DeWalt DW745-XE Instruction Manual

DW745-XE

HEAVY-DUTY 250 mm (10") COMPACT JOB SITE TABLE SAW

INSTRUCTION MANUAL

2

TABLE OF CONTENTS

General Safety Rules .................................................................................................... 1

Double Insulation................................................................................................. 1

Electrical Safety ................................................................................................... 1

Important Safety Instructions ........................................................................................ 1

Additional Safety Rules for Table Saws......................................................................... 3

Specifications .......................................................................................................... 6

Unpacking ................................................................................................................ 6

Features ................................................................................................................... 6

Assembly ................................................................................................................. 7

Rip Fence .......................................................................................................8

Anti-Kickback Assembly .................................................................................. 9

Blade Guard Assembly .................................................................................... 9

Miter Gauge .................................................................................................. 10

Bench Mounting ............................................................................................ 10

Connecting to Power Source ......................................................................... 11

On/Off Switch ............................................................................................... 11

Rip Fence Operation ......................................................................................11

Adjustments ........................................................................................................... 12

Rail Lock Adjustment .................................................................................... 12

Rip Scale Adjustment ....................................................................................12

Blade Alignment Adjustment ..........................................................................13

Fence Alignment Adjustment ......................................................................... 13

Bevel Stop and Pointer Adjustment ................................................................13

Bevel Lock Adjustment ..................................................................................13

Miter Gauge Adjustment ................................................................................14

Aligning Riving Knife to Blade ........................................................................14

Saw Blades ................................................................................................... 15

Riving Knife Selection ...................................................................................16

Kickback ....................................................................................................... 17

Operation ............................................................................................................... 17

Guard Operating Feature ................................................................................17

Ripping .........................................................................................................18

Narrow Rip Auxiliary Fence ...........................................................................19

Push Block ................................................................................................... 19

Bevel Ripping ................................................................................................ 20

Crosscutting ................................................................................................. 20

Bevel Crosscutting ........................................................................................ 21

Mitering ........................................................................................................ 21

Miter Gauge Operation ..................................................................................22

Compound Mitering....................................................................................... 22

Featherboard Construction ............................................................................ 22

Dust Collection.............................................................................................. 23

Lubrication .................................................................................................... 23

Storage ......................................................................................................... 23

Maintenance .......................................................................................................... 24

Cleaning........................................................................................................24

Repairs .........................................................................................................24

Accessories .................................................................................................. 24

Push Stick Pattern ..................................................................................................25

1

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.

DANGER: Indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury.

WARNING: Indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.

CAUTION: Indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate injury.
NOTICE: indicates a practice not related to personal injury which, if

not avoided, may result in property damage.

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL,
CALL US AT: 1800 444 224 (Aust) or 0800 339 258 (NZ).

General Safety Rules

WARNING: Read all instructions before operating product. Failure to follow all
instructions listed below may result in electric shock, fire and/or serious injury.

SAVE ALL WARNINGS AND INSTRUCTIONS FOR

FUTURE REFERENCE

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.

NOTE: Double insulation does not take the place of normal safety precautions when
operating this tool. The insulation system is for added protection against injury
resulting from a possible electrical insulation failure within the tool.

CAUTION: WHEN SERVICING USE ONLY IDENTICAL REPLACEMENT PARTS. Repair

or replace damaged cords.

Electrical Safety

The electric motor has been designed for one voltage only. Always check that the
power supply corresponds to the voltage on the rating plate. 230 V AC means your
tool will operate on alternating current. As little as 10% lower voltage can cause loss
of power and can result in overheating. All DEWALT tools are factory tested; if this
tool does not operate, check the power supply. Your DEWALT tool is double insulated,
therefore no earth wire is required.

• Young children and the infirm. This appliance is not intended for use by
young children or infirm persons without supervision. Young children should be
supervised to ensure that they do not play with this appliance.

– This appliance is not intended for use by persons (including children) with

reduced physical, sensory or mental capabilities, or lack of experience and
knowledge, unless they have been given supervision or instruction concerning
use of the appliance by a person responsible for their safety.

– Children should be supervised to ensure that they do not play with the appliance.

• Replacement of the supply cord. If the supply cord is damaged, it must be
replaced by the manufacturer or an authorised D

EWALT Service Centre in order

to avoid a hazard.

Important Safety Instructions

• TO REDUCE THE RISK OF KICKBACK AND OTHER INJURIES, use all
components of the guarding system (blade guard assembly, riving knife and anti­kickback) for every operation for which they can be used including all through
cutting.

• REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see
that keys and adjusting wrenches are removed from spindle before turning tool
on. Tools, scrap pieces, and other debris can be thrown at high speed, causing
injury.

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

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

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

• KEEP CHILDREN AWAY. All visitors should be kept at a safe distance from work
area. Your shop is a potentially dangerous environment.

2

• MAKE WORKSHOP CHILDPROOF with padlocks, master switches, or by
removing starter keys. The unauthorized star t-up of a machine by a child or
visitor may result in 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 force tool or attachment to do a job for which it was not
designed. Using the incorrect tool or attachment may result in personal injury.

• USE PROPER EXTENSION CORD. Make sure your extension cord is in good
condition. If your product is equipped with a cordset, use only 3-wire extension
cords that have 3-prong grounding-type plugs and 3-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

For Cable length (m): 7.5 15 25 30 45 60
Use Cable with minimum rating (Amperes)
Tool Amperes

0 - 3.4 7.5 7.5 7.5 7.5 7.5 7.5

3.5 - 5.0 7.5 7.5 7.5 7.5 10 15

5.1 - 7.0 10 10 10 10 15 15

7.1 - 12.0 15 15 15 15 20 20

12.1 - 20.0 20 20 20 20 25 –

• WEAR PROPER APPAREL. No loose clothing, gloves, neckties, rings,
bracelets, or other jewelry to get caught in moving parts. Non-slip footwear is
recommended. Wear protective hair covering to contain long hair. Air vents may
cover moving parts and should also be avoided.

• ALWAYS wear approved protective safety equipment complying with the following
standards:

• Eye protection: AS/NZS1337 Eye Protectors for Industrial Applications;

• Hearing protection: AS/NZS1270 Acoustics – Hearing Protection;

• Respiratory protection: AS/NZS1716 Respiratory Protective Devices.

• DO NOT OVERREACH. Keep proper footing and balance at all times. Loss of
balance may cause personal injury.

• MAINTAIN TOOLS WITH CARE. Keep blades sharp and clean for best and safest
performance. Follow 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 recommended accessories. The use of improper
accessories may cause risk of injury to persons.

• NEVER STAND ON TOOL. Serious injury could occur if the tool is tipped or if the
cutting tool is unintentionally contacted.

• 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 par ts,
binding of moving parts, breakage of par ts, mounting and any other conditions
that may affect its operation. A guard or other part that is damaged should be
properly repaired or replaced. Do not use tool if switch does not turn it on and
off. 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.

3

• 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 Rules for Table Saws

WARNING: ALWAYS USE SAFETY GLASSES. Everyday eyeglasses are NOT
safety glasses. Also use face or dust mask if cutting operation is dusty. All users and
bystanders MUST ALWAYS wear certified safety equipment:

• Eye protection: AS/NZS1337 Eye Protectors for Industrial Applications;

• Hearing protection: AS/NZS1270 Acoustics – Hearing Protection;

• Respiratory protection: AS/NZS1716 Respiratory Protective Devices.

WARNING: Do not expose to rain or use in damp locations.

• 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 workpiece.

• KEEP ARMS, HANDS AND FINGERS AWAY from the blade to prevent serious

injury.

• USE A PUSH STICK THAT IS APPROPRIATE TO THE APPLICATION TO PUSH

WORKPIECES THROUGH THE SAW. A push stick is a wooden or plastic stick,
usually homemade, that should be used whenever the size or shape of the
workpiece would cause you to place your hands within 152 mm (6") of the
blade.

• USE HOLD-DOWNS, JIGS, FIXTURES OR FEATHER BOARDS TO HELP

GUIDE AND CONTROL THE WORKPIECE. Accessories for use with your tool
are available at extra cost from your local dealer or authorized service center.

Instructions for making a push stick, a narrow rip auxiliary fence, a push block
and feather boards are included in this manual.

• 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.

• NEVER CUT METALS, CEMENT BOARD OR MASONRY. Cer tain man-made
materials have special instructions for cutting on table saws. Follow the
manufacturer’s recommendations at all times. Damage to the saw and personal
injury may result.

• THE PROPER THROAT PLATE MUST BE LOCKED IN PLACE AT ALL TIMES to
reduce the risk of a thrown workpiece and possible injury.

• USE THE CORRECT SAW BLADE FOR THE INTENDED OPERATION. The blade
must rotate toward the front of the saw. Always tighten the blade arbor nut
securely. Before use, inspect the blade for cracks or missing teeth. Do not use a
damaged or dull blade.

• NEVER ATTEMPT TO FREE A STALLED SAW BLADE WITHOUT FIRST TURNING

THE MACHINE OFF AND DISCONNECTING THE SAW FROM THE POWER
SOURCE. If a workpiece or cut-off piece becomes trapped inside the blade guard

assembly, turn saw off and wait for blade to stop before lifting the blade guard
assembly and removing the piece.

• NEVER START THE MACHINE with the workpiece against the blade to reduce the
risk of a thrown workpiece and personal injury.

• NEVER have any part of your body in line with the path of the saw blade.
Personal injury may 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 workpiece) unsupported so the spring

of the board causes it to shift on the table resulting in loss of control and

4

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

WARNING: Never perform freehand cutting with this saw.

• Plunge cutting refers to blind cuts in the workpiece made by either raising the
blade through the workpiece or lowering the workpiece down to the blade.

WARNING: Never perform plunge cutting with this saw.

• Resawing – Flipping material to make a cut the saw is not capable of making in
one pass.

WARNING: Resawing IS NOT recommended.

SAW BLADE GUARD ASSEMBLY, ANTI-KICKBACK ASSEMBLY AND RIVING KNIFE

Your table saw is equipped with a blade guard assembly, anti-kickback assembly
and riving knife that covers the blade and reduces the possibility of accidental blade
contact. The riving knife 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 blade guard assembly and anti-kickback assembly can only be used when
making through cuts that sever the wood. When making rabbets and other cuts
that make non through cuts, the blade guard assembly and anti-kickback assembly
must be removed and riving knife lowered to the non through cut position marked
on the riving knife. Two anti-kickback pawls are located on the sides of the riving

knife that allow the wood to pass through the blade in the cutting direction but reduce
the possibility of the material being thrown backwards toward the operator.

Use all components of the guarding system (blade guard assembly, riving knife and anti­kickback assembly) for every operation for which they can be used including all through
cutting. If you elect not to use any of these components for a particular application
exercise additional caution regarding control of the workpiece, the use of push sticks,
the position of your hands relative to the blade, the use of safety glasses, the means to
avoid kickback and all other warnings contained in this manual and on the saw itself.
Replace the guarding systems as soon as you return to thru-cutting operations.
Keep the guard assembly in working order.

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 workpiece would cause your hands to be within 152 mm
(6") 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 400 mm (15.7") is recommended with a notch

possible injury. 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.

• IF YOUR SAW makes an unfamiliar noise or if it vibrates excessively, cease
operating immediately, turn unit off and disconnect from power source until the
problem has been located and corrected. Contact a D

EWALT factory ser vice

center, a DEWALT authorized service center or other qualified service personnel if
the problem can not be found.

• KEEP OUT of the line of saw blade. Stand to the side whenever possible.

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

• DO NOT OPERATE THIS MACHINE until it is completely assembled and installed
according to the instructions. A machine incorrectly assembled can cause
serious injury.

• OBTAIN ADVICE from your supervisor, instructor, or another qualified person if
you are not thoroughly familiar with the operation of this machine. Knowledge is
safety.

• 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
AND YOU SHOULD BECOME FAMILIAR WITH THEM.

• Thru sawing refers to any cut that completely cuts through the workpiece.

• Non-thru sawing refers to any cut that does not completely cut through the
workpiece.

• Push Stick refers to a wooden or plastic stick, usually homemade, that is used to
push small workpiece 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
workpiece back toward the operator.

5

that fits against the edge of the workpiece to prevent slipping. It’s a good idea to
have several push sticks of the same length [400 mm (15.7")] with different size
notches for different workpiece 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

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.

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 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 a push stick for narrow work,
152 mm (6") wide or less.

c. Keep saw blade guard assembly, riving knife and anti-kickback assembly in place

and operating properly. If anti-kickback assembly is not operational, return your
unit to the nearest authorized DEWALT service center for repair. The riving knife
must be in alignment with the saw blade and the anti-kickback assembly must
stop a kickback once it has started. Check their action before ripping by pushing
the wood under the anti-kickback assembly. The teeth must prevent the wood
from being pulled toward the front of the saw.

d. Plastic and composite (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 assembly, anti-kickback assembly and riving knife for every

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

f. Push the workpiece past the saw blade prior to release.

g. NEVER rip a workpiece that is twisted or warped, or does not have a straight

edge to guide along the fence.
h. NEVER saw a large workpiece that cannot be controlled.
i. NEVER use the fence as a guide or length stop when crosscutting.
j. NEVER saw a workpiece with loose knots, flaws, nails or other foreign objects.
k. NEVER rip a workpiece shor ter than 250 mm (10").
l. NEVER use a dull blade – replace or have resharpened.

WARNING: Some dust created by power sanding, sawing, grinding, drilling, and
other construction activities contains chemicals known to cause cancer, birth defects
or other reproductive harm. Some examples of these chemicals are:

• lead from lead-based paints,

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

• arsenic and chromium from chemically-treated lumber.

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.

• 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 AS/NZS standard
approved respiratory protection appropriate for the dust exposure. Direct particles
away from face and body.

WARNING: We recommend the use of a residual current device with a residual
current rating of 30mA or less.

WARNING: Always wear proper personal hearing protection that conforms to
AS/NZS1270 during use. Under some conditions and duration of use, noise from this

product may contribute to hearing loss.

6

SAVE ALL WARNINGS AND INSTRUCTIONS FOR

FUTURE REFERENCE

Specifications

Amperes 7.9 A
Miter Angle 60° L and R
Bevel Angle 0° to 45° L
Blade Size 250 mm (10")
Max. Cut Depth 0° Bevel 77 mm (3-1/8")
Max. Cut Depth 45° Bevel 57 mm (2-1/4")
RPM, no load 3800

Unpacking

WARNING: To reduce the risk of injury, DO NOT connect the machine to the power
source until the table saw is completely assembled and you read the entire instruction
manual.
Open the box and slide the saw out, as

FIG. 1

shown in Figure 1. Carefully unpack the
table saw and all loose items from the
carton. Examine all par ts 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.

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 assembly

4. Miter gauge

5. Push stick (attached to rip fence)
WARNING: To reduce the risk of serious personal injury, have push stick ready

to use before starting cut.

FIG. 2

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.

7

FIG. 3

A

B

D

E

F

G

H

I

N

J

K

M

L

N

O

P

C

Q

FIGURE 3

A. Table J. Bevel lock lever
B. Miter gauge K. On/off switch
C. Blade L. Rip fence indicator
D. Blade guard assembly M. Adjustable feet
E. Fence N. Mounting holes
F. Fence rails O. Cord wrap
G. Rip fence front latch P. Handle
H. Fine adjustment knob Q. Anti-kickback assembly
I. Blade height adjustment wheel

FIG. 4

W

S

R

D

T

V

U

FIGURE 4

R. Rip fence rear latch V. Arbor wrench, spindle wrench
S. Dust collection port W. Rail lock lever
T. Dust shroud U. Push stick

ASSEMBLY

WARNING: 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.