DeWalt DW716 Instruction manual

DW716
12" (305 mm) Double Bevel Compound Miter Saw
INSTRUCTION MANUAL
1-800-4-DEWALT • www.dewalt.com
If you have questions or comments, contact us.
DEWALT Industrial Tool Co., 701 Joppa Road, Baltimore, MD 21286
(AUG09)
Part No. N039235
DW716 Copyright © 2005, 2008, 2009 DEWALT
The following are trademarks for one or more DEWALT power tools: the yellow and black color scheme;
the “D” shaped air intake grill; the array of pyramids on the handgrip; the kit box configuration; and the
array of lozenge-shaped humps on the surface of the tool.
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 TOLL FREE AT: 1-800-4-DEWALT (1-800-433-9258)
IMPORTANT SAFETY INSTRUCTIONS
WARNING: When using electric tools, basic safety precautions should
always be followed to reduce risk of fire, electric shock, and personal injury,
including the following:
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. As a result, your tool is
equipped with a two prong plug which permits you to use extension cords without concern for
maintaining a ground connection.
NOTE: Double insulation does not take the place of normal safety precautions when 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.
Polarized Plugs
Polarized plugs (one blade is wider than the other) are used on equipment to reduce the risk of
electric shock. When provided, this plug will fit in the polarized outlet only one way. If the plug
does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician
to install the proper outlet. Do not change the plug in any way.
Safety Instructions For All Tools
This miter saw accepts the DEWALT worklight and laser attachments.
WARNING: To reduce the risk of eye injury, ALWAYS use eye protection when operating
the miter 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 unauthorized start-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"
(152 mm). 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 gauge. The smaller the gauge number, the
heavier the cord.
Ampere Rating
•
•
•
•
•
•
Minimum Gauge for Cord Sets
Volts
Total Length of Cord in Feet (meters)
120V
25 (7.6)
50 (15.2) 100 (30.5) 150 (45.7)
240V
50 (15.2) 100 (30.5) 200 (61.0) 300 (91.4)
AWG
More
Not More
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
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 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 Miter 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 miter 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 miter 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 miter saws. For best results, do
not use carbide tipped blades with hook angles in excess of 7 degrees. 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" (152 mm) 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.
WARNING: Do not connect unit to electrical power source until complete instructions are read
and understood.
WARNING: Always wear proper personal hearing protection that conforms to ANSI
S12.6 (S3.19) during use. Under some conditions and duration of use, noise from this product
may contribute to hearing loss.
WARNING: NEVER MAKE ANY CUT UNLESS THE MATERIAL IS SECURED ON THE
TABLE AND AGAINST THE FENCE.
WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other
construction activities contains chemicals known to cause cancer, birth defects or other
reproductive harm. Some examples of these chemicals are:
• lead from lead-based paints,
• crystalline silica from bricks and cement and other masonry products, and
• arsenic and chromium from chemically-treated lumber (CCA).
Your risk from these exposures varies, depending on how often you do this type of work.
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 NIOSH/OSHA approved respiratory protection
appropriate for the dust exposure. Direct particles away from face and body.
For your convenience and safety, the following warning labels are on your miter saw.
ON MOTOR HOUSING:
WARNING: FOR YOUR OWN SAFETY, READ INSTRUCTION MANUAL BEFORE
OPERATING SAW.
WHEN SERVICING, USE ONLY IDENTICAL REPLACEMENT PARTS.
ALWAYS WEAR EYE PROTECTION.
DO NOT EXPOSE TO RAIN OR USE IN DAMP LOCATIONS.
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.
FIG. 1
DW7082
DW7051
TOP HOLE
(USE FOR
DW716)
KNOBS
BRACKET
DW7080
END
PLATE
DW7084
LOCKNUTS
DWS7085
DW7187
FIG. 1A
FIG. 2
OPERATING HANDLE
GUARD
LOCK DOWN
PIN
0º BEVEL STOP
ADJUSTMENT
SCREW
BEVEL SCALE
RIGHT SIDE
FENCE
ON TABLE: (2 PLACES)
WARNING: FOR YOUR OWN SAFETY, READ INSTRUCTION
MANUAL BEFORE OPERATING MITER SAW. KEEP HANDS OUT
OF PATH OF SAW BLADE. DO NOT OPERATE SAW WITHOUT
GUARDS IN PLACE. CHECK LOWER GUARD FOR PROPER
CLOSING BEFORE EACH USE. ALWAYS TIGHTEN ADJUSTMENT
KNOBS BEFORE USE. DO NOT PERFORM ANY OPERATION FREEHAND. NEVER
REACH IN BACK OF SAW BLADE. NEVER CROSS ARMS IN FRONT OF BLADE.
TURN OFF TOOL AND WAIT FOR SAW BLADE TO STOP BEFORE MOVING
WORKPIECE, CHANGING SETTINGS OR MOVING HANDS. DISCONNECT POWER
BEFORE CHANGING BLADE OR SERVICING. TO REDUCE THE RISK OF INJURY,
RETURN CARRIAGE TO THE FULL REAR POSITION AFTER EACH CROSSCUT
OPERATION. THINK! YOU CAN PREVENT ACCIDENTS.
ON BASE: (2 PLACES)
BENCH MOUNTING
HOLES
TRIGGER
SWITCH
Electrical Connection
Be sure your power supply agrees with the nameplate marking. 120 volts, AC means that your
saw will operate on alternating current. The switch is susceptible to failure if direct current is
used. 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.
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 for purchase from your local
dealer or authorized service center. If you need assistance in locating any accessory for your
tool, please contact DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286,
call 1-800-4-DEWALT (1-800-433-9258) or visit our website www.dewalt.com.
OPTIONAL ACCESSORIES (FIG. 1)
The following accessories, designed for your saw, may be helpful. In some cases, other locally
obtained work supports, length stops, clamps, etc., may be more appropriate. Use care in
selecting and using accessories.
Laser Guide System: DW7187
Laser is available at extra cost from DEWALT Service Centers and your home
improvement retailer. Instructions for installation are included with the accessory. Read
and follow all directions for safe installation and use (not shown).
Extension, Work Support: DW7080
Used to support long overhanging workpieces, the work support is user assembled. Your
saw table is designed to accept two work supports; one on each side.
Adjustable Length Stop: DW7051
Requires the use of one work support. It is used to make repetitive cuts of the same
length from 0 to 42" (0–107 cm).
Clamp: DW7082
Used for firmly clamping workpiece to the saw table for precision cutting.
MITER
LOCK LEVER
MITER
SCALE
OPERATING
HANDLE
CARRY HANDLE
MOTOR END CAP
MOTOR
HOUSING
LEFT SIDE
FENCE
LOCK DOWN
PIN
FENCE LOCK
KNOB
FENCE LOCK
KNOB
DUST
SPOUT
BEVEL LOCK
KNOB
HAND
INDENTATIONS
0º BEVEL
OVERRIDE KNOB
45º BEVEL
OVERRIDE
LEVERS
45º
BEVEL STOP
ADJUSTMENT
SCREW
BEVEL STOP
33.85º PAWLS
BLADE
WRENCH
FIG. 3
FIG. 3A
Dust Bag: DW7053 (Included with some models)
Equipped with a zipper for easy emptying, the dust bag will capture the majority of the
sawdust produced (not shown).
Crown Molding Fence: DW7084
Used for precision cutting of crown molding.
Kerf Plate Blank: DW7055
Used to limit back side tear out of material or as a replacement kerf plate (not shown).
Miter Saw LED Worklight System: DWS7085
Lighting used for greater visibility and cutting alignment during operation. Easy to install.
SAW BLADES: ALWAYS USE 12" (305 mm) SAW BLADES WITH 1" (25.4 mm) ARBOR
HOLES. SPEED RATING MUST BE AT LEAST 4800 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 7º.
C
A
B
D
BLADE DESCRIPTIONS
APPLICATION
DIAMETER
TEETH
Construction Saw Blades (thin kerf with anti-stick rim)
General Purpose
12" (305 mm)
40
Fine Crosscuts
12" (305 mm)
60
Woodworking Saw Blades (provide smooth, clean cuts)
Fine crosscuts
12" (305 mm)
80
Non-ferrous metals
12" (305 mm)
96
NOTE: For cutting non-ferrous metals, use only saw blades with
TCG teeth designed for this purpose.
FIG. 3B
F
E
G
H
Unpacking Your Saw
Check the contents of your miter saw carton to make sure that you have received all parts. In
addition to this instruction manual, the carton should contain:
1. One No. DW716 miter saw.
2. One DEWALT 12" (305 mm) dia. saw blade
3. One blade wrench in wrench pocket shown in Figure 2.
4. One DW7053 dustbag (some models).
I
Specifications
FIG. 4
FIG. 5
CAPACITY OF CUT
50º miter left and right
48º bevel left and right
0º miter
Max. Height 3.6" (91.5 mm) Result Width 7.2" (183 mm)
Max. Width 7.9:" (200.7 mm) Result Height 2.9" (73.7mm)
45º miter
Max. Height 3.6" (91.5 mm) Result Width 4.9" (125 mm)
Max. Width 5.5” (140 mm) Result Height 2.9" (73.7 mm)
45º bevel - Left
Max. Height 2.3" (58.4 mm) Result Width 7.4" (188 mm)
Max. Width 7.9" (200.7 mm) Result Height 1.9" (48.3 mm)
K
45º bevel - Right
Max. Width 7.9" (200.7 mm) Result Height 1.1" (28 mm)
Max. Height 1.6" (40.6 mm) Result Width 7.1" (180.3 mm)
J
FIG. 7
FIG. 6
T
POINTER
M
L
MITER
SCALE
POINTER
ADJUSTMENT
SCREW
DRIVE
120 Volt Motor
1675 Watts (max in)
3600 RPM
Multi-V Belt
Automatic Electric Brake
15 Amp Motor
Cut Helical Gears
Roller Bearings
Carbide Blade
Familiarization
U
FIG. 8
Your saw is capable of cutting baseboard moldings 0.9" (22.9 mm) thick by 6" (152 mm) tall on a
45º right or left miter.
NOTE: Your saw is capable of cutting the following once a special set-up procedure is followed
(see Special Cuts).
0º miter
height 1.5" (38.1 mm)
width 10" (255 mm)
45º miter
height 1.5" (38.1 mm)
width 7.5" (190.5 mm)
R
R
Your miter saw is fully assembled in the carton. Open the box and lift the saw out by the convenient carrying handle, as shown in Figure 1A. Place the saw on a smooth, flat surface such as
a workbench or strong table. Examine Figure 2 to become familiar with the saw and its various
parts. The section on adjustments will refer to these terms and you must know what and where
the parts are.
CAUTION: Pinch Hazard. To reduce the risk of injury, keep thumb underneath the handle
when pulling the handle down. The lower guard will move up as the handle is pulled down which
could cause pinching. The handle is placed close to the guard for special cuts.
Press down lightly on the operating handle and pull out the lock down pin, as shown in Figure 2.
Gently release the downward pressure and hold the arm allowing it to rise to its full height. Use the
lock down pin when carrying the saw from one place to another. Always use the carrying handle
to transport the saw or the hand indentations shown in Figure 2 and 4.
Bench Mounting
Holes are provided in all four feet to facilitate bench mounting, as shown in Figure 2. (Two
different sized holes are provided to accommodate different sizes of screws. Use either hole,
it is not necessary to use both.) Always mount your saw firmly to a stable surface to prevent
movement. To enhance the tool’s portability, it can be mounted to a piece of 1/2" (12.7 mm) or
thicker plywood which can then be clamped to your work support or moved to other job sites
and reclamped.
NOTE: If you elect to mount your saw to a piece of plywood, make sure that the mounting screws
don’t protrude from the bottom of the wood. The plywood must sit flush on the work support.
When clamping the saw to any work surface, clamp only on the clamping bosses where the
mounting screw holes are located. Clamping at any other point will surely interfere with the
proper operation of the saw.
CAUTION: To prevent binding and inaccuracy, be sure the mounting surface is not warped or
otherwise uneven. If the saw rocks on the surface place a thin piece of material under one saw
foot until the saw sits firmly on the mounting surface.
L
S
FIG. 9
N
O
P
FIG. 10
IMPORTANT SAFETY INSTRUCTIONS
Changing or Installing a New Saw Blade (Fig. 3)
WARNING: To reduce the risk of serious personal injury, turn off the tool and disconnect
it from the power source before attempting to move it, change accessories or make any
adjustments accept as written in laser adjustment instructions.
CAUTION:
• Never depress the spindle lock button while the blade is under power or coasting.
• Do not cut ferrous metal (containing iron or steel) or masonry or fiber cement product with
this miter saw.
SCREWS
(two each
side)
V
FIG. 11
Removing the Blade
1. Unplug the saw.
2. Raise the arm to the upper position and raise the lower guard (A) as far as possible.
3. Loosen, but do not remove guard bracket screw (B) until the bracket can be raised far
enough to access the blade screw. Lower guard will remain raised due to the position of the
guard bracket screw.
4. Depress the spindle lock button (C) while carefully rotating the saw blade by hand until the
lock engages.
5. Keeping the button depressed, use the other hand and the wrench provided (D) to loosen
the blade screw. (Turn clockwise, left-hand threads.)
6. Remove the blade screw (E), outer blade clamp (F), and blade (G). The 1" (25.4mm) blade
adapter (H), if used, and the inner blade clamp (I), may be left on the spindle.
NOTE: For blades with a blade hole of 5/8" (15.88 mm), the 1" (25.4 mm) blade adapter is
not used.
FIG. 12
Installing a Blade
FIG. 12A
1. Unplug the saw.
2. With the arm raised, the lower guard held open and the guard bracket raised, place the
blade on the spindle, onto the blade adapter [if using a blade with a 1" (25.4 mm) diameter
blade hole] and against the inner blade clamp with the teeth at the bottom of the blade
pointing toward the back of the saw.
3. Assemble the outer blade clamp onto the spindle.
4. Install the blade screw and, engaging the spindle lock, tighten the screw firmly with wrench
provided. (Turn counterclockwise, left-hand threads.)
NOTE: When using blades with a 5/8" (15.88 mm) diameter blade hole, the blade adapter will not
be used and should be stored in a safe place for future use.
5. Return the guard bracket to its original position and firmly tighten the guard bracket screw
to hold bracket in place.
WARNING:
• The guard bracket must be returned to its original position
and the screw tightened before activating the saw.
• Failure to do so may allow the guard to contact the spinning
saw blade resulting in damage to the saw and severe personal
injury.
Transporting the Saw
IMPROPER CUT
PROPER CUT
FIG. 13
A
B
FIG. 14
WARNING: To reduce the risk of serious personal injury, turn off the tool and disconnect
it from the power source before attempting to move it, change accessories or make any
adjustments accept as written in laser adjustment instructions.
WARNING: To reduce the risk of serious personal injury, ALWAYS lock the miter lock
handle, bevel lock handle, lock down pin and fence adjustment knobs before transporting saw.
In order to conveniently carry the miter saw from place to place, a carrying handle has been
included on the top of the saw arm and hand indentations in the base, as shown in Figures 2, 4.
FIG. 15
Adjustments
FIG. V1
ANGLE “A”
FIG. V2
WARNING: To reduce the risk of serious personal injury, turn off the tool and disconnect
it from the power source before attempting to move it, change accessories or make any
adjustments accept as written in laser adjustment instructions.
NOTE: Your miter saw is fully and accurately adjusted at the factory at the time of manufacture.
If readjustment due to shipping and handling or any other reason is required, follow the steps
below to adjust your saw.
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.
MITER SCALE ADJUSTMENT (FIG. 5)
Place a square against the saw’s fence and blade. (Do not touch the tips of the blade teeth with
the square. To do so will cause an inaccurate measurement.) Unlock miter lock lever (J) and
swing the miter arm until the miter latch locks it at the 0 miter position. Do not lock miter lock
lever (J). If the saw blade is not exactly perpendicular to the fence, loosen the three screws that
hold the miter scale to the base and move the scale left or right until the blade is perpendicular
to the fence, as measured with the square. Retighten the three screws. Pay no attention to the
reading of the miter pointer at this time.
KERF PLATE
MITER
ANGLE
1/4° VERNIER MARK ALIGNS WITH
CLOSEST WHOLE DEGREE MARK ON
MITER SCALE (24-1/4° RIGHT MITER)
CENTER MARK ON VERNIER SCALE
ALIGNS WITH DESIRED WHOLE
ANGLE ON MITER SCALE
(24° RIGHT MITER)
MITER POINTER ADJUSTMENT (FIG. 5, 6)
To unlock, lift the miter lock lever (J) up and squeeze the miter latch (K) to move the miter arm
to the zero position. With the miter lock lever unlocked allow the miter latch to snap into place
as you rotate the miter arm to zero. Observe the pointer and miter scale through the viewing
opening shown in Figure 6. If the pointer does not indicate exactly zero, loosen the screw
holding the pointer in place, reposition the pointer and tighten the screw.
BEVEL SQUARE TO TABLE (FIG. 7)
To align the blade square to the rotary table, lock the arm in the down position. Place a square
against the blade taking care to not have the square on top of a tooth. Loosen the bevel lock
knob (L) and ensure the arm is firmly against the 0º bevel stop. Move the 0º bevel stop adjusting
screw (T) as necessary so that the blade is at 0º bevel to the table.
BEVEL POINTER (FIG. 7)
If the bevel pointer (M) does not indicate zero, loosen the screw that holds it in place and
move the pointer as necessary. Do not remove the steel plate in front of the bevel pointer. This
plate prevents wood resin from accumulating on the bevel scale during use.
FIG. 16
ADJUSTING THE BEVEL STOP TO 45º LEFT OR RIGHT (FIG. 8)
NOTE: Adjust the 45º bevel angles only after performing the 0º bevel angle and pointer
adjustment. Ensure the 45º bevel override levers (N) are pushed inward to obtain an accurate
adjustment.
To adjust the right 45º bevel angle, loosen the bevel lock knob (L) and pull the bevel stop override
knob (S) to override the 0º bevel stop. When the saw is fully to the right, if the pointer does not
indicate exactly 45º, turn the right bevel stop screw (O) until the pointer indicates 45º.
To adjust the left 45º bevel stop, first loosen the bevel lock knob (L) and tilt the head to the left.
If the pointer does not indicate exactly 45º, turn the left bevel stop screw until the pointer reads
45º.
FIG. 17
FIG. 17A
FENCE
BOTTOM SIDE
OF MOLDING
TOP SIDE
OF MOLDING
TABLE
DW7084
CROWN
MOLDING
FENCE
TABLE
FENCE
CROWN MOLDING FLAT ON TABLE AND
AGAINST FENCE
FIG. 18
CROWN MOLDING BETWEEN FENCE
AND TABLE
FIG. 18A
BLADE
BLADE
RIGHT
WRONG
FENCE
FENCE
ADJUSTING THE BEVEL STOP TO 33.85º (FIG. 8)
NOTE: Adjust the 33.85º bevel angles only after performing the 0º bevel angle and pointer
adjustment.
To set the 33.85º bevel angle, flip out the stop pawls (P). Loosen the bevel lock knob (L) and tilt
the head to the left. If the pointer does not indicate exactly 33.85º, turn the screw contacting the
pawl until the pointer reads 33.85º.
To adjust the right 33.85º bevel angle, flip out the stop pawl. Loosen the bevel lock knob (L) and
pull the bevel stop override button (S) to override the 0º bevel stop. When the saw is fully to the
right, if the pointer does not indicate exactly 33.85º, turn the screw contacting the pawl until the
pointer indicates 33.85º.
FENCE ADJUSTMENT
WARNING: To reduce the risk of serious personal injury, turn off the tool and
disconnect it from the power source before attempting to move it, change accessories
or make any adjustments accept as written in laser adjustment instructions.
In order that the saw can bevel to a full 48° left or right, the fences can be adjusted to provide
clearance. To adjust a fence, loosen the plastic knob (Figure 8, R), and slide the fence outward.
Make a dry run with the saw turned off and check for clearance. Adjust the fence to be as close
to the blade as practical to provide maximum workpiece support, without interfering with arm
up and down movement. Tighten knob securely. When the bevel operations are complete, don’t
forget to relocate the fence.
NOTE: The guide groove of the fences can become clogged with sawdust. If you notice that it is
becoming clogged, use a stick or some low pressure air to clear the guide groove.
AUTOMATIC ELECTRIC BRAKE
Your saw is equipped with an automatic electric blade brake which stops the saw blade within
5 seconds of trigger release. This is not adjustable.
On occasion, there may be a delay after trigger release to brake engagement. On rare occasions,
the brake may not engage at all and the blade will coast to a stop.
If a delay or “skipping” occurs, turn the saw on and off 4 or 5 times. If the condition persists, have
the tool serviced by an authorized DEWALT service center.
Always be sure the blade has stopped before removing it from the kerf. The brake is not a
substitute for guards. Ensure your own safety by giving the saw your complete attention.
FIG. 20
FIG. 19A
FIG. 19
RIGHT
WRONG
E
ST FENC
ADJU RE USE
ALWAYS Y BEFO
PROPERL
FIG. 21
SET
SCREW
SCREWS
GUARD ACTUATION AND VISIBILITY
CAUTION: Pinch Hazard. To reduce the risk of injury, keep thumb underneath the handle
when pulling the handle down. The lower guard will move up as the handle is pulled down which
could cause pinching.
The blade guard on your saw has been designed to automatically raise when the arm is brought
down and to lower over the blade when the arm is raised.
The guard can be raised by hand when installing or removing saw blades or for inspection of the
saw. NEVER RAISE THE BLADE GUARD MANUALLY UNLESS THE SAW IS TURNED OFF.
NOTE: Certain special cuts of large material will require that you manually raise the guard.
Refer to Cutting Large Material under Special Cuts.
The front section of the guard is louvered for visibility while cutting. Although the louvers dramatically reduce flying debris, they are openings in the guard and safety glasses should be worn at
all times when viewing through the louvers.
MITER LOCK ADJUSTMENT (FIG. 11)
The miter lock rod should be adjusted if the table of the saw can be moved when the miter
lock handle is locked down. To adjust, put the miter lock handle in the up position. Using a
slotted screwdriver, adjust the lock rod in 1/8 clockwise turn increments to increase the lock
force. To ensure the miter lock is functioning properly, re-lock miter lock handle to a non-detent
miter angle.
Brushes
WARNING: To reduce the risk of serious personal injury, turn off the tool and disconnect
it from the power source before attempting to move it, change accessories or make any
adjustments accept as written in laser adjustment instructions.
Inspect carbon brushes regularly by unplugging tool, removing the motor end cap (Fig. 2), lift
the brush spring and withdraw the brush assembly. Keep brushes clean and sliding freely in
their guides. Always replace a used brush in the same orientation in the holder as it was prior
to its removal. Carbon brushes have varying symbols stamped into their sides, and if the brush
is worn down to approximately 1/2" (12.7 mm), the spring will no longer exert pressure and they
must be replaced. Use only identical DEWALT brushes. Use of the correct grade of brush is
essential for proper operation of electric brake. New brush assemblies are available at DEWALT
service centers. The tool should be allowed to “run in” (run at no load) for 10 minutes before
use to seat new brushes. The electric brake may be erratic in operation until the brushes are
properly seated (worn in). Always replace the brush inspection cap after inspection or servicing
the brushes.
While “running in” DO NOT TIE, TAPE, OR OTHERWISE LOCK THE TRIGGER SWITCH ON.
HOLD BY HAND ONLY.
Controls
Your compound miter saw has several main controls, which will be discussed briefly here. For
more information on these controls, see the respective sections later in the manual.
MITER CONTROL (FIG. 5)
The miter lock/adjustment lever and trigger allows you to miter your saw 50º left and right. To
miter the saw, unlock miter lock lever (J) by pulling upward, squeeze the detent trigger (K) and
set the miter angle desired on the miter scale. Lock miter lock handle by pressing downward.
Override the detent trigger by rotating knob (Fig. 10, V).
TRIGGER SWITCH (FIG. 2)
The trigger switch turns your saw on and off. A hole is provided in the trigger for insertion of a
padlock to secure the saw.
BEVEL LOCK (FIG. 8)
The bevel lock knob (L) allows you to bevel the saw 48º left or right. To loosen the handle and
adjust the bevel setting, turn the handle counterclockwise, the saw head bevels easily to the left
or to the right once the 0º bevel override knob (S) is pulled. To tighten, turn the handle clockwise.
Bevel degree markings are on the bottom front of the saw arm (Fig. 7, M).
0º BEVEL OVERRIDE (FIG. 8)
The bevel stop override (S) allows you to bevel the saw to the right past the 0º mark.
The saw will automatically stop at 0º when brought up from the left. To move past 0º to the right,
pull the bevel stop knob. The stop knob can be locked out by pulling the knob out and rotating
it 180º.
45º BEVEL STOP OVERRIDES (FIG. 8)
The bevel stop overrides (N) are held secure with their attachment screw to prevent inadvertent
movement. Use the bit on the blade wrench to loosen the attachment screw. This allows the
slides, to be pulled outward and the saw head to pivot past the 45º mark. Be sure to retighten
the attachment screw when finished.
33.85º BEVEL STOPS (FIG. 8)
The two pawls (P) are used to stop the saw head bevel setting at 33.85º. This setting is used
primarily for cutting crown moldings laid flat on the table.
HEAD DOWNLOCK PIN (FIG. 8)
To lock the saw head in the down position, push the head down, push the pin (U) in and release
the saw head. This will hold the saw head safely down for moving the saw from place to place.
To release, press the saw head down and pull the pin out.
OPERATION
WARNING: To reduce the risk of serious personal injury, turn off the tool and disconnect
it from the power source before attempting to move it, change accessories or make any
adjustments accept as written in laser adjustment instructions.
WARNING: Always use eye protection. All users and bystanders must wear eye protection
that conforms to ANSI Z87.1 (CAN/CSA Z94.3).
Plug the saw into any household 60 Hz power source. Refer to the nameplate for voltage. Be
sure the cord will not interfere with your work.
SWITCH
To turn the saw on, depress the trigger switch. To turn the tool off, release the switch. Allow the
blade to spin up to full operating rpm before making the cut. Release the trigger switch and allow
the brake to stop the blade before raising the saw head. There is no provision for locking the
switch on, but a hole is provided in the trigger for insertion of a padlock to lock the saw off.
CUTTING WITH YOUR SAW
NOTE: Although this saw will cut wood and many non-ferrous materials, we will limit our
discussion to the cutting of wood only. The same guidelines apply to the other materials. DO
NOT CUT FERROUS (IRON AND STEEL) MATERIALS OR MASONRY WITH THIS SAW. Do
not use any abrasive blades.
CROSSCUTS
Cutting of multiple pieces is not recommended but can be done safely by ensuring that each
piece is held firmly against the table and fence. A crosscut is made by cutting wood across the
grain at any angle. A straight crosscut is made with the miter arm at the zero degree position.
Set the miter arm at zero, hold the wood on the table and firmly against the fence. Turn on the
saw by squeezing the trigger.
CAUTION: Always use a work clamp to maintain control and reduce the risk of workpiece
damage and personal injury.
When the saw comes up to speed (about 1 second) lower the arm smoothly and slowly to cut
through the wood. Let the blade come to a full stop before raising arm.
Miter crosscuts are made with the miter arm at some angle other than zero. This angle is often 45°
for making corners, but can be set anywhere from zero to 50° left or right. After selecting the desired
miter angle, be sure to lock miter lock lever. Make the cut as described above.
To cut through an existing pencil line on a piece of wood, match the angle as close as possible.
Cut the wood a little too long and measure from the pencil line to the cut edge to determine
which direction to adjust the miter angle and recut. This will take some practice, but it is a
commonly used technique.
BEVEL CUTS
A bevel cut is a crosscut made with the saw blade at a bevel to the wood. In order to set the
bevel, loosen the bevel clamp knob and move the saw to the left as desired. (It is necessary
to move the fence to allow clearance). Once the desired bevel angle has been set, tighten the
bevel clamp knob firmly.
Bevel angles can be set from 48° right to 48° left and can be cut with the miter arm set between
zero and 50° right or left. At some extreme angles, the right or left side fence might have to be
removed. To remove the left or right fence, unscrew the knobs several turns and slide the fence
out.
QUALITY OF CUT
The smoothness of any cut depends on a number of variables. Things like material being cut, blade
type, blade sharpness and rate of cut all contribute to the quality of the cut.
When smoothest cuts are desired for molding and other precision work, a sharp (60 tooth
carbide) blade and a slower, even cutting rate will produce the desired results.
Ensure that material does not creep while cutting, clamp it securely in place. Always let the blade
come to a full stop before raising arm.
If small fibers of wood still split out at the rear of the workpiece, stick a piece of masking tape
on the wood where the cut will be made. Saw through the tape and carefully remove tape when
finished.
For varied cutting applications, refer to the list of recommended saw blades for your saw and
select the one that best fits your needs. Refer to Saw Blades under Optional Accessories.
BODY AND HAND POSITION (FIG. 12)
Proper positioning of your body and hands when operating the miter saw will make cutting
easier, more accurate and safer. Never place hands near cutting area. Place hands no closer
than 6" (152 mm) from the blade. Hold the workpiece tightly to the table and the fence when
cutting. Keep hands in position until the trigger has been released and the blade has completely
stopped. ALWAYS MAKE DRY RUNS (UNPOWERED) BEFORE FINISH CUTS SO THAT
YOU CAN CHECK THE PATH OF THE BLADE. DO NOT CROSS HANDS, AS SHOWN IN
FIGURE 12A.
Keep both feet firmly on the floor and maintain proper balance. As you move the miter arm left
and right, follow it and stand slightly to the side of the saw blade. Sight through the guard louvers
when following a pencil line.
CLAMPING THE WORKPIECE
WARNING: To reduce the risk of serious personal injury, turn off the tool and disconnect
it from the power source before attempting to move it, change accessories or make any
adjustments accept as written in laser adjustment instructions.
WARNING: A workpiece that is clamped, balanced and secure before a cut may become
unbalanced after a cut is completed. An unbalanced load may tip the saw or anything the saw
is attached to, such as a table or workbench. When making a cut that may become unbalanced,
properly support the workpiece and ensure the saw is firmly bolted to a stable surface. Personal
injury may occur.
WARNING: The clamp foot must remain clamped above the base of the saw whenever the
clamp is used. Always clamp the workpiece to the base of the saw–not to any other part of the
work area. Ensure the clamp foot is not clamped on the edge of the base of the saw.
CAUTION: Always use a work clamp to maintain control and reduce the risk of workpiece
damage and personal injury.
If you cannot secure the workpiece on the table and against the fence by hand, (irregular shape,
etc.) or your hand would be less than 6" (152 mm) from the blade, a clamp or other fixture must
be used.
For best results use the DW7082 clamp made for use with your saw. It is available for purchase
at your local retailer or DEWALT service center.
Other aids such as spring clamps, bar clamps or C-clamps may be appropriate for certain sizes
and shapes of material. Use care in selecting and placing these clamps. Take time to make a dry
run before making the cut. The left or right fence will slide from side to side to aid in clamping.
TO INSTALL CLAMP (SOLD SEPARATELY)
1. Insert it into the hole behind the fence. The clamp should be facing toward the back of the
miter saw. The groove on the clamp rod should be fully inserted into the base. Ensure this
groove is fully inserted into the base of the miter saw. If the groove is visible, the clamp will
not be secure.
2. Rotate the clamp 180º toward the front of the miter saw.
3. Loosen the knob to adjust the clamp up or down, then use the fine adjust knob to firmly
clamp the workpiece.
NOTE: Place the clamp on the opposite side of the base when beveling. ALWAYS MAKE DRY
RUNS (UNPOWERED) BEFORE FINISH CUTS TO CHECK THE PATH OF THE BLADE.
ENSURE THE CLAMP DOES NOT INTERFERE WITH THE ACTION OF THE SAW OR
GUARDS.
WARNING: A workpiece that is clamped, balanced and secure before a cut may become
unbalanced after a cut is completed. An unbalanced load may tip the saw or anything the saw
is attached to, such as a table or workbench. When making a cut that may become unbalanced,
properly support the workpiece and ensure the saw is firmly bolted to a stable surface.
WARNING: The clamp foot must remain clamped above the base of the saw whenever the
clamp is used. Always clamp the workpiece to the base of the saw–not to any other part of the
work area. Ensure the clamp foot is not clamped on the edge of the base of the saw.
SUPPORT FOR LONG PIECES
WARNING: To reduce the risk of serious personal injury, turn off the tool and disconnect it from the power source before attempting to move it, change accessories or make
any adjustments accept as written in laser adjustment instructions.
ALWAYS SUPPORT LONG PIECES.
Never use another person as a substitute for a table extension; as additional support for a
workpiece that is longer or wider than the basic miter saw table or to help feed, support or pull
the workpiece.
For best results, use the DW7080 extension work support to extend the table width of your saw.
Available from your dealer at extra cost. Support long workpieces using any convenient means
such as sawhorses or similar devices to keep the ends from dropping.
CUTTING PICTURE FRAMES, SHADOW BOXES AND OTHER FOUR-SIDED PROJECTS
To best understand how to make the items listed here, we suggest that you try a few simple
projects using scrap wood until you develop a “FEEL” for your saw.
Your saw is the perfect tool for mitering corners like the one shown in Figure 14. Sketch A in
Figure 13 shows a joint made by using the bevel adjustment to bevel the edges of the two boards
at 45° each to produce a 90° corner. For this joint the miter arm was locked in the zero position
and the bevel adjustment was locked at 45°. The wood was positioned with the broad flat side
against the table and the narrow edge against the fence. The cut could also be made by mitering
right and left with the broad surface against the fence.
CUTTING TRIM MOLDING AND OTHER FRAMES
Sketch B in Figure 13 shows a joint made by setting the miter arm at 45° to miter the two boards
to form a 90° corner. To make this type of joint, set the bevel adjustment to zero and the miter
arm to 45°. Once again, position the wood with the broad flat side on the table and the narrow
edge against the fence.
The two sketches in Figure 13 are for four side objects only.
As the number of sides changes, so do the miter and bevel angles. The chart below gives the
proper angles for a variety of shapes.
NO. SIDES
4
5
6
7
8
9
10
- EXAMPLES ANGLE MITER OR BEVEL
45°
36°
30°
25.7°
22.5°
20°
18°
(The chart assumes that all sides are of equal length.) For a shape that is not shown in the chart,
use the following formula. 180° divided by the number of sides equals the miter (if the material
is cut vertically) or bevel angle (if the material is cut laying flat).
CUTTING COMPOUND MITERS
A compound miter is a cut made using a miter angle and a bevel angle at the same time.
This is the type of cut used to make frames or boxes with slanting sides like the one shown in
Figure 15.
NOTE: If the cutting angle varies from cut to cut, check that the bevel clamp knob and the miter
lock knob are securely tightened. These knobs must be tightened after making any changes in
bevel or miter.
The chart (Table 1) will assist you in selecting the proper bevel and miter settings for common
compound miter cuts. To use the chart, select the desired angle “A” (Figure 15) of your project
and locate that angle on the appropriate arc in the chart. From that point follow the chart straight
down to find the correct bevel angle and straight across to find the correct miter angle.
Set your saw to the prescribed angles and make a few trial cuts. Practice fitting the cut pieces
together until you develop a feel for this procedure and feel comfortable with it.
Example: To make a four-sided box with 26° exterior angles (Angle A, Figure 15), use the upper
right arc. Find 26° on the arc scale. Follow the horizontal intersecting line to either side to get
miter angle setting on saw (42°). Likewise, follow the vertical intersecting line to the top or bottom
to get the bevel angle setting on the saw (18°). Always try cuts on a few scrap pieces of wood to
verify settings on saw.
VERNIER SCALE
Your saw is equipped with a vernier scale for added precision. The vernier scale allows you to
accurately set miter angles to the nearest 1/4°. To use the vernier scale follow the steps listed
below.
(As an example, let’s assume that the angle you want to miter is 24-1/4° right).
1. Turn off miter saw.
2. Set the miter angle to the nearest whole degree desired by aligning the center mark in the
vernier scale, shown in Figure V1, with the whole degree number etched in the miter scale.
Examine Figure V2 closely; the setting shown is 24° right miter.
3. To set the additional 1/4°, squeeze the miter arm lock and carefully move the arm to the
RIGHT until the 1/4° vernier mark aligns with the CLOSEST degree mark on the miter scale.
In our example, the closest degree mark on the miter scale happens to be 25°. Figure V2
shows a setting of 24-1/4° right miter.
For settings that require partial degrees (1/4, 1/2, 3/4°) align the desired vernier mark with the
CLOSEST degree mark on the miter scale, as described below (The plastic vernier plate is
inscribed with marks for 1/4, 1/2, 3/4 and 1°. Only the 1/2° and the 1° are numerically labeled.)
ALUMINUM CUTTING
ALWAYS USE THE APPROPRIATE SAW BLADE MADE ESPECIALLY FOR CUTTING
ALUMINUM. These are available at your local DEWALT retailer or DEWALT service center.
Certain workpieces, due to their size, shape or surface finish, may require the use of a clamp
or fixture to prevent movement during the cut. Position the material so that you will be cutting
the thinnest cross section, as shown in Figure 18. Figure 18A illustrates the wrong way to cut
these extrusions. Use a stick wax cutting lubricant when cutting aluminum. Apply the stick wax
directly to the saw blade before cutting. Never apply stick wax to a moving blade.
The wax, available at most hardware stores and industrial mill supply houses, provides proper
lubrication and keeps chips from adhering to the blade.
Be sure to properly secure workpiece.
Refer to Saw Blades under Optional Accessories for correct saw blade.
WHEN MITERING TO THE RIGHT
To increase the miter angle when mitering to the right, move the arm to align the appropriate
vernier mark with the closest mark on the miter scale to the right. To decrease the miter angle
when mitering to the right, move the arm to align the appropriate vernier mark with the closest
mark on the miter scale to the left.
CUTTING PLASTIC PIPE OR OTHER ROUND MATERIAL
Plastic pipe can be easily cut with your saw. It should be cut just like wood and CLAMPED OR
HELD FIRMLY TO THE FENCE TO KEEP IT FROM ROLLING. This is extremely important
when making angle cuts.
WHEN MITERING TO THE LEFT
To increase the miter angle when mitering to the left, move the arm to align the appropriate
vernier mark with the closest mark on the miter scale to the left. To decrease the miter angle
when mitering to the left, move the arm to align the appropriate vernier mark with the closest
mark on the miter scale to the right.
CUTTING BASE MOLDING
ALWAYS MAKE A DRY RUN WITHOUT POWER BEFORE MAKING ANY CUTS.
Straight 90° cuts:
Position the wood against the fence and hold it in place as shown in Figure 16. Turn on the
saw, allow the blade to reach full speed and lower the arm smoothly through the cut.
CUTTING BASE MOLDING UP TO 6" (152 MM) VERTICALLY AGAINST THE FENCE
Position material as shown in Figure 16.
All cuts made with the back of the molding against the fence and bottom of the molding against
the base.
INSIDE CORNER:
OUTSIDE CORNER:
Left side
Left side
1. Miter left 45
1. Miter right at 45°
2. Save left side of cut
2. Save left side of cut
Right side
Right side
1. Miter Right 45°
1. Miter left at 45°
2. Save right side of cut
2. Save right side of cut
Material up to 6" (152 mm) can be cut as described above.
CUTTING CROWN MOLDING
Your miter saw is better suited to the task of cutting crown molding than any tool made. In order
to fit properly, crown molding must be compound mitered with extreme accuracy.
The two flat surfaces on a given piece of crown molding are at angles that, when added together,
equal exactly 90°. Most, but not all, crown molding has a top rear angle (the section that fits
flat against the ceiling) of 52° and a bottom rear angle (the part that fits flat against the wall)
of 38°.
Your miter saw has special pre-set miter latch points at 31.62° left and right for cutting crown
molding at the proper angle and bevel stop pawls at 33.85º left and right. There is also a mark
on the bevel scale at 33.85°.
The chart below gives the proper settings for cutting crown molding. (The numbers for the
miter and bevel settings are very precise and are not easy to accurately set on your saw.)
Since most rooms do not have angles of precisely 90°, you will have to fine tune your
settings anyway.
PRETESTING WITH SCRAP MATERIAL IS EXTREMELY IMPORTANT!
INSTRUCTIONS FOR CUTTING CROWN MOLDING LAYING FLAT AND USING THE
COMPOUND FEATURES:
1. Molding laying with broad back surface down flat on saw table (Figure 17).
2. The settings below are for All Standard (U.S.) crown molding with 52° and 38° angles.
BEVEL SETTING
33.85° Left
33.85° Right
33.85° Right
33.85° Left
TYPE OF CUT
LEFT SIDE, INSIDE CORNER:
1. Top of molding against fence
2. Miter table set right 31.62°
3. Save left end of cut
RIGHT SIDE, INSIDE CORNER:
1. Top of molding against fence.
2. Miter table set at left 31.62°
3. Save right end of cut
LEFT SIDE, OUTSIDE CORNER:
1. Top of molding against fence.
2. Miter table set at left 31.62°
3. Save left end of cut
RIGHT SIDE, OUTSIDE CORNER:
1. Top of molding against fence
2. Miter table set right 31.62°
3. Save right end of cut
When setting bevel and miter angles for all compound miters, remember that:
The angles presented for crown moldings are very precise and difficult to set exactly. Since
they can easily shift slightly and very few rooms have exactly square corners, all settings
should be tested on scrap molding.
PRETESTING WITH SCRAP MATERIAL IS EXTREMELY IMPORTANT!
ALTERNATIVE METHOD FOR CUTTING CROWN MOLDING
Place the molding on the table at an angle between the fence and the saw table, as shown
in Figure 17A. Use of the crown molding fence accessory (DW7084) is highly recommended
because of its degree of accuracy and convenience. The crown molding fence accessory is
available for purchase from your local dealer.
The advantage to cutting crown molding using this method is that no bevel cut is required.
Minute changes in the miter angle can be made without affecting the bevel angle. This way,
when corners other than 90° are encountered, the saw can be quickly and easily adjusted for
them. Use the crown molding fence accessory to maintain the angle at which the molding will
be on the wall.
INSTRUCTIONS FOR CUTTING CROWN MOLDING ANGLED BETWEEN THE FENCE
AND BASE OF THE SAW FOR ALL CUTS:
1. Angle the molding so the bottom of the molding (part which goes against the wall when
installed) is against the fence and the top of the molding is resting on the base of the saw, as
shown in Figure 17A.
2. The angled “flats” on the back of the molding must rest squarely on the fence and base of the
saw.
INSIDE CORNER:
OUTSIDE CORNER:
Left side
Left side
1. Miter right 45
1. Miter left at 45°
2. Save right side of cut
2. Save right side of cut
Right side
Right side
1. Miter left 45°
1. Miter right at 45°
2. Save left side of cut
2. Save left side of cut
Special Cuts
NEVER MAKE ANY CUT UNLESS THE MATERIAL IS SECURED ON THE TABLE
AND AGAINST THE FENCE.
BOWED MATERIAL
When cutting bowed material always position it as shown in Figure 19 and never like that
shown in Figure 19A. Positioning the material incorrectly will cause it to pinch the blade near the
completion of the cut.
CUTTING LARGE MATERIAL
Occasionally you will encounter a piece of wood a little too large to fit beneath the blade guard.
If this occurs, simply place your right thumb on the upper side of the guard and roll the guard
up just enough to clear the workpiece, as shown in Figure 20. Avoid doing this as much as
possible, but if need be, the saw will operate properly and make the bigger cut. NEVER TIE,
TAPE, OR OTHERWISE HOLD THE GUARD OPEN WHEN OPERATING THIS SAW.
SPECIAL SET-UP FOR WIDE CROSSCUTS
Your saw can cut very wide [up to 10" (406 mm)] workpieces when a special set up is used. To
set the saw up for these workpieces, follow these steps:
1. Remove both left and right sliding fences from the saw and set aside. To remove them,
unscrew the fence knobs several turns and slide each fence outward. Adjust and lock the
miter control so that it is at 0° miter.
2. Make a platform using a piece of 1.5 inch (38 mm) thick particleboard or similar flat strong
1.5" (38 mm) thick wood to the dimensions: 10" x 24" (254 x 610 mm). The platform must be
flat otherwise the material could move during cutting and cause injury.
3. Mount the 10" x 24" (254 x 610 mm) platform to the saw using 4 three-inch (76 mm) long
wood screws through the holes in the base fence (Fig. 9). Four screws must be used to
properly secure the material. When the special set up is used, the platform will be cut into
two pieces. Ensure the screws are tightened properly otherwise material could loosen and
cause injury. Ensure the platform is firmly flat on the table, against the fence, and centered
evenly from left to right.
WARNING: Ensure the saw is mounted firmly to a stable flat surface. Failure to do so could
cause the saw to be unstable and fall causing personal injury.
4. Place the workpiece to be cut on top of the platform mounted to the table. Ensure the
workpiece is firmly against the backfence (Fig. 9).
5. Secure the material before cutting. Cut slowly through the material. Failure to clamp securely
or cut slowly could result in the material coming loose and causing injury.
After several cuts are made at various miter angles other than 0º, the platform may weaken
and not properly support the work. Install a new, unused platform to the saw after presetting the
desired miter angle.
CAUTION: Continued use of a platform with several kerfs may cause loss of material control
and possible injury.
Removing and Replacing Belt
The belt is designed to last the life of the tool. However, abuse of the tool could cause the belt
to fail.
If the blade does not turn when the motor is running, the belt has failed. To inspect or replace the
belt, remove the belt cover screws. Remove the belt cover. Inspect the ribs of the belt for wear or
failure. Check belt tension by squeezing the belt as shown in Figure 21. The belt halves should
almost touch when squeezing firmly with the thumb and index finger.
To adjust the tension, loosen, but do not remove, the four Phillips head screws shown. Then
rotate the set screw on the top of the motor plate casting until the proper tension is achieved.
Tighten the four screws securely and replace the belt cover.
NOTE: Over tightening the belt will cause premature motor failure.
MAINTENANCE
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.
1. All bearings are sealed. They are lubricated for life and need no further maintenance.
2. Periodically clean all dust and wood chips from around AND UNDER the base and the
rotary table. Even though slots are provided to allow debris to pass through, some dust will
accumulate.
3. The brushes are designed to give you several years of use. If they ever need replacement
follow the instructions or return the tool to the nearest service center for repair. Service
center locations are packed with your tool.
Service Infor mation
Please have the following information available for all service calls:
Model Number _____________________ Serial Number __________________________
Date and Place of Purchase ____________________________________________________
Repairs
To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including
brush inspection and replacement) should be performed by authorized service centers or other
qualified service organizations, always using identical replacement parts.
Three Year Limited Warranty
DEWALT will repair, without charge, any defects due to faulty materials or workmanship for
three years from the date of purchase. This warranty does not cover part failure due to normal
wear or tool abuse. For further detail of warranty coverage and warranty repair information, visit
www.dewalt.com or call 1-800-4-DEWALT (1-800-433-9258). This warranty does not apply to
accessories or damage caused where repairs have been made or attempted by others. This
warranty gives you specific legal rights and you may have other rights which vary in certain
states or provinces.
In addition to the warranty, DEWALT tools are covered by our:
1 YEAR FREE SERVICE
DEWALT will maintain the tool and replace worn parts caused by normal use, for free, any time
during the first year after purchase.
90 DAY MONEY BACK GUARANTEE
If you are not completely satisfied with the performance of your DEWALT Power Tool, Laser, or
Nailer for any reason, you can return it within 90 days from the date of purchase with a receipt
for a full refund – no questions asked.
LATIN AMERICA: This warranty does not apply to products sold in Latin America. For products
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 (1-800-433-9258) for a free replacement.
Patent Notification
Manufactured under one or more of
the following U.S. patents:
6,431,040
5,582,089
6,427,570
5,375,495
D454,577
5,285,708
5,819,619
5,199,343
Other patents pending.
Troubleshooting Guide
BE SURE TO FOLLOW SAFETY RULES AND INSTRUCTIONS
TROUBLE!
Saw will not start
WHAT’S WRONG?
1. Saw not plugged in
2. Fuse blown or circuit breaker tripped
3. Cord damaged
4. Brushes worn out
1. Dull blade
2. Blade mounted backwards
3. Gum or pitch on blade
4. Incorrect blade for work being done
1. Extension cord too light or too long
Saw makes
unsatisfactory cuts
Blade does not come up
to speed
Machine vibrates excessively
Does not make accurate
miter cuts
Material pinches blade
WHAT TO DO
1. Plug in saw.
2. Replace fuse or reset circuit breaker.
3. Have cord replaced by authorized service center.
4. Have brushes replaced by authorized service center or replace them yourself. Refer to Brushes.
1. Replace blade. Refer to Changing or Installing a New Saw Blade.
2. Turn blade around. Refer to Changing or Installing a New Saw Blade.
3. Remove blade and clean with turpentine and coarse steel wool or household oven cleaner.
4. Change the blade type. Refer to Saw Blades.
1. Replace with adequate size cord. Refer to Use Proper Extension Cord under Important Safety
Instructions.
2. Low house current
1. Saw not mounted securely to stand or
work bench
2. Stand or bench on uneven floor
3. Damaged saw blade
1. Miter scale not adjusted correctly
2. Miter pointer not adjusted correctly
3. Workpiece is not perpendicular to table
4. Workpiece moving
1. Cutting bowed material
2. Contact your electric company.
1. Tighten all mounting hardware. Refer to Bench Mounting.
2. Reposition on flat level surface. Refer to Familiarization.
3. Replace blade. Refer to Changing or Installing a New Saw Blade.
1. Check and adjust. Refer to Miter Scale Adjustment under Adjustments.
2. Check and adjust. Refer to Miter Pointer Adjustment under Adjustments.
3. Check and adjust fence. Refer to Fence Adjustment under Adjustments.
4. Clamp workpiece securely to fence or glue 120 grit sandpaper to fence with rubber cement.
1. Refer to Bowed Material under Special Cuts.
TABLE 1: COMPOUND MITER CUT
(POSITION WOOD WITH BROAD FLAT SIDE ON THE TABLE AND THE NARROW EDGE AGAINST THE FENCE)
10
20
30
40
ANGLE OF SIDE OF BOX (ANGLE A)
X
BO
10
20
60
30
SI
6-
40
ED
D
10
50
30
X
BO
20
70
40
D
DE
SI
8-
SET THIS MITER ANGLE ON SAW
E
R
UA
SQ
50
60
X
BO
50
60
70
80
70
80
80
SET THIS BEVEL ANGLE ON SAW