DeWalt DW745 TYPE 1 Owner’s Manual

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iNSTRUCTiON MANUAL

GUIDE D'UTILISATION

MANUAL DE INSTRUCCIONES

DW745 Heavy-Duty 10" (254 ram) Job Site Table Saw

INSTRUCTIVO DE OPERACION, CENTROS DE SERVlCIO Y POLIZA DE GARANTiA. ADVERTENCIA: Lt_ASE ESTE INSTRUCTIVO ANTES

DE USAR EL PRODUCTO.

Scie circulaire &table de chantier robuste avec lame de 254 mm (10 po), DW745 Sierra de banco para el lugar de trabajo de 254 mm (10") de alta resistencia DW745

Definitions: Safety Guidelines

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

i_DANGER: Indicates an imminently hazardous

situation which, if not avoided, wifl result in death or serious injury.

AWARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

_,CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION: Used without the safety alert symbol indicates a potentially hazardous situation which, if

not avoided, may result in property damage.

SAVE THESE INSTRUCTIONS

General Safety Rules

_ ARNING: Read all instructions before operating product. Failure to follow all

instructions listed below may result in electric shock, fire and/or serious injury.

SAVE THESE INSTRUCTIONS

_WARNING: FOLLOW ALL WIRING CODES and recommended electrical connections

to prevent shock or electrocution.

Grounding Instructions

If saw is of grounded construction, read the following instructions.

_DANGER: SHOCK HAZARD. THiS MACHINE MUST BE GROUNDED WHILE IN USE.

SERIOUS INJURY COULD RESULT.

ALL GROUNDED, CORD-CONNECTED MACHINES

In the event of a malfunction or breakdown, grounding provides a path of least resis- tance for electric current to reduce the risk of electric shock. This machine is equipped with an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances. Do not modify the plug provided - if it will not fit the outlet, have the proper outlet installed by a qualified electrician. Improper connection of the equipment-grounding conductor can result in risk of electric shock. The conductor with insulation having an outer surface that is green with or without yel- low stripes is the equipment-grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal. Check with a qualified electrician or service personnel if the grounding instruc- tions are not completely understood, or if in doubt as to whether the machine is properly grounded. Use only three-wire extension cords that have three-prong grounding type plugs and matching three-conductor receptacles that accept the machine's plug, as shown in Fig. A. Repair or replace damaged or worn cord immediately.

GROUNDED, CORD-CONNECTED MACHINES iNTENDED FOR USE ON A SUPPLY CIRCUIT HAVING A NOMINAL RATING LESS THAN 150 VOLTS

If the machine is intended for use on a circuit that has an outlet that looks like the one illustrated in Fig. A, the machine will have a grounding plug that looks like the plug illus-

trated in Fig. A. A temporary adapter, which looks like the adapter illustrated in Fig. B, may be used to connect this plug to a matching two-conductor receptacle as shown in

Fig. B if a properly grounded outlet is not available. The temporary adapter should be used only until a properly grounded outlet can be installed by a qualified electrician. The

green-colored rigid ear, lug, and the like, extending from the adapter must be connected to a permanent ground such as a properly grounded outlet box. Whenever the adapter

is used, it must be held in place with a metal screw.

A GROUNDED B C D

GROUNDING

MEANS

GROUNDING PIN ADAPTER GROUNDING PIN

NOTE: In Canada, the use of a temporary adapter is not permitted by the Canadian Electric Code.

ADANGER: IN ALL CASES, MAKE CERTAIN THATTHE RECEPTACLE IN QUESTION IS

PROPERLY GROUNDED. IF YOU ARE NOT SURE, HAVE A QUALIFIED ELECTRICIAN

CHECK THE RECEPTACLE.

Double Insulation

If saw is of double-insulated construction, read the following instructions.

Double insulated tools are constructed throughout with two separate layers of electrical insulation or one double thickness of insulation between

you and the tool's electrical system. Tools built with this insulation system are not intended to be grounded. As a result, your tool is equipped with a two prong plug which permits you to use extension cords without concern for maintaining a ground connection. Repair or replace damaged or worn cord immediately

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.

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 qualified electrician to install the proper outlet. Do not change the plug in any way.

Important Safety Instructions

, TO REDUCE THE RISK OF KICKBACK AND OTHER INJURIES, KEEP GUARDS IN

PLACE and in working order at all times.

, REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see that

keys and adjusting wrenches are removed from spindle before turning tool on. Tools, scrap pieces, and other debris can be thrown at high speed, causing injury.

, KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents. , DO NOT USE THE MACHINE INA DANGEROUS ENVIRONMENT. The use of power

tools in damp or wet locations or in rain can cause shock or electrocution. Keep your

work area well-lit to avoid tripping or placing arms, hands, and fingers in danger.

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

Your shop is a potentially dangerous environment.

MAKEWORKSHOPCHILDPROOFwithpadlocks,masterswitches,orbyremoving starterkeys.Theunauthorizedstart-upofamachinebyachildorvisitormayresultin

injury.

DO NOT FORCE TOOL. It will do the job better and be safer at the rate for which it was

designed.

USE RIGHT TOOL. Don't fome tool or attachment to do a job for which it was not

designed. Using the incorrect tool or attachment may result in personal injury.

USE PROPER EXTENSION CORD. Make sure your extension cord is in good condi-

tion. If your product is equipped with a cord set, use only three-wire extension cords that have three-prong grounding-type plugs and three-pole receptacles that accept the tool's plug. When using an extension cord, be sure to use one heavy enough to carry

the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. The following table shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

MINIMUM GAUGE FOR CORD SETS

Volts Total Length of Cord in Feet

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. No loose clothing, gloves, neckties, rings, bracelets, or

other jewelry to get caught in moving parts. Non-slip footwear is recommended. Wear protective hair covering to contain long hair. Air vents may cover moving parts and

should also be avoided.

, ALWAYS USE SAFETY GLASSES. Everyday eyeglasses are NOT safety glasses.

Also use face or dust mask ff cutting operation is dusty. ALWAYS wear certified safety equipment:

* ANSI Z87.1 eye protection (CAN/CSA Z94.3) * ANSI S12.6 ($3.19) hearing protection * NIOSH/OSHA/MSHA respiratory protection.

, DO NOT OVERREACH. Keep proper footing and balance at aft times. Loss of balance

may cause personal injury.

, MAINTAIN TOOLS WITH CARE. Keep blades sharp and clean for best and safest

performance. Foflow instructions for lubricating and changing accessories. Poorly maintained blades and machines can further damage the blade or machine and/or cause injury.

, TURN THE MACHINE "OFF'; AND DISCONNECT THE MACHINE FROM THE

POWER SOURCE before installing or removing accessories, before adjusting or changing set-ups, when making repairs or changing locations. Do not touch the plug's metal prongs when unplugging or plugging in the cord. An accidental start-up can cause injury. REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure that the switch is

in the "OFF'position before plugging in the power cord. In the event of a power failure, move the switch to the "OFF"position. An accidental start-up can cause injury.

, USE RECOMMENDED ACCESSORIES. Use only accessories that are recommended

by the manufacturer for your model Accessories that may be suitable for one tool may be hazardous when used on another tooL Consult the instruction manual for recom-

mended 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 cut-

ting tool is unintentionally contacted.

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

that is damaged should be carefully checked to determine that it will operate properly and perform its intended function--check for alignment of moving parts, binding of moving parts, breakage of parts, mounting and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced. Do not use tool ff switch does not turn it on and off. Damaged parts can cause further damage to the machine and/or personal injury.

, 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. Serious injury can result.

, DO NOT OPERATE ELECTRIC TOOLS NEAR FLAMMABLE LIQUIDS OR IN

GASEOUS OR EXPLOSIVE ATMOSPHERES. Motors and switches in these tools may spark and ignite fumes.

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

NOT USE THE MACHINE WHEN YOU ARE TIRED OR UNDER THE INFLUENCE OF DRUGS, ALCOHOL, OR MEDICATION. A moment of inattention while operating

power tools may result in serious injury.

, DO NOT ALLOW FAMILIARITY (gained from frequent use of your saw) TO

REPLACE SAFETY RULES. Always remember that a careless fraction of a second is sufficient to inflict severe injury.

.Additional Safety Ru#es for Tab#e Saws

_WARNING: ALWAYS USE SAFETY GLASSES. Everyday eyeglasses are NOT safety

glasses. Also use face or dust mask ff cutting operation is dusty. Aft users and bystanders MUST ALWAYS wear certified safety equipment:

* ANSI Z87.1 eye protection (CAN/CSA Z94.3), * ANSI S12.6 ($3.19) hearing protection, * NIOSH/OSHA/MSHA respiratory protection.

* AVOID AWKWARD POSITIONS, where a sudden slip could cause a hand to move into

a saw blade.

* NEVER REACH IN BACK OF, OR AROUND, THE CUTTING TOOL with either hand

to hold down the work piece.

* KEEP ARMS, HANDS AND FINGERS AWAY from the blade to prevent serious injury. * USE A PUSH STICK OR PUSH BLOCKTHAT IS APPROPRIATE TO THE APPLICA-

TION TO PUSH WORK PIECES THROUGH THE SAW. A push stick is a wooden or

non-metallic stick, usually homemade, that should be used whenever the size or shape of the work piece would cause you to place your hands within six inches of the blade.

Use hold-downs, jigs, fixtures or feather boards to help guide and control the work piece when the guard cannot be used. Use saw-blade guard and spfitter for

every operation for which it can be used, including all through sawing.

* DO NOT PERFORM RIPPING, CROSSCUTTING OR ANY OTHER OPERATION

FREEHAND.

* NEVER reach around or over saw blade. * STABILITY. Make sure the table saw is firmly mounted to a secure surface before use

and does not move.

* NEVERCUTFERROUSMETALS(thosewithanyironorsteelcontent),CEMENT

BOARDORMASONRY.Certainman-madematerialshavespecialinstructionsfor cuttingon tablesaws.Followthemanufacturer'srecommendationsat all times.

Damagetothesawandpersonalinjurymayresult.

* THEPROPERTHROATPLATEMUSTBEINPLACEATALLTIMEStoreducethe

riskofathrownworkpieceandpossibleinjury

* USETHECORRECTSAWBLADEFORTHEINTENDEDOPERATION.Theblade

mustrotatetowardthefrontofthesaw.Alwaystightenthebladearbornutsecurely Beforeuse,inspectthebladeforcracksormissingteeth.Donotuseadamaged

blade.

* NEVERATTEMPTTOFREEASTALLEDSAWBLADEWITHOUTFIRSTTURNING

THEMACHINEOFFANDDISCONNECTINGTHESAWFROMTHEPOWER

SOURCE.ffaworkpieceorcut-offpiecebecomestrappedinsidetheguard,turnsaw offandwaitforbladetostopbeforeliftingtheguardandremovingthepiece.

* NEVERSTARTTHEMACHINEwiththeworkpieceagainstthebladetoreducetherisk

ofathrownworkpieceandpersonalinjury

, NEVER run the work piece between the fence and a molding cutterhead to reduce the

risk of a thrown work piece and personal injury.

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

injury will occur.

, NEVER PERFORM LAYOUT, ASSEMBLY OR SET-UP WORK on the table/work area

when the machine is running. A sudden slip could cause a hand to move into the blade.

Severe injury can result.

, CLEAN THE TABLE/WORK AREA BEFORE LEAVING THE MACHINE. Lock

the switch in the "OFF" position and disconnect from the power source to prevent unauthorized use.

* DO NOT leave a long board (or other work piece) unsupported so the spring of

the board causes it to shift on the table resulting in loss of control and possible injury. Provide proper support for the work piece, 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.

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

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

* OBTAINADVICE from your supervisor, instructor, or another qualifiedperson if you are

not thoroughly familiar with the operation of this machine. Knowledge is safety. ADDITIONAL INFORMATION regarding the safe and proper operation of power

tools (i.e., a safety video) is available from the Power Tool Institute, 1300 Sumner Avenue, Cleveland, OH 44115-2851 (www.powertoolinstitute.com). Information is also available from the National Safety Council, 1121 Spring Lake Drive, Itasca, IL 60143-

3201. Please refer to the American National Standards Institute ANSI 01.1 Safety Requirements for Woodworking Machines and the U.S. Department of Labor OSHA

1910.213 Regulations.

TERMS: THE FOLLOWING TERMS WILL BE USED THROUGHOUT THE MANUAL ANDYOU SHOULD BECOME FAMILIAR WITH THEM.

Through-sawing refers to any cut that completely severs the work piece.

Push Stick refers to a wooden stick, usually homemade, that is used to push small

work piece through the saw and keeps the operator's hands clear of the blade.

Kickback occurs when the saw blade binds in the cut and violently thrusts the work piece back toward the operator.

Freehand refers to cutting without the use of a miter gauge or rip fence or any other means of guiding or holding the work piece other than the operator's hand.

SAW BLADE GUARD AND SPLITTER

Your table saw is equipped with a blade guard and spfitter assembly that covers the blade

and prevents accidental contact. The spfitter is a flat plate that fits into the cut made by the saw blade and effectively fights kickback by lessening the tendency of the blade to bind

in the cut. The spfitter can only be used when making through cuts that sever the wood.

When making rabbets and other cuts that make less than through cuts, the blade guard and spfitter assembly must be removed from the saw. Two anti-kickback pawls are located on the sides of the spfitter that allow the wood to pass through the blade in the cutting

direction but lock it if it tries to move backwards toward the operator.

MAKING A PUSH STICK (Inside Back Cover)

* In order to operate your table saw safely you must use a push stick whenever the size

or shape of the work piece would cause your hands to be within 6" (152 mm) of the saw blade or other cutter. A push stick is included with this saw.

* No special wood is needed to make additional push-sticks as long as it's sturdy and

long enough. A length of 12" (305 mm) is recommended with a notch that fits against the edge of the work piece to prevent slipping. It's a good idea to have several push

sticks of the same length [12" (305 mm)] with different size notches for different work piece thicknesses.

* See the inside back cover for a picture of a push stick. The shape can vary to suit your

own needs as long as it performs its intended function of keeping your hands away from the blade.

KICKBACKS

How to Avoid Them and Protect Yourself from Possible Injury

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

b. Do not rip by applying the feed force to the section of the work piece that will become

the cut-off (free) piece. Feed force when ripping should always be applied between the saw blade and the fence; use a push stick for short work, 6" (152 mm) wide or less. For

less than 2" (51 mm) 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 authorized DEWALT 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 pawls 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

aft through-sawing.

f. Push the work piece past the saw blade prior to release.

g. NEVER rip a work piece that is twisted or warped, or does not have a straight edge to

guide along the fence.

h. Use featherboards when the anti-kickback device or the guard and spfitter cannot be

used.

L NEVER saw a large work piece that cannot be controlled.

j. NEVER use the fence as a guide or length stop when crosscutting.

k. NEVER saw a work piece with loose knots, flaws, nails or other foreign objects.

L NEVER rip a workpiece shorter than 10".

iI, WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of California to cause cancer,

birth defects or other reproductive harm. Some examples of these chemicals are:

* leadfromlead-basedpaints, * crystallinesilicafrombricksandcementandothermasonryproducts,and

* arsenicandchromiumfromchemically-treatedlumber(CCA).

Yourriskfromtheseexposuresvaries,dependingonhowoftenyoudothistypeofwork. Toreduceyourexposuretothesechemicals:workinawell-ventilatedarea,andworkwith

approvedsafetyequipment,suchasthosedustmasksthatarespeciallydesignedtofilter outmicroscopicparticles.

, Avoid prolonged contact with dust from power sanding, sawing, grinding,

drilling, and other construction activities. Wear protective clothing and wash exposed areas with soap and water. Allowing dust to get into your mouth, eyes, or lay on the skin may promote absorption of harmful chemicals.

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

serious and permanent respiratory or other injury. Always use NIOSH/OSHA approved respiratory protection appropriate for the dust exposure. Direct particles away from face and body. Always operate tool in well-ventilated area and provide for proper dust removal

Use dust collection system wherever possible.

SAVE THESE INSTRUCTIONS FOR FUTURE USE

Specifications

15 AMP Miter Angle

Bevel Angle Blade Size

Max. Cut Depth Max. Cut Depth RPM, no load

FIG. 1

60° L and R 0° to 45° L

10" (254 mm)

0° Bevel 3-1/8" (79 mm) 45° Bevel 2-1/4" (57 ram)

3850

FIG.2

been damaged during shipping. If any parts are missing or damaged, contact your dealer to replace them before attempting to assemble the tool.

Refer to Figure 2 for the loose items and hardware included with the saw:

1. Rip fence

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

3. Blade guard

4. Miter gauge

5. Push stick (attached to saw base)

6. Extra guard shims

FEATURES (Fig. 3, 4)

Examine Figures 3 and 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.

FIG.3

i_i_i_ii{i_ii{i_ii{i_ii(iiiii(iiiii(iiiii(iiiii(iiiii(iiiii(ii

Unpacking

_WARNING: To reduce the risk of injury, do not connect the machine to the power source until the machine is completely assembled and you read and understand the entire

instruction manual.

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

FIGURE 3

A. Table B. Miter gauge

C. Blade D. Blade guard

E. Fence

R Fence rails

G. Rip fence front latch

H. Fine adjustment knob

I. Blade height adjustment wheel

FIGURE 4

R. Rip fence rear latch S. Dust collection port

T. Dust shroud

U. Push stick

J. Bevel lock lever

K. ON/OFF switch

L. Rip fence indicator

M. Adjustable feet

N. Mounting holes

O. Cord wrap

R Handle

Q. Anti-kickback teeth

V. Arbor wrench, spindle wrench

W. Rail lock lever

FIG. 4 D

ASSEMBLY

JLWARNING: Shock Hazard. To reduce the risk of serious personal injury, turn

unit off and disconnect machine from power source before attempting to move it,

change accessories or make any adjustments.

ASSEMBLE YOUR SAW IN THE FOLLOWING ORDER

1. Rip fence (NOTE: Adjust rip scale before proceeding; refer to Rip Scale Adjustment.)

2. Blade guard

3. Push stick

4. Miter gauge (if required for application)

5. Blade height adjustment crank

Tools needed for assembly include a Phillips screwdriver and the wrenches included with your saw. FIG.5

Blade c

ATTACHING AND REPLACING THE BLADE

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

blade height adjustment wheel (I) clockwise.

2. If replacing the blade, remove the blade guard (D) and throat plate (X) prior to installing the new blade. (Refer to To Remove Blade Guard and To Remove Throat Plate.)

NOTE: It may be easier to change the blade with the saw blade

beveled to 45°

3. Remove the arbor nut (Y) and outer washer (Z) and set aside.

4. Place the blade (C) on the arbor making sure the FIG. 6 teeth of the blade point downward and toward the front of the saw.

5. Place the outer washer (Z) against the blade, raised side out and tighten the arbor nut against the washer as far as possible by hand. Ensure that

the outer washer and arbor nut are free of dust and debris before installing.

6. To further tighten the arbor nut (Y), use the open ended spindle wrench (supplied) to keep the spindle from rotating (Fig 6).

7. Use the arbor wrench (supplied) to hold the nut and tighten it by turning it clockwise. Reposition the wrench on the arbor nut and repeat as necessary until the nut and washer are securely fastened against the blade (Fig. 6).

Rip Fence

The rip fence can be installed on the left or right side of your table saw.

FIG.7 FIG.8

TO ASSEMBLE THE RIP FENCE (FIG. 7, 8)

FIG. 9

1. Align the Iocator screw (AA) on the fence rail (F) with the fence head slot and align the latch (G) with the opening (BB).

2. Secure the rip fence by snapping the latches onto the rails as shown in Figure

8. Be sure to snap both front (G) and rear (R) latches in place.

Throat Plate (Fig. 9)

TO REMOVE THE THROAT PLATE

1. Remove the throat plate (X) by turning the cam lock screw (CC) in the front

middle 1/4 turn as shown.

2. Insert the hooked end of the arbor nut wrench into the slot on the plate and pull

it up and forward to expose the inside of the saw.

-X

TO ATTACH THE THROAT PLATE

1. Align the throat plate as shown in Figure 9, and insert the tabs on the back of the throat plate into the holes on the back of the table.

2. Rotate cam out of the way until the front of throat plate drops into place. Secure by rotating 1/4 turn (when cam lock is under the table holding the throat plate in place) as

shown in Figure 9.

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.

,_CAUTION: To reduce the risk of serious personal injury, the throat plate must be in place

at all times.

Blade Guard FiG.10A

TO ATTACH THE BLADE GUARD

1. Remove the throat plate. (Refer to Throat Plate.)

2. Raise the saw blade arbor to its maximum height by turning the blade height adjustment

wheel (I) clockwise.

3. Loosen the wing nut (DD) [minimum of three complete turns].

4. Insert the splitter (EE) into the locking mecha- nism on the saw as shown in Figure 10A until

the guard snaps into place. Pull up on the guard to make sure it is secure in the mecha-

nism.

5. Tighten the wing nut against the locking mechanism.

IMPORTANT: THE BLADE GUARD SHOULD BE IN PLACE FOR ALL POSSIBLE CUTS.

,_,WARNING: Before connecting the table saw to

the power source or operating the saw, always

inspect the guard and spfitter for proper align- ment 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. Using a straight edge, ensure that the blade is aligned with the splitter as shown

in Figure 10B. With power disconnected, operate the blade tilt and height adjustments through the extremes of travel and ensure the guard clears the

blade in all operations and that the anti-kickback teeth are functioning. Replace the throat plate.

TO REMOVE THE BLADE GUARD

1. Remove the throat plate. (Refer to Throat

Plate.)

2. Insert the hooked end of the arbor nut wrench into the slot on the plate and pull it up and

forward to expose the inside of the saw.

3. Flip the guard back and loosen the wing nut beside the guard clamp mechanism.

FIG. lOB

4. Press the wing nut toward the guard mechanism and pull the guard out of the saw.

NOTE: For ease of use, the blade guard can be inserted directly into the saw without push- ing the nut in toward the guard mechanism. However, the wing nut must still be tightened.

TO ADJUST THE BLADE GUARD The blade guard and splitter are aligned at the factory. In the event that additional adjust-

ment is needed, extra guard shims have been provided to adjust the alignment.

1. Raise the blade (C) to its highest level.

2. Remove the blade guard (D) and blade. (Refer to To Attach the Blade Guard under

Blade Guard.)

FIG.11

3. Remove the two screws (FF) holding the guard retainer (GG) using a 5 mm hex wrench (HH), as shown in Figure 11.

4. Add or remove shims (ll) to align the splitter to the blade.

FIG. 12

5. Reassemble, torquing the screws securely in place. Make sure the splitter is aligned properly to the blade. (Refer to To Attach the Blade Guard under Blade Guard.)

Push Stick

i_WARNING: To reduce the risk of serious personal injury, have push stick ready to use before starting cut.

TO ATTACH THE PUSH STICK (FIG. 4) The push stick included with the DW745 mounts to the right of the saw under the blade

wrench storage. To attach the push stick to the saw, align the slots in the handle of the stick with the mounting pins on the saw housing.

Miter Gauge

NOTE: A large auxiliary miter gauge face may be used. TO ATTACH THE MITER GAUGE FIG. 13 The DW745 includes a miter gauge

for crosscutting materials. The miter

gauge can be used by insertion into

one of the two miter gauge slots (JJ)

in the table top (Fig. 13).

NOTE: See crosscutting and bevel crosscutting instructions before per-

forming these operations on the table

saw.

Bench Mounting

NOTE: A portable table saw stand is

designed for use with this saw and is

available at a local DEWALT dealer or service center at extra cost.

TO BENCH MOUNT SAW

i_WARNING: To reduce the risk of serious personal injury, turn unit off and discon-

nect machine from power source before attempting to move it, change accessories

or make any adjustments. An accidental start-up can cause injury.

,&CAUTION: To reduce the risk of personal injury, make sure table saw is firmly mounteQ

before use.

The table saw must be mounted firmly. Four mounting holes (N) are provided in the metal frame for mounting. We strongly recommend that these holes be used to anchor the table saw to your workbench or other rigid, stationary work support.

,&CAUTION: Ensure that the surface is stable enough that large pieces of material will nol

cause it to tip over during use.

1. Center the saw on the desired, stable work surface.

2. Drive four 3-1/2" (88.9 mm) long screws through the holes in the metal frame. Make sure the screws extend through the frame and securely attach to the supporting work

surface.

If marring the supporting work surface is a concern, the DW745 can be mounted to scrap

wood which can then be clamped onto the desired work surface.

1. Cut a piece of 3/4" (19 mm) plywood to fit beneath the footprint of the saw.

2. Screw the saw to the plywood and clamp the overhang of the plywood to the work surface. If the screws protrude through the plywood base, set it on two scrap pieces of

material of equal thickness and attach them to the edges of the plywood to hold the saw

further off of the work surface and prevent the screws from marring the surface.

Connecting Saw to Power Source

_,WARNING: To reduce the risk of injury, before connecting saw to power source, make

sure the switch is in the OFF position.

Be sure your power supply agrees with the nameplate marking. AC Only means that your

saw will operate on alternating 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.

On-Off Switch

i_WARNING: To reduce the risk of injury, be sure switch is in the OFF position before

plugging machine in.

Lift the ON/OFF switch (K) paddle up to turn your saw ON and push it down to turn your saw OFF.

A hole (KK) is provided in the switch for insertion of a FIG. 14 padlock with a removable shank to lock the saw off

(Fig. 14). NOTE: A conventional padlock will not fit.

Rip Fence Operation KK

RAiL LOCK LEVER (FIG. 4) The rail lock lever (W) locks the fence in place pre-

venting movement during cutting. To lock the rail lever, push it down and toward the rear of the saw. To K

unlock, pull it up and toward the front of the saw. 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 15. When not in use, the work support extension retracts, as shown in Figure 16.

NOTE: Retract the work support extension whenever working over the table.

FIG. 15 FIG. 16

FiNE ADJUSTMENT KNOB (FIG. 17) The fine adjustment knob (H) 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 The rip scale pointer will need to be adjusted

for proper performance of the rip fence if the user switches between thick and thin kerf

blades. Refer to Rip Scale Adjustment under Adjustments for alignment instructions.

FIG. 17

Adjustments

,&WARNING: To reduce the risk of injury,

turn unit off and disconnect machine from

power source before installing and removing accessories, before adjusting or changing set-ups or when making repairs. An acciden-

tal start-up can cause injury.

NOTE: Your saw is fully and accurately adjusted at the factory at the time of manufacture. If readjustment due to shipping and handling or any other reason is required, follow the steps

below to adjust your saw. Once made, these adjustments should remain accurate. Take a little time now to follow

these directions carefully to maintain the accuracy of which your saw is capable. RAiL LOCK ADJUSTMENT FIG. 18

(Tightening Fence Clamping System)

1. Lock the rail lock lever (W).

2. On the underside of the saw, loosen the nut (LL) (Fig. 18).

3. Tighten the hex rod (MM) until the spring on the locking system MM is compressed creating the desired tension on the rail lock lever. Retighten the jam nut against the hex rod. LL

4. Flip the saw over and check that the fence does not move when the lock lever is engaged. If the fence is still loose, tighten the spring further.

RIP SCALE ADJUSTMENT

FiG. 19

(Calibrating Rip Scale)

1. Unlock the rail lock lever (W).

2. Set the blade at 0° bevel and move the fence until it is flush with the blade.

3. Lock the rail lock lever.

4. Loosen the screws (NN) in the rip scale pointer with a Phillips screwdriver and

reset the red line to 0° on the scale. See Figure 17.

5. Tighten the screws back into the rail.

NOTE: The rip scale only reads correctly when the fence is mounted on the right side

of the blade. BLADE ALIGNMENT ADJUSTMENT

(Blade Parallel to Miter Slot)

_WAFtNING: Cut Hazard. Check the blade

at 0 ° and 45 ° to make sure blade does not hit the throat plate, causing personal injury.

If the blade appears to be out of alignment

FiG. 20

with the miter slot on the table top, it will require calibration for alignment. To realign the blade and miter slot, use the following procedure:

1. Locate the black Allen Iocator screws (OO) that hold up the trunnion to the

bottom of the table in the rear of the saw.

2. Loosen both screws and align the blade with the miter slot. Be sure to measure

between the miter slot and the back and front of the blade to ensure parallelism.

3. Snugly tighten the screws to secure the trunnion and blade assembly to the table at the parallel position.

FENCE ALIGNMENT ADJUSTMENT (Blade Parallel to Fence) If you experience fence alignment problems and want to correct an out of parallel between

the fence and the blade, be sure to check the alignment of the blade to the miter slot first. After confirming that those elements are aligned, proceed with alignment of the blade to the

fence using the following procedure:

1. Unlock the rail lock lever (W) and locate the two fence Iocator screws (AA) that support the fence on the front and rear rails.

2. Loosen the rear Iocator screw and adjust the position of the fence in the groove on the fence until it sets the fence face parallel to the blade. Make sure you measure from the

fence face to the front and back of the blade to ensure alignment.

3. Tighten the Iocator screw and repeat on the left side of the blade.

4. Check rip scale adjustment.

BEVEL STOP AND POINTER ADJUSTMENT (Calibrating Bevel Scale) Calibrating the bevel system on the saw may require two separate steps, one for the bevel

scale and another for the bevel pointer. The scale should always be checked first followed by adjustments to the red pointer.

FIG.21

BEVEL LOCK ADJUSTMENT (FIG. 21) The bevel lock lever (J) may need adjustment to maintain lock force. To do this, put the lock lever in the locked position. Use a Phillips screwdriver to remove the

screw (PP) holding the lock lever in place (Fig. 21). Remove the lock lever from the locking bolt and place lock lever inthe desired position. Insert the screw (PP) and tighten securely.

FiG. 22 FIG.23

QQ RR

Part A - Adjusting the Bevel Scale System (Fig. 22, 23)

1. Remove the blade guard from the saw and raise the blade all the way up in the table.

2. Unlock the bevel lock lever (J) and loosen the bevel stop screw (QQ).

3. Place a square against the table and blade. NOTE: Be sure to place the square between the teeth on the blade to ensure an

accurate measurement.

4. Adjust the bevel angle until the blade is flat against the square. Lock the bevel lock lever (J).

5. Move the bevel stop cam (RR) until it firmly contacts the trunnion casting. Tighten the bevel stop screw.

6. Repeat procedure at 45 ° using a triangle or speed square.

Part B - Adjusting the Bevel Scale Pointer NOTE: Complete this step only if Part A has been completed.

7. Check the bevel scale angle. If the pointer does not read 0°, loosen the pointer screw (SS) and move it to the 0° mark on the bevel scale. Retighten the pointer screw.

MITER GAUGE ADJUSTMENT FIG.24 (Calibrating Miter Gauge Pointer) Your miter gauge features adjustable stops at

90° and 45 ° left and right. Toadjust the miter gauge, loosen the screw (TT)

and move to desired position. Tighten the screw against the stop plate (Fig. 24).

Saw Blades

NOTE: This saw is intended for the use of saw blades 10" in diameter or smaller. NOTE: This saw is not intended for use with

dado blades and molding cutters. Personal TT injury may occur.

1. The saw blade furnished with your new saw is a 10" (254 mm) combination blade, used for crosscutting (across the grain) and ripping (with the grain) through the material. The center hole to fit on the arbor is 5/8" (16 mm) 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 operating speeds of 5,000 RPM or greater.

4. Saw blades should always be kept sharp. It is recommended that you locate a reputable sharpening service to sharpen your blades when needed.

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 direc- tion. During kickback, the work piece 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-kick- back teeth and guards before resuming work.

_WARNING:

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 splitter minimize

the possibility of kickback. Use extra caution until the work piece 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 work piece must sit flat on

the table without rocking.

3. Do not cut "freehand': 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 non-through cuts).

5. Support large work pieces carefully. Allowing them to sag or droop can cause kick- back.

OPERATION

AWARNING: Before using the saw, verify the following each and every time:

1. ALWAYS wear proper eye, hearing and respiratory equipment.

2. Blade is tight.

3. Bevel angle and height lock knobs are tight.

4. If ripping, ensure fence lock lever is tight and fence is parallel to the blade.

5. If crosscutting, miter gauge knob is tight.

6. The blade guard is properly attached and the anti-kickback teeth are functioning.

7. ALWAYS inspect the guard and spfitter for proper alignment operation and clearance

with saw blade.

Failure to adhere to these common safety rules can greatly increase the likelihood of

injury.

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

AWARNING: Before connecting the table saw to the power source or operating the saw, always inspect the guard and spfitter for proper operation alignment and clearance with

saw blade. Personal injury may result.

,&WARNING: Ripping or crosscutting may cause saw to tip over while operating. Make sure saw is securely mounted to a stable surface.

_&WARNING: Never use the fence and miter gauge together. This may cause a kickback condition and injure the operator.

_&CAUTION: 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.

ACAUTION: The proper throat plate must be in place at aft times to reduce the risk of a

thrown work piece and possible injury,

There are two basic types of cutting with table saws: ripping and crosscutting. Cutting with the grain is ripping and cutting against the grain is crosscutting. With manmade materials, the distinction is made such that ripping is cutting to a different width and cross- cutting describes cutting material across the shorter dimension.

AWARNING: When ripping, always use the fence to provide a guide for the material and

guard against a kickback situation.

ACAUTION: When crosscutting, always use the miter gauge.

Ripping

,&WARNING: Never touch the "free end" of the work piece or a "free piece" that is cut off,

while the power is ON and/or the saw blade is rotating. Piece may contact the blade result- ing in a thrown work piece of possible injury.

_,WARNING: A rip fence should ALWAYS be used for ripping operations to prevent loss of control and personal injury, NEVER perform a ripping operation freehand. ALWAYS lock

the fence to the rail.

,&WARNING: When bevel ripping and whenever possible, place the fence on the side of

the blade so that the blade is tilted away from the fence and hands. Keep hands clear of

thebladeanduseapushsticktofeedtheworkpieceffthereis less than 6" (152 mm)

between the fence and the blade.

1. Lock the rip fence by pressing the FIG.25 rail lock lever down. Remove the

miter gauge.

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

work piece.

3. Hold the work piece flat on the table and against the fence. Keep the work piece about 1" (25.4 ram) away from the blade.

_,CAUTION: The work piece 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. See proper hand position in Figure 25.

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 12" (305 mm) left to be ripped, use only one hand, with your thumb pushing the material, your index and second finger hold- ing 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 work piece against the table and fence, slowly feed the work piece rearward all the way through the saw blade. Continue pushing the work piece 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 work piece back with the blade turning. Turn the switch off, allow the blade to stop, raise the anti-kickback teeth on each side of the splitter if necessary and slide the work piece out.

7. When sawing a long piece of material or a panel, always use a work support. A saw- horse, rollers, or out feed assembly provides adequate support for this purpose. The work support must be at the same height as the saw table.

ACAUTION: Never push or hold onto the "free" or "cut off" side of the work piece.

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 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.

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 at the end of this manual to make push sticks. A push stick (U) is included with this saw, located on

the right-side panel. Use the push stick(s) to

hold the work piece against the table and fence, and push the work piece fully past the blade. See Figure 26.

FIG. 26

Crosscutting

_WARNING: NEVER touch the "free end" of the work piece or a "free piece" that is cut off, while the power is ON and/or the saw blade is rotating. Piece may contact the blade resulting in a thrown work piece and possible injury.

,_,WARNING: To reduce the risk of injury, NEVER use the fence as a guide or length stop

when crosscutting. ZCWARN/NG: NEVER use a length stop on the free end of the work piece when crosscut-

ting. In short, the cut-off piece in any through-sawing (cutting completely through the work piece) operation must never be confined -- it must be allowed to move away from saw blade

to prevent contact with blade resulting in a thrown work piece and possibly injury.

i_WARNING: Use caution when starting the cut to prevent binding of the guard against the

work piece resulting in damage to saw and possible injury,

_I,CAUTION: When using a block as a cut-off gauge, the block must be at least 3/4"

(19 mm) thick and is very important that the rear end of the block be positioned so the work piece is clear of the block before it enters the blade to prevent contact with blade resulting in a thrown work piece and possibly injury,

1. Remove the rip fence and place the FIG.27 miter gauge in the desired slot.

2. Adjust the blade height so that the blade is about 1/8" (3.2 mm) higher

than the top of the work piece.

3. Hold the work piece firmly against the miter gauge with the path of the

blade in line with the desired cut loca- tion. Keep the work piece an inch or

so in front of the blade. KEEP BOTH HANDS AWAY FROM THE BLADE AND THE PATH OF THE BLADE

(Fig. 27).

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

5. While using both hands to keep the work piece against the face of the miter gauge, and holding the work piece flat against the table, slowly push the work piece through the blade. See Figure 27.

6. Never try to pull the work piece with the blade turning. Turn the switch off, allow the blade to stop, and carefully slide the work piece out.

ACAUTION: Never touch or hold onto the "free" or "cut off" end of the work piece.

Bevel Crosscutting FIG.28

This operation is the same as crosscut- ting except that the bevel angle is set to an angle other than 0°. For proper hand position, refer to Figure 28.

_iWARNING: 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

_WARN/NG: Miter angles greater than 45 ° may force the guard into the saw blade causing damage to

the guard and personal injury. Before starting the motor, test the operation by feeding the work piece into the guard, ff the guard contacts the blade, place the work piece under the guard, not touching the blade, before starting

the motor.

_CAUTION: Certain work piece shapes, such as molding may not rift

the guard properly. Feed the work piece slowly to start the cut. If the guard contacts the blade, place the work piece under the guard, not touching the blade, before starting the

motor.

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 work piece from moving). See Figure 29.

FIG. 29

Miter Gauge Operatien

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

Compound Mitering FIG.30

This is a combination of bevel crosscutting

and mitering. Follow the instructions for both bevel crosscutting and mitering.

Dust Collection

Your table saw is equipped with a dust shroud and dust collection port. For best results, connect a vacuum to the port at the rear of

the saw.

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

dust collection system:

1. Unplug the saw.

2. Turn the saw on its side, so the bottom, open part of the unit is accessible.

3. Open the dust access door (UU) shown in Figure 30 by removing the wing screws (VV). Clean out the excess dust, and re-secure the access door with the wing screws.

Lubrication FIG.31

1. All motor bearings are permanently lubricated at the factory and no additional lubrication is

needed.

2. The height adjustment gear may require periodic cleaning and lubrication (Fig. 31). If you have difficulty raising or lowering

the blade, contact a DEWALT authorized service center.

Accessories

iCWARNING: Since accessories, other than those offered by DEWALT, have not been tested with this product, use of such accessories with this tool could be hazardous. To

reduce the risk of injury, only DEWALT recommended accessories should be used with

this product.

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.

MAINTENANCE

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

Cleaning

,_WARNING: When cleaning, use only mild soap and a damp cloth on plastic parts. Many

household cleaners contain chemicals which could seriously damage plastic. Also, do not

use gasoline, turpentine, lacquer or paint thinner, dry cleaning fluids or similar products which may seriously damage plastic parts. Never let any liquid get inside the tool; never

immerse any part of the tool into a liquid.

Repairs

To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including brush inspection and replacement) 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 £irnited 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 nor- mal wear or tool abuse. For further detail of warranty coverage and warranty repair informa- tion, visit www.dewalt.com or call 1-800-4-DEWALT (1-800-433-9258). This warranty does not apply to accessories or damage caused where repairs have been made or attempted by others. This warranty gives you specific legal rights and you may have other rights which vary in certain states or provinces.

In addition to the warranty, DEWALT tools are covered by our:

1YEAR 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.

LATIN AMERICA: This warranty does not apply to products sold in Latin America. For prod- ucts sold in Latin America, see country specific warranty information contained either in the packaging, call the local company or see website for warranty information.

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

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