DeWalt | DW777 | Instruction manual | DeWalt DW777 Instruction manual

INSTRUCTION MANUAL
DW777-XE
216 mm (8.5") CROSS-CUT MITRE SAW
TABLE OF CONTENTS
DOUBLE INSULATION ............................................................................................................................................... 1
BASIC SAW CUTS ................................................................................................................................................ 7
SAFETY INSTRUCTIONS FOR ALL TOOLS ................................................................................................................. 1
VERTICAL STRAIGHT CROSS CUT ................................................................................................................... 7
ADDITIONAL SAFETY RULES FOR MITRE SAWS ....................................................................................................... 2
VERTICAL MITRE CROSS-CUT ........................................................................................................................ 8
ELECTRICAL CONNECTION ....................................................................................................................................... 3
BEVEL CROSS-CUTS........................................................................................................................................ 8
ACCESSORIES .......................................................................................................................................................... 3
QUALITY OF CUT .................................................................................................................................................. 8
OPTIONAL ACCESSORIES .................................................................................................................................... 3
CLAMPING THE WORKPIECE ............................................................................................................................... 8
SAW BLADES ....................................................................................................................................................... 3
COMPOUND MITRE ............................................................................................................................................. 8
PACKAGE CONTENTS ............................................................................................................................................... 3
SUPPORT FOR SHORT AND LONG PIECES .......................................................................................................... 8
SPECIFICATIONS ....................................................................................................................................................... 3
CUTTING SHORT MATERIAL ............................................................................................................................. 8
DESCRIPTION ........................................................................................................................................................... 3
CUTTING LARGE MATERIAL ............................................................................................................................. 8
ASSEMBLY ............................................................................................................................................................... 5
DUST EXTRACTION................................................................................................................................................... 8
UNPACKING ......................................................................................................................................................... 5
TRANSPORTING........................................................................................................................................................ 8
CABLE CLAMP ..................................................................................................................................................... 5
MAINTENANCE ......................................................................................................................................................... 8
BENCH MOUNTING .............................................................................................................................................. 5
USING THE ROLLER TABLE .................................................................................................................................. 9
MOUNTING THE SAW BLADE ............................................................................................................................... 5
SERVICE INFORMATION ............................................................................................................................................ 9
ADJUSTMENTS......................................................................................................................................................... 5
REPAIRS ................................................................................................................................................................... 9
ADJUSTING THE TRAVERSE BARS FOR CONSTANT CUTTING DEPTH .................................................................. 5
TROUBLESHOOTING GUIDE ...................................................................................................................................... 9
ADJUSTING THE FENCE ....................................................................................................................................... 6
TABLE 1: COMPOUND MITRE CUT .......................................................................................................................... 10
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
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
Voltage
Power input
Blade diameter
Blade bore
Max. blade speed
Mitre (max. positions)
Bevel (max. positions)
Compound mitre
Capacities
cross-cut 90°
mitre 45°
mitre 48°
bevel 45°
bevel 48°
Overall dimensions
Weight
V
W
mm
mm
min-1
left and right
left
bevel
mitre
DW777
230
1800
216
30
6300
50°
48°
45°
45°
mm
mm
mm
mm
mm
mm
kg
60 x 270
60 x 190
60 x 180
48 x 270
45 x 270
460 x 560 x 430
15.0
LPA (sound pressure)
dB(A)
93
KPA (sound pressure
uncertainty)
dB(A)
3
LWA (acoustic power)
dB(A)
104
KWA (acoustic power
uncertainty)
dB(A)
3.9
Vibration total values (triax vector sum) determined according to EN 61029:
Vibration emission value ah
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.
1
• MAKE WORKSHOP CHILDPROOF with padlocks, master switches, or by
removing starter keys. The unauthorised 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"). 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
•
•
•
•
•
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 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.
2
• 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.
Package Contents
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.
Check the contents of your mitre saw carton to make sure that you have received all parts. 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 48 mm (1.9") Result Width 270 mm (10.6")
DRIVE
230 Volt Motor
1800 Watts In
6000 RPM
Multi-V Belt
Automatic Electric Brake
Cut Helical Gears
Roller Bearings
Carbide Blade
Description (Fig. 1-6, 9)
Electrical Connection
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 accessory)
R. Traverse lock
S. Guard lock up hook
T. Bevel clamp handle
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
3
FIG. 1
FIG. 2
Q
R
A
D
B
X
W
DD
DD
Z
BB
AA
Q
C
Y
E
S
F
I
V
G
J
EE
P
V
T
K
L
FF
O
U. Bevel scale
V. Bench mounting holes
W. Lock down button
X. Traverse bars
Y. Saw head
Z. Hex keys
AA. Cable clamp
BB. Cable
DD. Padlock hole
EE. Override button
FF. Carrying handle (left and right)
GG. Inner flange
OPTIONAL ACCESSORIES (FIG. 3–6)
HH. Table end plate
II. Support guide rails
JJ. Material support plate
KK. Material clamp
LL. Swivelling stop
MM. Adjustable stand 760 mm (max. height)
NN. Legstand
H
FF
M
N
OO.
PP.
QQ.
RR.
V
Length stop for short workpieces (to be used with guide rails [II])
Roller table
Dust extraction tubes
Three-way connector
FIG. 4
JJ
FIG. 3
HH
II
JJ
KK
LL
OO
FIG. 5
NN
MM
MM
NN
4
U
PP
ASSEMBLY
WARNING: To reduce the risk of injury, turn unit off and disconnect
machine from power source before installing and removing accessories,
before adjusting or changing set-ups or when making repairs. Be sure the
trigger switch is in the OFF position. An accidental start-up can cause injury.
FIG. 6
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 interfere with the
proper operation of the saw.
3. 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 is firm on the mounting
surface.
5. Replace the outer flange (E), making sure that the location lugs (SS) are
engaged correctly, one on each side of the motor shaft.
6. Tighten the blade bolt (F) by turning anti-clockwise while holding the 6 mm
hex key (Z) engaged with your other hand (Fig. 10).
FIG. 10
Mounting the Saw Blade (Fig. 8–10)
WARNING: To reduce the risk of injury, turn unit off and disconnect
machine from power source before installing and removing accessories, before
adjusting or changing set-ups or when making repairs. Be sure the trigger
switch is in the OFF position. An accidental start-up can cause injury.
WARNING:The teeth of a new blade are very sharp and can be dangerous.
1. Insert the 6 mm hex key (Z) into the opposite location of the blade shaft
and hold it (Fig. 8).
FIG. 8
ADJUSTMENTS
WARNING: To reduce the risk of injury, turn unit off and disconnect
machine from power source before installing and removing accessories, before
adjusting or changing set-ups or when making repairs. Be sure the trigger
switch is in the OFF position. An accidental
start-up can cause injury.
Your mitre saw was accurately adjusted at the factory. 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.
RR
QQ
Q
Unpacking
The motor and guards are already assembled onto the base.
Cable Clamp (Fig. 7)
Adjusting the Traverse Bars for Constant Cutting Depth
(Fig. 1, 2, 11, 12)
Insert the cable (BB) into the cable clamp (AA). Allow enough cable for the saw
head to travel, then tighten the clamp by means of the screw.
Z
FIG. 7
BB
2. Loosen the blade bolt (F) by turning clockwise. Remove the blade bolt (F)
and the outer flange (E).
B
FIG. 9
AA
GG
SS
H
The blade must run at a constant cutting depth along the full length of the table
and must not touch the fixed table at the rear of the slot or at the front of the
rotating arm. To achieve this, the traverse arms must be perfectly parallel to the
table when the saw head is fully depressed.
1. Press the lower guard lock up release lever (B) (Fig. 1).
2. Press the saw head fully to the rear position and measure the height from
the rotating table (N) to the bottom of the outer flange (E) (Fig. 11).
E
FIG. 11
E
F
Bench Mounting (Fig. 2)
1. Holes (V) are provided in all four feet to facilitate bench mounting. The
holes are provided to accommodate different sizes of bolts. Use either
hole; it is not necessary to use both. Always mount your saw firmly to
prevent movement.
To enhance the portability, the tool can be mounted to a piece of 12.5 mm
or thicker plywood which can then be clamped to your work support or
moved to other job sites and reclamped.
2. When mounting your saw to a piece of plywood, make sure that the
mounting screws do not protrude from the bottom of the wood.
G
3. Press the lower guard lock up release lever (B) to raise the lower blade
guard (G) and remove the saw blade (H).
4. Install the new saw blade onto the shoulder provided on the inner flange
(GG) making sure that the teeth at the bottom edge of the blade are pointing
towards the fence (away from the operator).
5
N
3. Turn the saw head traverse lock (R) (Fig. 2).
4. Keeping the saw head fully depressed, pull the head to the end of its travel.
5. Measure the height indicated in Figure 11 again. Both values should be
identical.
6. If adjustment is required, proceed as follows (Fig.12):
FIG. 12
Checking and Adjusting the Blade to the Fence
(Fig. 2, 14, 15)
1. Slacken the mitre latch (M).
2. Place your thumb on the mitre arm (L) and squeeze the mitre latch (M) to
release the rotating table/mitre arm (N).
3. Swing the mitre arm until the latch locates it at the 0° mitre position.
4. Pull down the head and lock it in this position using the lock down button (W).
5. Check that the two 0° markings (WW) on the mitre scale (O) are just
visible.
6. Place a square (XX) against the left side of the fence (P) and blade (H).
WARNING: Do not touch the tips of the blade teeth with the square.
7. If adjustment is required, proceed as follows:
a. Loosen the screws (YY) and move the scale/mitre arm assembly left or
right until the blade is at 90° to the fence as measured with the square
(Fig. 14).
b. Retighten the screws (YY).
FIG. 14
VV
UU
Checking and Adjusting the Blade to the Table
(Fig. 16–19)
1. Loosen the bevel clamp handle (T) (Fig. 16).
2. Press the saw head to the right to ensure it is fully vertical and tighten the
bevel clamp handle.
3. Place a set square (XX) on the table and up against the blade (H) (Fig. 17).
WARNING: Do not touch the tips of the blade teeth with the square.
4. If adjustment is required, proceed as follows:
a.
Loosen the bevel clamp handle (T) and turn the vertical position
adjustment stop screw (ZZ) in or out until the blade is at 90° to the
table as measured with the square.
b.
If the bevel pointer (A1) does not indicate zero on the bevel scale
(U), loosen the screws (A2) that secure the scale and move the
scale as necessary.
FIG. 16
YY
N
TT
A3
a.
Loosen the locknut (TT) in the bracket (UU) under the upper dust
extraction nozzle (QQ) and adjust the screw (VV) as required,
proceeding in small steps.
b.
Tighten the locknut (TT).
WARNING: Always check that the blade does not touch the table at the
rear of the slot or at the front of the rotating arm at 90° vertical and 45° bevel
positions. Do not switch on before having checked this!
M
EE
O
Adjusting the Fence (Fig. 13)
Turn the sliding fence lock knob (I) anti-clockwise to loosen. Move the sliding
fence (P) to a position that avoids the blade cuts it,then tighten the fence lock
knob by turning clockwise.
WW
L
T
H
FIG. 15
FIG. 17
FIG. 13
I
P
H
XX
6
XX
Checking and Adjusting the Bevel Angle
(Fig. 1, 18, 19)
The bevel override allows the max. bevel angle to be set at 45° or 48° as
required.
Left = 45°
Right = 48°
1. Make sure the override knob (A3) is located in the left position.
2. Loosen the bevel clamp handle (T) and move the saw head to the left.
3. This is the 45° bevel position.
4. If adjustment is required, turn the stopscrew (A4) in or out as necessary
until the pointer (A1) indicates 45°.
WARNING: The guide grooves can become clogged with sawdust. Use a
stick or some low pressure air to clear the guide grooves.
FIG. 18
A3
Brushes
Body and Hand Position
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, 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 12.7 mm (1/2"), 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.
Proper positioning of your body and hands when operating the mitre saw will
make cutting easier, more accurate and safer.
WARNING:
• Never place your hands near the cutting area.
• Place your hands no closer than 150 mm (6") from the blade.
• Hold the workpiece tightly to the table and the fence when cutting. Keep
your hands in position until the switch has been released and the blade
has completely stopped.
• Always make dry runs (without power) before finish
cuts so that you can check the path of the blade.
• Do not cross your hands.
• Keep both feet firmly on the floor and maintain proper balance.
• As you move the saw arm left and right, follow it and stand slightly to
the side of the saw blade.
While “running in” DO NOT TIE, TAPE, OR OTHERWISE LOCK THE TRIGGER
SWITCH ON. HOLD BY HAND ONLY.
VERTICAL STRAIGHT CROSS CUT (FIG. 1, 20)
NOTE: Use 216 mm (8.5") saw blades with 30 mm arbor holes to obtain the
desired cutting capacities.
1. Slacken the mitre latch (M) and subsequently lift it up.
2. Engage the mitre latch (M) at the 0° position and fasten the mitre latch.
3. Place the wood to be cut against the fence (P).
4. Take hold of the carrying handle (C) and press the guard lock up release
lever (B) to release the guard. Press the trigger switch (A) to start the
motor. It is recommended to start the cut near the fence.
5. Depress the head to allow the blade to cut through the timber and enter the
plastic kerf plate (K).
6. When the head is fully depressed, slowly pull it across to complete the cut.
7. After completing the cut, release the switch and wait for the saw blade to
come to a complete standstill before returning the head to its upper rest
position.
WARNING:
• For some types of plastic profiles, it is advisable to follow the sequence
in reverse order.
• The lower blade guard is designed to close quickly when the lever (B) is
released. If it does not close within 1 second, have the saw serviced by
an authorised DEWALT repair agent.
OPERATION
T
ZZ
WARNING: To reduce the risk of injury, turn unit off and disconnect
machine from power source before installing and removing accessories, before
adjusting or changing set-ups or when making repairs. Be sure the trigger
switch is in the OFF position. An accidental start-up can cause injury.
Instructions for Use
EE
FIG. 19
A4
A2
U
A1
A2
WARNING: Always observe the safety instructions and applicable
regulations.
We recommend the use of a residual current device with a residual current
rating of 30mA or less.
WARNING:
• Install the appropriate saw blade. Do not use excessively worn blades.
The maximum rotation speed of the tool must not exceed that of thesaw
blade.
• Do not attempt to cut excessively small pieces.
• Allow the blade to cut freely. Do not force.
• Allow the motor to reach full speed before cutting.
• Make sure all locking knobs and clamp handles are tight.
• Secure the workpiece.
• Although this saw will cut wood and plastic materials,these operating
instructions refer to the cutting of wood only. The sameguide-lines apply
to the other materials. Do not cut ferrous (iron and steel) materials or
masonry with this saw! Do not use any abrasive discs!
• Make sure to use the kerf plate. Do not operate the machine if the kerf
slot is wider than 10 mm.
• Placing the workpiece on a piece of wood will increase the capacities to
300 mm.
Switching On and Off (Fig. 1)
A hole (DD) is provided in the on/off switch (A) for insertion of a padlock to
lock the tool.
1. To run the tool, press the on/off switch (A).
2. To stop the tool, release the switch.
7
Basic Saw Cuts
FIG. 20
VERTICAL MITRE CROSS-CUT (FIG. 21)
1. Squeeze the mitre latch (M). Move the arm left or right to the required
angle.
2. The mitre latch will automatically locate at 0°, 15°, 22.5°, 31.62°, 45° and
50° both left and right. If any intermediate angle is required hold the head
firmly and lock by fastening the mitre latch.
3. Always ensure that the mitre lock lever is locked tightly before cutting.
4. Proceed as for a vertical straight cross-cut.
WARNING: When mitring the end of a piece of wood with a small off-cut,
position the wood to ensure that the off-cut is to the side of the blade with the
greater angle to the fence, i.e.:
left mitre, off-cut to the right
right mitre, off-cut to the left
FIG. 21
Quality of Cut
The smoothness of any cut depends on a number of variables, i.e. the material
being cut. When smoothest cuts are desired for moulding andother precision
work, a sharp (60-tooth carbide) blade and a slower, even cutting rate will
produce the desired results.
WARNING: Ensure that the material does not creep while cutting; clamp it
securely in place. Always let the blade come to a full stop before raising the
arm. If small fibres 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.
Clamping the Workpiece (Fig. 3)
1. Whenever possible, clamp the wood to the saw.
2. For best results use the material clamp (KK) made for use with your saw.
Clamp the workpiece to the fence whenever possible. You can clamp to
either side of the saw blade; remember to position your clamp against a
solid, flat surface of fence.
WARNING: Always use a material clamp when cutting small pieces.
Compound Mitre (Fig. 23, 24)
This cut is a combination of a mitre and a bevel cut. This is the type of cut used
to make frames or boxes with slanting sides like the one shown in Figure 23.
FIG. 24
FIG. 23
CUTTING LARGE MATERIAL
WARNING: To reduce the risk of injury, always support long workpieces.
Figure 3 shows the ideal configuration for sawing long workpieces when the
saw is used free-standing (all items available as an option).
These items (except the legstand and the material clamp) are required both on
the infeed and the outfeed side:
– Legstand (NN) (supplied with mounting instructions).
– Guide rails (500 or 1,000 mm) (II).
– Stands (MM) to support the guide rails. Do not use the stands to support
the machine! The height of the stands is adjustable.
– Material support plates (JJ).
– Table end plate (HH) for supporting the rails (also when working on an
existing bench).
– Material clamp (KK).
– Swivelling stop (LL).
1. Place your saw on the legstand and fit the guide rails.
2. Firmly screw the material support plates (JJ) to the guide rails (II).
3. The material clamp (KK) now functions as a length stop.
4. Install the table end plates (HH).
5. Install the swivelling stop (LL) to the rear rail.
6. Use the swivelling stop (LL) to adjust the length of medium and long
workpieces. It can be adjusted sideways or swung out of the way when
not in use.
Dust Extraction (Fig. 1, 6)
BEVEL CROSS-CUTS (FIG. 18, 22)
Bevel angles can be set from 0° to 48° to the left. Bevels up to 45° can be cut
with the mitre arm set between zero and a maximum of 45° mitre position right
or left.
1. Loosen the bevel clamp handle (T) and set the bevel as desired.
2. Set the override button (EE) if required.
3. Hold the head firmly and do not allow it to fall.
4. Tighten the bevel clamp handle (T) firmly.
5. Proceed as for a vertical straight cross-cut.
FIG. 22
WARNING: If the cutting angle varies from cut to cut, check that the bevel
clamp handle and the mitre clamping knob are securely tightened. These must
be tightened after making any changes in bevel or mitre.
• The chart on page 11 will assist you in selecting the proper bevel and mitre
settings for common compound mitre cuts.
• To use the chart, select the desired angle “A” (Fig. 24) 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 mitre angle.
1. Set your saw to the prescribed angles and make a few trial cuts.
2. Practice fitting the cut pieces together.
Example: To make a four-sided box with 25° exterior angles
(angle “A”) (Fig. 24), use the upper right arc. Find 25° on the arc scale.
Follow the horizontal intersecting line to either side to get the mitre angle
setting on the saw (23°). Likewise follow the vertical intersecting line to the
top or bottom to get the bevel angle setting on the saw (40°). Always try
cuts on a few scrap pieces of wood
to verify the settings on the saw.
WARNING: Never exceed the compound mitre limits of 45° bevel with 45°
left or right mitre.
Support for Short and Long Pieces (Fig. 3)
CUTTING SHORT MATERIAL
It is advisable to use the length stop (OO) for short workpieces both for batch
sawing and for short individual workpieces of different lengths. The length stop
can only be used in conjunction with a pair of optional guide rails (II).
8
WARNING: Whenever possible, connect a dust extraction device designed in
accordance with the relevant regulations regarding dust emission.
Connect a dust collection device designed in accordance with the relevant
regulations. The air velocity of externally connected systems shall be 20m/s
+/- 2 m/s. Velocity to be measured in the connection tube at the point of
connection, with the tool connected but not running.
A separate dust kit is available as an option (DE7777).
1. Fit the dust extraction tubes (QQ) to the nozzles (Q); the longer hose
to upper nozzle.
2. Connect the hoses to the three-way connector (RR).
Transporting (Fig. 1)
WARNING: In order to conveniently carry the mitre saw, the base is provided
with two hand indentations (FF).
1. To transport the saw, set the bevel and mitre positions to 0°.
2. Press the lower guard lock up release lever (B) (Fig.1).
3. Press the head down and press the lock down button (W) (Fig. 2).
4. Bring the saw blade to rest position and press the traverse lock (R).
MAINTENANCE
WARNING: To reduce the risk of injury, turn unit off and disconnect
machine from power source before installing and removing accessories,
before adjusting or changing set-ups or when making repairs. Be sure the
trigger switch is in the OFF position. An accidental start-up can cause injury.
WARNING: If the saw blade is worn replace it with a new sharp blade.
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 on page 7 or return the tool to the
nearest service center for repair. Service center locations are packed with
your tool.
USING THE ROLLER TABLE (FIG. 3–5)
The roller table (PP) makes the handling of large and long pieces of wood
very easy (Fig. 5). It can be connected either to the left or to the right of the
machine. The roller table requires the use of the optional legstand (Fig. 3).
WARNING: Assemble the roller table following the instructions supplied with
the legstand.
• Replace the short support bars provided with the legstand with the irregular
rails from the table on the side the table is to be used.
• Follow all instructions provided with the roller table.
TROUBLESHOOTING GUIDE
WARNING: TO REDUCE THE RISK OF INJURY, BE SURE TO FOLLOW SAFETY RULES AND INSTRUCTIONS
WHAT’S WRONG?
WHAT TO DO
1. Saw not plugged in
1. Plug in saw.
2. Fuse blown or circuit breaker tripped
2. Replace fuse or reset circuit breaker.
3. Cord damaged
3. Have cord replaced by authorised service center.
4. Brushes worn out
4. Have brushes replaced by authorised service center
or replace them yourself as instructed in Brushes
paragraph under Adjustments.
1. Dull blade
1. Replace blade, refer to Mounting the Saw Blade
paragraph under Assembly.
2. Blade mounted backwards
2. Turn blade around, refer to Mounting the Saw
Blade paragraph under Assembly.
Service Information
3. Gum or pitch on blade
Please have the following information available for all service calls:
Model Number __________________ Serial Number __________________
Date and Place of Purchase ______________________________________
3. Remove blade and clean with turpentine and
coarse steel wool or household oven cleaner.
4. Incorrect blade for work being done
4. Change the blade type, refer to Saw Blades under
Optional Accessories.
1. Extension cord too light or too long
1. Replace with adequate size cord, refer to Use
Proper Extension Cord under Safety Instructions
For All Tools.
2. Low house voltage
2. Contact your electric company.
1. Saw not mounted securely to stand or
work bench
1. Tighten all mounting hardware, refer to Bench
Mounting paragraph under Assembly.
2. Stand or bench on uneven floor
2. Reposition on flat level surface, refer to Bench
Mounting paragraph under Assembly.
3. Damaged saw blade
3. Replace blade, refer to Mounting the Saw Blade
paragraph under Assembly.
1. Mitre scale not adjusted correctly
1. Check and adjust, refer to Checking and
Adjusting the Blade to the Fence paragraph
under Adjustments.
2. Blade is not square to fence
2. Check and adjust, refer to Checking and
Adjusting the Blade to the Fence paragraph
under Adjustments.
3. Blade is not perpendicular to table
3. Check and adjust fence, refer to Checking and
Adjusting the Blade to the Table paragraph under
Adjustments..
4. Workpiece moving
4. Clamp workpiece securely to fence or glue
120 grit sandpaper to fence with rubber cement.
Repairs
To assure product SAFETY and RELIABILITY, repairs, maintenance and
adjustments should be performed by a DEWALT factory service center, a
DEWALT authorised service center or other qualified service personnel. Always
use identical replacement parts.
TROUBLE!
SAW WILL NOT START
SAW MAKES UNSATISFACTORY CUTS
BLADE DOES NOT COME UP TO
SPEED
MACHINE VIBRATES EXCESSIVELY
DOES NOT MAKE ACCURATE
MITRE CUTS
9
TABLE 1: COMPOUND MITRE CUT (POSITION WOOD WITH BROAD FLAT SIDE ON THE TABLE AND THE NARROW EDGE AGAINST THE FENCE)
10
20
30
40
E
R
UA
SQ
50
X
BO
10
20
60
30
SI
6-
SET THIS MITRE
ANGLE ON SAW
DE
40
D
ANGLE OF SIDE OF
BOX (ANGLE A)
BO
X
10
20
50
ED
SID
8-
30
70
X
BO
40
60
MITRE DEGREE SETTING
50
60
70
80
70
80
80
BEVEL DEGREE SETTING
SET THIS BEVEL ANGLE ON SAW
10
Stanley Black & Decker
82 Taryn Drive, Epping, VIC 3076 Australia • 1800 338 002 (Aust) or 0800 339 258 (NZ)
www.dewalt.com.au • www.dewalt.co.nz
(OCT13)
Part No. N363281
DW777-XE
Copyright © 2009, 2013 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.
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