crosscutting. Never hang onto or touch the free end of the workpiece when crosscutting, or a free piece that is cut off when ripping while power is ON and/or the saw

blade is rotating. In short, the cut-off piece in any 'thru- sawing" (cutting completely through the workpiece) operation must never be confined -- it must be allowed to move away from saw blade.

• IF YOUR SAW makes an unfamiliar noise or ff it vibrates excessively, cease operating immediately until the source

has been located and the problem corrected.

• KEEP OUT of the fine of saw blade. Stand to the side whene vet possible.

• USE a push-stick when required. (See page 9)

• PAYparticular attention to instructions on reducing risk of kickback.

• DO NOTperform any operation free hand.

• NEVER reach around, behind or over saw blade.

• USE RECOMMENDED ACCESSORIES. The use of improper accessories may cause risk of personal injury.

i_,WARNING: Some dust created by power sanding, saw-

ing, grinding, drilling, and other construction activities con- tains chemicals known to cause cancer, birth defects or

other reproductive harm. Some examples of these chemi- cals are:

• lead from lead-based paints,

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

• arsenic and chromium from chemically-treated lum- ber (CCA).

Your risk from these exposures varies, depending on how

often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work

with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

• Avoidprolonged contact with dust from power sand- ing, sawing, grinding, drilling, and other construc- tion 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 respira- tory protection appropriate for the dust exposure. Direct par- ticles away from face and body.

i_, CA UTION: Wear appropriate hearing protection dur- ing use. Under some conditions and duration of use, noise from this product may contribute to hearing loss.

SAVE THESE INSTRUCTIONS FOR

FUTURE USE

FIG. 1

FIG. 2

FIG. 3

SCREW-DOWN

HOLES

FIG. 4

WORK SUPPORT

EXTENSION

(RETRACTED)

GAUGE

MOUNTING

BLADE GUARD

ON-OFF SWITCH

RIP SCALE INDICATOR

FINE ADJUST

BLADE HEIGHT

BEVEL LOCK

LEVER

ANTI-KICKBACK TEETH

RAIL LOCK

LEVER

KNOB

ADJUSTMENT

WHEEL

RIP FENCE

LATCH

Specifications

Horsepower 2-1/2

Table Size 19 1/4" x 26 1/2"

Miter Angle 30° L&R Bevel Angle 0° to 45°L Blade Size 10" (254mm)

Max. Cut Depth 0° Bevel ................ 3 1/8" (79ram)

Max. Cut Depth 45° Bevel ..............2-1/4" (57mm)

RPM, no load 3650

Unpacking

Open the box and slide the saw out, as shown in Figure 1. Carefully unpack the table saw and all loose items from the

carton. Examine all parts to make sure that parts have not been damaged during shipping. If any parts are missing or

damaged, contact your dealer to replace them before attempting to assemble the tool.

Figure 2 shows all the loose items and hardware packed with

the saw.

1. Rip fence

2. Blade (attached to saw base)

3. Arbor wrench and spindle wrench (attached to saw base)

4. Blade guard

5. Throat plate

6. Miter gauge

Examine Figures 3 & 4 to become familiar with the saw and

its various parts. The following sections on assembly and adjustments will refer to these terms and you must know what and where the parts are.

Assembly

YOUR SAW SHOULD BE ASSEMBLED IN THE

FOLLOWING ORDER:

1. Blade

2. Rip fence (NOTE: Adjust rip scale before proceeding. See "Adjusting Rip Scale".)

3. Blade guard

4. Throat plate

FIG. 5

BLADE/WRENCH

STORAGE

OPENING

DUST EXHAUST

Tools needed for assembly include a screwdriver and the wrenches included with your saw.

ASSEMBLING THE RIP FENCE The rip fence can be installed on the left or right side of your

table saw.

1. Locate the pin and opening on fence rails, as shown in Figure 5. Align the pin with the slot and align the latch

with the opening.

2. Secure the rip fence by snapping the latches onto the rails as shown in Figure 6. Be sure to snap both latches in place.

ATTACHING/REPLACING THE BLADE

1. Raise the saw blade arbor to its maximum height by turning the blade height adjustment wheel clockwise.

2. Remove the arbor nut and flange from the saw arbor by turning counterclockwise.

3. Place the saw blade on to the spindle making sure the teeth of the blade point down at the front of the table. Assemble the washers and arbor nut to the spindle and tighten arbor nut as far as possible by hand, making sure that the saw blade is against the inner washer and the large washer diameters are against the blade.

Ensure the side of outer washer marked "Blade Side" is against the blade (see Figure 7). Ensure the spindle and

washers are free from dust and debris.

4. To keep the spindle from rotating when tightening the

arbor nut, use the open-ended spindle wrench to secure

the spindle (see Figure 8).

5. Using the arbor wrench, tighten the arbor nut by turn- ing it clockwise (see Figure 8).

6. NOTE: Different types of blades make different kerfs (width of cuts). Therefore, it is necessary to check

adjustment of rip fence pointer and blade guard splitter

when changing blades.

ADJUSTING THE RIP SCALE

1. Unlock the rail lock lever (see Figure 9).

2. Set the blade at 0° bevel and move the fence in until it touches the blade.

3. Lock the rail lock lever.

4. Loosen the rip scale pointer screws (see Figure 16) and set the rip scale pointer to read zero (0). Retighten the

rip scale pointer screws. The rip scale reads correctly only when the fence is mounted on the right side of the

blade.

ATTACHING THE BLADE GUARD

1. Raise the saw blade arbor to its maximum height by turning the blade height adjustment wheel clockwise.

2. Loosen, but do not remove the two bolts shown in Figure 10.

3. Insert the blade guard as shown in Figure 11, ensuring

the bolts fit into the slots on the blade guard. The edge

of the splitter should protrude below and hook under the

shims. Tighten the bolts. Make sure the splitter is cen-

tered and parallel to the blade by lining up the parts with

a straight edge. If the blade and splitter are not aligned, loosen, but do not remove the bolts again. Remove the

guard and reinsert it after adjusting the shims. These shims allow for precision alignment of the blade and splitter. Tighten the bolts securely. Make sure that there

is clearance between the splitter and the blade, and that the blade spins freely. If the splitter is tilted relative to the blade, the splitter plate can be bent until it lines

up correctly.

IMPORTANT: THE GUARD SHOULD BE IN PLACE

FOR ALL POSSIBLE CUTS.

4. Retighten the bolts securely.

_ WARNING: Before connecting the table saw to the power

source or operating the saw, always inspect the guard and spfitter for proper alignment and clearance with saw blade. Check alignment after each change of bevel angle.

When properly aligned, the splitter will be in line with the

blade at both table top level, and at the top of the blade. Check using the straight edge. With power disconnected, operate the blade tilt and height adjustments through the extremes of travel and insure the guard clears the blade in all operations and that the anti-kickback teeth are functioning.

ATTACHING THE THROAT PLATE

1. Align the throat plate as shown in Figure 12, and insert the tabs on the back of the throat plate into the holes on

the back of the table.

2. Press down on the front of the throat plate to snap it into place.

3. The throat plate includes four adjustment screws which raise or lower the throat plate. When properly adjusted,

the front of the throat plate should be flush or slightly

below the surface of the table top and secured in place.

The rear of the throat plate should be flush or slightly

above the table top.

4. Turn the cam lock screw (Detail Fig. 12) clockwise 1/4

turn to lock the throat plate in place.

i_, CAUTION: The throat plate must be in place at all times.

Bench Mounting

TURN OFF AND UNPLUG TABLE SAW The table saw must be mounted firmly. The mounting sup

face must have a 15" by 20" opening to allow dust to escape.

Four holes are provided in the tool's feet for mounting. We strongly recommend that these holes be used to anchor the table saw to your workbench or other stationary rigid frame. Alternately, to enhance the saw's portability, it can be

mounted to a piece of wood that can be "C" clamped to your work surface, stand or Workmate® Workcenter. The

DEWALT DW7440 Table Saw Stand is designed for use with this saw, and is available from your local DEWALT dealer or

service center.

FIG. 7A

FIG. 6

iNNER

WASHER

BLADE

REAR PINION BEARING ASSEMBLY

(SAW SHOWN UPSIDE DOWN FOR CLARITY)

OUTER

WASHER

ARBOR

NUT

FIG.8

FIG.10

SHIMS

ARBOR

WRENCH

FIG.9

RAILLOCKLEVER

BOLTS

FIG.13

FIG.14

FIG.11

EDGEOF

SPLITTER

_ CAUTION: Failure to securely mount the table saw to the

work surface can be hazardous.

1. Center the saw on a square piece of 1/2" (12.7mm) ply- wood. The plywood must have a 15" by 20" opening to

allow dust to escape.

2. Mark the positions of the four mounting holes in the base of the saw with a pencil.

3. Remove the saw and drill 1/4" (6.4mm) holes in the places you have just marked.

4. Position the saw over the four holes you drilled in the plywood and insert four 1/4" (6.4mm) machine screws

FROM THE BOTTOM. Install washers and 1/4" (6.4mm) nuts on the top. Tighten securely.

5. In order to prevent the screw heads from marring the

surface to which you clamp the saw, attach two strips of scrap wood to the bottom of the plywood base. These strips can be attached with glue, or wood screws can be

installed from the top side as long as they don't protrude

through the bottom of the strip.

6. "C" clamp the plywood base to your workbench when-

ever you want to use the saw.

CAUTION: Make sure table saw is firmly mounted before

use.

Connecting Saw to Power Source

IMPORTANT: Before connecting saw to power source, make sure the switch is inthe OFF position.

Be sure your power supply agrees with the nameplate mark- ing. AC ONLY means that your saw will operate on alternat-

ing current only. A voltage decrease of 10 percent or more

will cause a loss of power and overheating. All DeWalt tools are factory tested. If this tool does not operate, check the

power supply.

Rip Fence Operation

RAIL LOCK LEVER

The rail lock lever locks the rip fence rails in place, prevent-

ing their movement. To lock the rail lock lever, push it down.

To unlock the lever, pull it up (see Figure 9).

NOTE: When ripping, always lock the rail lock lever.

WORK SUPPORT EXTENSION Your table saw is equipped with a work support extension to

support work that extends beyond the saw table. To use the work support extension, rotate it as shown in Figure 13. When not in use, the work support extension retracts, as shown in Figure 14.

NOTE: Retract the work support extension whenever work- ing over the table.

FINE ADJUST KNOB

The fine adjust knob (shown in Figure 15) allows smaller adjustments when setting the fence. Before adjusting, be

sure the rail lock lever is in its up, or unlocked, position.

RIP SCALE POINTER NOTE: The rip scale pointer will need to be readjusted

whenever a thicker or thinner blade is installed.

On-Off Switch

Lift the switch paddle up to turn your saw ON and push it

down to turn your saw OFF. A hole is provided in the switch for insertion of a padlock to

lock the saw off (Figure 17). _ WARNING: Be sure switch is in the OFF position before

plugging machine in.

Adjustments

NOTE: Your saw is fully and accurately adjusted at the fac- tory at the time of manufacture. If readjustment due to ship- ping 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.

RAiL LOCK ADJUSTMENT

1. Lock the rail lock lever (Figure 9) by pushing down.

2. On the underside of your saw, tighten the nut shown in Figure 18. Adjust this nut until the gap between the

belleville washers closes.

3. Once the springs are almost touching, tighten the nut 1/2 turn.

RIP SCALE ADJUSTMENT

See "ADJUSTING THE RIP SCALE" on page 4. ADJUST BLADE ALIGNMENT TO TABLE

1. THE SAW MUST BE UNPLUGGED BEFORE YOU MAKE ANY ADJUSTMENT TO THE BLADE.

2. Place the unit in an upright position. Using a 10ram socket, loosen rear pivot bracket fasteners just enough to allow the bracket to move side-to-side.(Figure 7A).

3. Adjust the bracket until the blade is parallel to the miter

gauge slot.

4. Tighten the rear pivot bracket fasteners to 7-8 ft.lbs.

BEVEL STOP AND POINTER ADJUSTMENT

1. Raise the blade fully by rotating the blade height adjust- ment wheel clockwise until it stops.

2. Unlock the bevel lock lever (Figure 3) by pushing it up and to the right. Loosen the bevel stop screw (Figure 19).

3. Place a square flat against the table top and against the blade between teeth, as shown in Figure 20. Ensure the bevel lock lever is in its unlocked, or up, position.

4. Using the bevel lock lever, adjust the bevel angle until it is flat against the square.

5. Tighten the bevel lock lever by pushing it down.

6. Turn the bevel stop cam until it firmly contacts the bear- ing block. Tighten the bevel stop screw.

7. Check the bevel angle scale. If the pointer does not read 0°, loosen pointer screw (see Figure 19) and move the pointer so it reads correctly. Retighten the pointer screw.

8. Repeat at 45°, but do not adjust pointer.

MITER GAUGE ADJUSTMENT

Your miter gauge features adjustable stops at 90° and 45°

left and right. To adjust these stops, loosen the lock nuts and

tighten or loosen the three adjusting screws against the stop

plate (see Figure 21). FENCE PARALLEL ADJUSTMENT

1. Unlock rail lock lever.

2. Locate rear pinion bearing and loosen the two hex bolts just enough to allow side-to-side movement.

3. Adjust fence parallel to blade.

4. Lock rail lock lever and check parallel alignment of the

blade.

5. Tighten the 2 hex bolts that secure the rear pinion bear- ing assembly to the table.

NOTE: If there is not enough travel in the pinion bearing assembly to allow the fence to be parallel to the blade,

take the unit to an authorized service center.

RACK AND PINION MESH ADJUSTMENT Proper adjustment of the rack and pinion mesh is done at

the factory. If it should become necessary to adjust the rack

and pinion mesh, use the following procedure.

1. Turn the saw upside down and locate the front pinion bearing.

2. Using a narrow blade screw driver or #20 torx driver, access the screw through the slot. Loosen the screw

(counterclockwise) until the head touches the inside of

the bearing box.

3. Tighten the screw (clockwise) 3/4 of a turn.

4. Repeat procedure for rear pinion bearing.

Saw Blades

THIS SAW IS INTENDED FOR THE USE OF SAW

BLADES 10" IN DIAMETER OR SMALLER

1. The saw blade furnished with your new saw is a 10" (254mm) combination blade, used for cross cutting (across the grain) and ripping (with the grain) through

the material. The center hole to fit on the arbor is 5/8"

(16mm) diameter (.625"). This blade will produce a good quality cut for most applications.

2. There are many types of blades available to do specific and special jobs such as cross cut only, rip only, hollow ground, thin plywood, paneling, etc.

3. Use only saw blades designed for maximum safe oper- ating speeds of 5,000 RPM or greater.

4. Saw blades should always be kept sharp. It is recom- mended that you locate a reputable sharpening service

to sharpen your blades when needed.

5. Never stack blades on top of one another to store. Place material such as cardboard between them to keep the blades from coming in contact with one another.

i_, CAUTION: Abrasive wheels should not be used on this

saw.

FINE ADJUST KNOB

SCREWS

FIG. 16

PADLOCK

INSERTION

HOLE

ON-OFF SWITCH

FIG. 17

FIG.18

FIG.19

FIG.20

BEVELSTOP

SCREW

BELVILLE

WASHERS

STOP CAM

POINTER

SCREW

I GAP

BEVEL

FIG. 21

STOP PLATE

PUSH STICK

LOCK HANDLE

ADJUSTING

SCREW

NUT

FIG. 22

FIG. 23

Kickback

Kickback is a dangerous condition! It is caused by the work- piece binding against the blade. The result is that the work- piece can move rapidly in a direction opposite to the feed direction. During kickback, the workpiece could be thrown back at the operator. It can also drag the operator's hand back into the blade if the operator's hand is at the rear of the blade. If kickback occurs, turn the saw OFF and verify the proper functioning of the splitter, anti-kickback teeth and guards before resuming work.

CA UTION:

1.Always use the guard and make certain it is in good working order. The guard's spfitter helps prevent binding and the anti-kickback teeth on each side of the spfitter minimize the possibility of kickback. Use extra caution until the workpiece is through the spfitter and has engaged anti-kickback teeth.

2. Do not saw warped, bowed or cupped wood. The work- piece must have one straight, smooth side to go against

the rip fence or miter gauge. The workpiece must sit flat on the table without rocking.

3. Do not cut '_reehand" Always use either the rip fence or the miter gauge. Never use both.

4. Use extra care when the guard assembly cannot be used (during dadoing or molding).

5. Support large workpieces carefully. Allowing them to sag or droop can cause kickback.

Operation

Plain sawing includes ripping and cross cutting, plus a few

other standard operations of fundamental nature. The fol-

lowing methods feature safety. As with all power tools respecting the tool, using caution and following safe prac-

tices will considerably lessen the possibility of personal

injury. However, if normal safety precautions are overlooked

or completely ignored, personal injury to the operator can

result. Read and follow all warnings indicated on the saw. Through sawing is any operation which renders the materi- al into two separate pieces.Observe the safety rules includ-

ed in this manual. THIS SAW IS NOT INTENDED FOR CUTTING METAL.

Operating Instructions

There are two basic types of cuts: ripping and crosscutting.

In general, cutting with the grain is ripping and across the grain is crosscutting. However, with man made materials this distinction is somewhat difficult to make. Therefore, cut- ting a piece of wood to a different width is ripping and cut- ting across the short dimension is crosscutting. Neither rip- ping or crosscutting may be done safely freehand! Ripping

requires the use of the rip fence and crosscutting uses the

miter gauge.

_J,CAUTION: Before using the saw each and every time

verify the following:

1. Blade is tight.

2. Bevel angle lock knob is tight.

3.Ifripping,ensureraillockleveristightandfenceispar- alleltotheblade.

4.Ifcrosscutting,mitergaugeleveristight.

5.Guardisinplaceandworkingproperly.

6.Safetyglassesarebeingworn.

7.Thebladeguardisproperlyattachedandtheanti-kick- backteetharefunctioning.

Failuretoadheretothesecommonsafetyrulescangreatly increasethelikelihoodofinjury.

Ripping

1. Lock the rip fence by pressing the rail lock lever down, Remove the miter gauge.

2. Raise the blade so it is about 1/8"(3.2mm) higher than the top of the workpiece.

3. Hold the workpiece flat on the table and against the fence. Keep the workpiece about 1" (25.4mm) away

from the blade.

,& CAUTION: The workpiece must have a straight edge

against the fence and must not be warped, twisted or bowed. Keep both hands away from the blade and away from the path of the blade.

4. Turn the saw on and allow the blade to come up to speed. Both hands can be used in starting the cut. When there is approximately twelve (12) inches

(305mm) left to be ripped...use only one hand, with your

thumb pushing the material, your index and second fin-

ger holding the material down and your other fingers hooked over the fence. Always keep your thumb along

side your first two fingers and near the fence.

5. Keeping the workpiece against the table and fence, slowly feed the workpiece rearward all the way through the saw blade. Continue pushing the workpiece until it is clear of the guard and it falls off the rear of the table. Do

not overload the motor.

6. Never try to pull the workpiece back with the blade turn-

ing. Turn the switch off, allow the blade to stop, raise the anti-kickback teeth on each side of the splitter if neces-

sary and slide the workpiece out.

7. When sawing a long piece of material or a panel, always use a work support. A sawhorse, rollers, or out feed assembly provides adequate support for this purpose. The

work support must be at the same height as the saw table.

A CAUTION: Never push or hold onto the '_ree" or "cut off"

side of the workpiece.

Bevel Ripping

This operation is the same as ripping except the bevel angle

is set to an angle other than zero degrees.

,_ WARNING: Before connecting the table saw to the power soume or operating the saw, always inspect the guard and spfitter for proper alignment and clearance with saw blade. Check alignment after each change of bevel angle.

Ripping Small Pieces

It is unsafe to rip small pieces. It is not safe to put your hands

close to the blade. Instead, rip a larger piece to obtain the

desired piece. When a small width is to be ripped and the hand cannot be safely put between the blade and the rip

fence, use one or more push sticks. A pattern is included on

page 9 to make push sticks. Use them to hold the workpiece against the table and fence, and push the workpiece fully past the blade. See Figure 22.

Crosscutting

1. Remove the rip fence and place the miter gauge in the desired slot.

2. Adjust the blade height so that the blade is about 1/8" (3.2ram) higher than the top of the workpiece.

3. Hold the workpiece firmly against the miter gauge with

the path of the blade in line with the desired cut location.

Keep the workpiece an inch or so in front of the blade. KEEP BOTH HANDS AWAY FROM THE BLADE AND

THE PATH OF THE BLADE.

4. Start the saw motor and allow the blade to come up to

speed.

5. While using both hands to keep the workpiece against the face of the miter gauge, and holding the workpiece flat against the table, slowly push the workpiece through the blade. See Figure 23.

6. Never try to pull the workpiece with the blade turning. Turn the switch off, allow the blade to stop, and carefully

slide the workpiece out.

i_ CAUTION: Never touch or hold onto the "free" or "cut off"

end of the workpiece.

Bevel Crosscutting

This operation is the same as crosscutting except that the

bevel angle is set to an angle other than 0°. _ WARNING: Before connecting the table saw to the power

source or operating the saw, always inspect the guard and splitter for proper alignment and clearance with saw blade.

Check alignment after each change of bevel angle.

Mitering

This operation is the same as crosscutting except the miter

gauge is locked at an angle other than 0°. Hold the work- piece FIRMLY against the miter gauge and feed the work-

piece slowly into the blade (to prevent the workpiece from moving). See Figure 23.

MITER GAUGE OPERATION

To set your miter gauge, loosen the lock handle and move the miter gauge to the desired angle. The miter gauge has

set stops and 90 ° and 45° left and right. To rotate the miter

gauge beyond these stops, flip the stop plate up, as shown in Figure 21.

Compound Mitering

This is a combination of bevel crosscutting and mitering.

Follow the instruction for both bevel crosscutting and mitering.

FIG. 24

DUST ACCESS

DOOR

HAIR PIN COTTERS

FIG. 25

HEIGHT

ADJUSTMENT

THREADS

Dado Cutting

A CAUTION: Do not attempt to stack dado blades thicker than 13/16" (20mm). Do not use dado blades larger than 8"

(200mm) diameter. When installing the dado stack, do not include the inner clamp washer. Replace it with the outer

clamp washer, then install the blade stack, arbor nut, and tighten with the wrench supplied.

Since dado cuts are not through cuts, the cuts must be per- formed with the blade guard removed. To remove the blade guard, loosen the two bolts shown in Figure 10 and remove the guard assembly.

When using the dado, the special dado insert (also sold as an accessory) must be used.

Anytime a cut is required that is considerably wider than the saw ken', a dado is used. A dado cut is commonly used to add support and line up a shelf for a cabinet, bookcase or some such project. When using the dado, the guard must be

removed. Use EXTREME care when using the dado without

the guard. If a deep cut is required. Use several successive

passesratherthanattemptingtomakeitwithonepass.

Maximumdadowidthonthissawis13/16"(20mm).DO NOTUSEWIDERCOMBINATIONS.

,_ CAUTION: Always check dado blade clearance before

plugging in the saw.

Be sure to place the guard and standard throat plate back in position and check adjustments when the dado cuts are complete.

Dust Collection

Your table saw is equipped with a dust shroud and dust col-

lection port. For best results, connect a vacuum to the port at the rear of the saw.

If the saw is operated without a vacuum attached, most of the dust will be blown out the dust collection port. However,

some dust will fall inside the base. If the saw is used on a table or other surface without an opening on the bottom,

clean out the base and accumulated saw dust after each cut.

After extended use, the saw's dust collection system may become clogged. To clear the dust collection system:

a) Unplug the saw. b) Turn the saw on its side, so the bottom, open part of the

unit is accessible.

c) Open the dust access door shown in Figure 24 by

removing the two hair pin cotters shown. Clean out the excess dust, and re-secure the access door with the hair pin cotters.

When cutting wet wood without a vacuum or when cutting with a dado blade, removing the dust access door may be

helpful in preventing clogs.

Lubricatiore

1. All motor bearings are permanently lubricated at the fac- tory and no additional lubrication is needed.

2. The height adjustment screw may require periodic cleaning and lubrication. If you have difficulty raising or

lowering the blade: a) Unplug the saw. b) Turn the saw on its side, so the bottom, open part of

the unit is accessible.

c) Clean and lubricate the height adjustment screws

threads on the underside of your saw with general purpose grease, shown in Figure 25.

Accessories

Recommended accessories for use with your tool are avail-

able at extra cost from your distributor or local service center.

DEWALT manufactures the following accessories for your

saw:

Portable Saw Stand

Outfeed Side Support

Replacement Throat Plate Dado Throat Plate

_ CAUTION: The use of any non-recommended accesso-

ry may be hazardous.

If you need assistance in locating any accessory, please

contact DEWALT Industrial Tool Co., 701 East Joppa Road,

Baltimore, MD 21286 or call 1-800-4-DEWALT (1-800-433-

9258).

Cleaning

Use only mild soap and damp cloth to clean the tool. Never let any liquid get inside the tool; never immerse any part of the tool

into a liquid. Never use solvents to clean saw or guard

components.

Important

To assure product SAFETY and RELIABILITY, repairs,

maintenance and adjustment (including brush inspection and replacement) should be performed by authorized ser-

vice centers or other qualified service organizations, always

using identical replacement parts.

Three Year Limited Warranty

DEWALT will repair, without charge, any defects due to

faulty materials or workmanship for three years from the

date of purchase. This warranty does not cover part failure due to normal wear or tool abuse. For further detail of war-

ranty coverage and warranty repair information, visit

www.dewalt.com or call 1-800-4-DEWALT (1-800-433-

9258). This warranty does not apply to accessories or dam- age caused where repairs have been made or attempted by others. This warranty gives you specific legal rights and you may have other rights which vary in certain states or provinces.

In addition to the warranty, DEWALT tools are covered by

our:

1 YEAR FREE SERVICE

DEWALT will maintain the tool and replace worn parts

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

after purchase.

90 DAY MONEY BACK GUARANTEE

If you 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.

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

for a free replacement.

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