DeWalt DW777-XE Instruction Manual

DW777-XE

216 mm (8.5") CROSS-CUT MITRE SAW

INSTRUCTION MANUAL

TABLE OF CONTENTS

DOUBLE INSULATION ...............................................................................................................................................1

SAFETY INSTRUCTIONS FOR ALL TOOLS .................................................................................................................1

ADDITIONAL SAFETY RULES FOR MITRE SAWS ....................................................................................................... 2

ELECTRICAL CONNECTION .......................................................................................................................................3

ACCESSORIES .......................................................................................................................................................... 3

OPTIONAL ACCESSORIES ....................................................................................................................................3

SAW BLADES ....................................................................................................................................................... 3

PACKAGE CONTENTS ...............................................................................................................................................3

SPECIFICATIONS .......................................................................................................................................................3

DESCRIPTION ........................................................................................................................................................... 3

ASSEMBLY ...............................................................................................................................................................5

UNPACKING ......................................................................................................................................................... 5

CABLE CLAMP ..................................................................................................................................................... 5

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

MOUNTING THE SAW BLADE ............................................................................................................................... 5

ADJUSTMENTS ......................................................................................................................................................... 5

ADJUSTING THE TRAVERSE BARS FOR CONSTANT CUTTING DEPTH ..................................................................5

ADJUSTING THE FENCE .......................................................................................................................................6

CHECKING AND ADJUSTING THE BLADE TO THE FENCE .....................................................................................6

CHECKING AND ADJUSTING THE BLADE TO THE TABLE .....................................................................................6

CHECKING AND ADJUSTING THE BEVEL ANGLE ..................................................................................................7

BRUSHES ................................................................................................................................................................. 7

OPERATION ..............................................................................................................................................................7

INSTRUCTIONS FOR USE .....................................................................................................................................7

SWITCHING ON AND OFF ..................................................................................................................................... 7

BODY AND HAND POSITION .................................................................................................................................7

BASIC SAW CUTS ................................................................................................................................................ 7

VERTICAL STRAIGHT CROSS CUT ...................................................................................................................7

VERTICAL MITRE CROSS-CUT ........................................................................................................................ 8

BEVEL CROSS-CUTS ........................................................................................................................................ 8

QUALITY OF CUT ..................................................................................................................................................8

CLAMPING THE WORKPIECE ...............................................................................................................................8

COMPOUND MITRE .............................................................................................................................................8

SUPPORT FOR SHORT AND LONG PIECES ..........................................................................................................8

CUTTING SHORT MATERIAL ............................................................................................................................. 8

CUTTING LARGE MATERIAL ............................................................................................................................. 8

DUST EXTRACTION ................................................................................................................................................... 8

TRANSPORTING........................................................................................................................................................8

MAINTENANCE ......................................................................................................................................................... 8

USING THE ROLLER TABLE .................................................................................................................................. 9

SERVICE INFORMATION ............................................................................................................................................ 9

REPAIRS ...................................................................................................................................................................9

TROUBLESHOOTING GUIDE ......................................................................................................................................9

TABLE 1: COMPOUND MITRE CUT .......................................................................................................................... 10

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 338 002 (Aust) or 0800 339 258 (NZ).

Technical Data

DW777

Voltage V 230
Power input W 1800
Blade diameter mm 216
Blade bore mm 30
Max. blade speed min-1 6300
Mitre (max. positions) left and right 50°
Bevel (max. positions) left 48°
Compound mitre bevel 45°
mitre 45°
Capacities
cross-cut 90° mm 60 x 270
mitre 45° mm 60 x 190
mitre 48° mm 60 x 180
bevel 45° mm 48 x 270
bevel 48° mm 45 x 270
Overall dimensions mm 460 x 560 x 430
Weight kg 15.0

L

PA

(sound pressure) dB(A) 93

K

PA

(sound pressure

uncertainty) dB(A) 3

L

WA

(acoustic power) dB(A) 104

K

WA

(acoustic power
uncertainty) dB(A) 3.9

Vibration total values (triax vector sum) determined according to EN 61029:
Vibration emission value a

h

ah

= m/s² 2.1

Uncertainty K = m/s² 1.5

The vibration emission level given in this information sheet has been measured
in accordance with a standardised test given in EN 60745 and may be used to
compare one tool with another. It may be used for a preliminary assessment
of exposure.

WARNING: The declared vibration emission level represents the
main applications of the tool. However if the tool is used for different
applications, with different accessories or poorly maintained, the vibration
emission may differ. This may significantly increase the exposure level over
the total working period.

An estimation of the level of exposure to vibration should also take into

account the times when the tool is switched off or when it is running but
not actually doing the job. This may significantly reduce the exposure level
over the total working period.

Identify additional safety measures to protect the operator from the effects

of vibration such as: maintain the tool and the accessories, keep the hands
warm, organisation of work patterns.

Important Safety Instructions

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

READ ALL INSTRUCTIONS

Double Insulation

Double insulated tools are constructed throughout with two separate layers of
electrical insulation or one double thickness of insulation between you and the
tool’s electrical 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.

Safety Instructions For All Tools

This mitre saw accepts the DEWALT worklight and laser attachments.

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

when operating the mitre saw.

• KEEP GUARD IN PLACE and in working order.

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

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

• DO NOT USE THE MACHINE IN A DANGEROUS ENVIRONMENT. The
use of power tools in damp or wet locations or in rain can cause shock
or electrocution. Keep your work area well-lit to avoid tripping or placing
arms, hands, and fingers in danger.

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

• MAKE WORKSHOP CHILDPROOF with padlocks, master switches, or by
removing starter keys. The unauthorised star t-up of a machine by a child
or visitor may result in injury.

• DON’T FORCE TOOL. It will do the job better and be safer at the rate for
which it was designed.

• USE RIGHT TOOL. Don’t force tool or attachment to do a job for which
it was not designed. Using the incorrect tool or attachment may result in
personal injury.

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

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

WEAR CERTIFIED SAFETY EQUIPMENT:

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

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

• NIOSH/OSHA/MSHA respiratory protection

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

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

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

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

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

• USE PROPER EXTENSION CORD. Make sure your extension cord is
in good condition. 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 gage. The smaller the gage 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 –

• CHECK for DAMAGED PARTS. Before further use of the tool, a guard
or other part that is damaged should be carefully checked to determine

2

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

• USE RECOMMENDED ACCESSORIES. Use only accessories that are
recommended by the manufacturer for your model. Accessories that may
be suitable for one tool may be hazardous when used on another tool.
Consult the instruction manual for recommended accessories. The use of
improper accessories may cause risk of injury to persons.

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

• NEVER LEAVE TOOL RUNNING UNATTENDED. TURN POWER OFF. Don’t
leave tool until it comes to a complete stop. Serious injury can result.

• DO NOT OPERATE ELECTRIC TOOLS NEAR FLAMMABLE LIQUIDS OR
IN GASEOUS OR EXPLOSIVE ATMOSPHERES. Motors 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 or ALCOHOL. A moment of inattention while

operating power tools may result in injury.

Additional Safety Rules For Mitre Saws

WARNING: Do not allow familiarity (gained from frequent use of your saw)
to replace safety rules. Always remember that a careless fraction of a second
is sufficient to inflict severe injury.

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

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

• OBTAIN ADVICE from your supervisor, instructor, or another qualified

person if you are not thoroughly familiar with the operation of this
machine. Knowledge is safety.

• STABILITY. Make sure the mitre saw is placed on a secure supporting

surface and does not slip or move during use. If the mobility kit is
installed, raise the moveable caster(s) so saw is in its stationary position.

• FOLLOW ALL WIRING CODES and recommended electrical connections

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

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

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

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

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

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

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

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

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

• DO NOT OPERATE ON ANYTHING OTHER THAN THE DESIGNATED

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

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

Damage to tool and possible personal injury may occur.

• DO NOT force cutting action. Stalling or partial stalling of motor can cause
damage. To the machine or blade and/or serious injury.

• ALLOW THE MOTOR TO COME TO FULL SPEED prior to starting cut.
Starting the cut too soon may cause damage to the machine or blade and/
or serious injury.

• NEVER CUT FERROUS METALS (Those with any iron or steel content) or
masonry. Either of these can cause the carbide tips to fly off the blade at
high speeds causing serious injury.

• DO NOT USE ABRASIVE WHEELS. The excessive heat and abrasive
particles generated by them may damage the saw and cause personal
injury.

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

• NEVER apply blade lubricant to a running blade. Applying lubricant could
cause your hand to move into the blade resulting in serious injury.

• DO NOT place either hand in the blade area when the saw is connected to
the power source. Inadvertent blade activation may result in serious injury.

• DO NOT PERFORM FREE-HAND OPERATIONS (workpiece not supported
by table and fence). Hold the work firmly against the fence and table.
Free-hand operations on a mitre saw could cause the workpiece to be
thrown at high speeds, causing serious injury.

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

• DO NOT reach underneath the saw unless it is unplugged and turned off.
Contact with saw blade may cause personal injury.

• SECURE THE MACHINE TO A STABLE SUPPORTING SURFACE. Vibration
can possibly cause the machine to slide, walk, or tip over, causing serious
injury.

• USE ONLY CROSSCUT SAW BLADES recommended for mitre saws. For
best results, use only zero-degree or negative hook angles when using
carbide-tipped blades. Do not use blades with deep gullets. These can
deflect and contact the guard, and can cause damage to the machine and/
or serious injury.

• USE ONLY BLADES OF THE CORRECT SIZE AND TYPE specified for this
tool to prevent damage to the machine and/or serious injury.

• INSPECT BLADE FOR CRACKS or other damage prior to operation. A
cracked or damaged blade can come apart and pieces can be thrown at
high speeds, causing serious injury. Replace cracked or damaged blades
immediately.

• CLEAN THE BLADE AND BLADE CLAMPS prior to operation. Cleaning the
blade and blade clamps allows you to check for any damage to the blade
or blade clamps. A cracked or damaged blade or blade clamp can come
apart and pieces can be thrown at high speeds, causing serious injury.

• DO NOT use lubricants or cleaners (particularly spray or aerosol) in the
vicinity of the plastic guard. The polycarbonate material used in the guard
is subject to attack by certain chemicals.

• ALWAYS USE THE KERF PLATE AND REPLACE THIS PLATE WHEN
DAMAGED. Small chip accumulation under the saw may interfere with the
saw blade or may cause instability of workpiece when cutting.

• USE ONLY BLADE CLAMPS specified for this tool to prevent damage to
the machine and/or serious injury.

• CLEAN THE MOTOR AIR SLOTS of chips and sawdust. Clogged motor
air slots can cause the machine to overheat, damaging the machine and
possibly causing a short which could cause serious injury.

• KEEP ARMS, HANDS, AND FINGERS away from the blade to prevent
severe cuts. Clamp all workpieces that would cause your hand to be within
6" of the saw blade.

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

• TURN OFF THE MACHINE and allow the blade to come to a complete stop
before raising the arm and prior to cleaning the blade area, removing debris
in the path of the blade, before servicing or adjusting tool. A moving blade
can cause serious injury.

• PROPERLY SUPPORT LONG OR WIDE WORKPIECES. Loss of control of
the workpiece can cause injury.

• NEVER cross arms in front of blade while using tool. Always make a dry
run (unpowered) before making a finish cut so that you can check the path
of the blade or severe personal injury may result.

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

CAUTION: Do not connect unit to electrical power source until complete

instructions are read and understood.

WARNING: NEVER MAKE ANY CUT UNLESS THE MATERIAL IS SECURED

ON THE TABLE AND AGAINST THE FENCE.

WARNING: Use of this tool can generate and/or disburse dust, which may
cause serious and permanent respiratory or other injury. Always use AS/
NZS1716 approved respiratory protection appropriate for the dust exposure.
Direct particles away from face and body.

WARNING: 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.

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.

3

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

ON MOTOR HOUSING:

WARNING: FOR YOUR OWN SAFETY, READ

INSTRUCTION
MANUAL BEFORE OPERATING SAW.
WHEN SERVICING, USE ONLY IDENTICAL REPLACEMENT

PARTS.
DO NOT EXPOSE TO RAIN OR USE IN DAMP LOCATIONS.
ALWAYS WEAR EYE PROTECTION.
ON MOVING FENCES:
ALWAYS ADJUST FENCE PROPERLY BEFORE USE. Clamp small pieces before cutting. See manual.
ON GUARD: DANGER – KEEP AWAY FROM BLADE.
ON UPPER GUARD: PROPERLY SECURE BRACKET WITH BOTH SCREWS BEFORE USE.
ON TABLE: (2 PLACES)
ALWAYS TIGHTEN ADJUSTMENT KNOBS BEFORE USE.
KEEP HANDS 6" FROM PATH OF SAW BLADE.
NEVER PERFORM ANY OPERATION FREEHAND.
NEVER CROSS ARMS IN FRONT OF BLADE.
THINK! YOU CAN PREVENT ACCIDENTS.
DO NOT OPERATE SAW WITHOUT GUARDS IN PLACE.
TURN OFF TOOL, KEEP SAW HEAD DOWN AND WAIT FOR SAW TO STOP BEFORE MOVING HANDS,

WORKPIECE OR CHANGING SETTINGS.
UNPLUG TOOL BEFORE CHANGING BLADE, MOVING OR SERVICING UNIT.

Electrical Connection

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.

• Replacement of the supply cord. If the supply cord is damaged, it must be replaced by the manufacturer or an
authorised DEWALT Service Centre in order to avoid a hazard.

Accessories

WARNING: Since accessories, other than those offered by DEWALT, have not been tested with this product, use of
such accessories with this tool could be hazardous. To reduce the risk of injury, only DEWALT recommended accessories
should be used with this product.

Recommended accessories for use with your tool are available at extra cost from your local service center. If you need
any assistance in locating any accessory, please contact Stanley Black & Decker, 82 Taryn Drive, Epping, VIC 3076
Australia or call 1800 338 002 or (NZ) 0800 339 258.

Optional Accessories

SAW BLADES: ALWAYS USE 216 mm (8.5") SAW BLADES WITH 30 mm (5/8") ARBOR HOLES. SPEED RATING MUST
BE AT LEAST 6500 RPM. Never use a smaller diameter blade. It will not be guarded properly. Use crosscut blades only!
Do not use blades designed for ripping, combination blades or blades with hook angles in excess of 5˚.

Type of blade Blade dimensions (diameter x bore x no. of teeth) Usage

DT4222 series 40 216 x 30 x 24 For general purpose, ripping and

cross-cutting of wood and plastics

DT4320 series 60 216 x 30 x 48 ATB for fine cutting of

manmade and natural wood

DT4350 series 60 216 x 30 x 60 TCG for extra fine cutting of

manmade and natural wood

Package Contents

Check the contents of your mitre saw carton to make sure that you have received all par ts. In addition to this instruction
manual, the carton should contain:

1 Partly assembled machine
2 Hex key 4/6 mm
1 216 mm (8.5") TCT saw blade
1 Instruction manual
1 Exploded drawing

Specifications

CAPACITY OF CUT

50º mitre right and left
48º bevel left
Compound mitre 45º bevel

0º mitre Max. Height 60 mm (2.36") Result Width 270 mm (10.6")
45º mitre Max. Height 60 mm (2.36") Result Width 190 mm (7.5")
45º bevel - Left Max. Height 4 8 mm (1.9") Result Width 270 mm (10.6")

DRIVE

230 Volt Motor Automatic Electric Brake
1800 Watts In Cut Helical Gears
6000 RPM Roller Bearings
Multi-V Belt Carbide Blade

Description (Fig. 1-6, 9)

WARNING: Never modify the power tool or any part of it. Damage or personal injury could result.

INTENDED USE

Your cross-cut mitre saw has been designed for professional cutting of wood, wood products and plastics. It will perform
the sawing operations of cross-cutting, bevelling and mitring easily, accurately and safely.

DO NOT use under wet conditions or in presence of flammable liquids or gases.
This cross-cut mitre saw is a professional power tool. DO NOT let children come into contact with the tool. Supervision is

required when inexperienced operators use this tool.
A. On/off switch
B. Guard lock up release lever
C. Carrying handle
D. Fixed upper guard
E. Outer flange
F. Blade bolt
G. Lower blade guard
H. Saw blade
I. Sliding fence lock knob
J. Fixed table
K. kerf plate
L. Mitre arm
M. Mitre latch
N. Rotating table/Mitre arm
O. Mitre scale
P. Sliding fence
Q. Dust extraction nozzle (optional accessor y)
R. Traverse lock
S. Guard lock up hook
T. Bevel clamp handle