EUROPEAN SERVICE REPAIR TRAINING

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EUROPEAN SERVICE REPAIR TRAINING

• DW718 Mitre Saw

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EUROPEAN SERVICE REPAIR TRAINING
Contents

• Service Tooling Application and Use 5.3
• Illustrated Tips 5.4
• 6 Summary Repair Notes
• Useful Information 6.1
• Strip Down / Repair / After Repair 6.2
• Safety Notes 6.3
• 7 Modifications Product Updates
• Engineering News 7.1
• Quality Changes 7.2
• 8 Additional Training Information
• Battery Performance 8.1
• Battery Tester 8.2
• Hammer Mechanism 8.3
• Good Practices 8.4
• Cordless Motor test unit 8.5

• 1 Training - House Rules
• 2 Product Information
• Customer Requirements 2.1
• Marketing Information 2.2
• Features Benefits 2.3
• Applications 2.4
• Technical Information/Specifications 2.5
• 3 Service Drawings
• 4 Repair Instructions
• Diagnosis and Root Cause 4.1
• Strip Down Guidelines/Procedures 4.2
• Repair Assembly Guide 4.3
• 5 Video Animation Instructions
• Disassembly 5.1
• Re-assembly 5.2

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1 Training - House Rules

• Start and Finish times
• Tea / Coffee Breaks
• Lunch
• Mobile Phones
• Smoking
• Questions
• Break out Groups
• Taking Notes
• Points to Remember

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2 Product Information
Customer Requirements
2.1
Slide Mitre Saw CTQ Research
Finish Cut Quality Ease of Use Fence System
Bevel Detents
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2 Product Information
Marketing Information
2.2
DW718-QS DW718-GB DW718-LX DW718V-QS DW718V-GB DW
718V-LX DW718-B4 DW718-XE
V indicates factory fitted laser system
DW708 WILL BE DISCONTINUED FROM AUGUST 2005
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2 Product Information
Marketing Information
2.2
DW718 - 305mm Compound Slide Mitre Saw

• Cam action mitre lock function makes mitre
  setting faster and easier allowing the user to
  quickly adjust angles between 0 - 60 left and
  0 - 50 right
• The innovative grooving stop allows the
  adjustment of the cutting depth for grooving and
  rebating applications.
• The large dual sliding fence gives maximum
  support in large material cuts at any angle or
  combination of angles.
• Linear horizontal rails utilise bronze guides to
  provide maximum precision when cutting materials
  up to 345mm wide.
• New quick release bevel setting provides accurate
  and simple setting of bevel angles up to 48 left
  and right.
• Compact and lightweight design characteristics
  deliver a saw with enormous capacity which is
  easy to transport around the jobsite

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2 Product Information
Features Benefits
2.3
1. Improved Accuracy 2. Improved Cut
Quality 3. Greater Horizontal Capacity 34
Greater than the competition 4. Greater
Vertical Capacity 5. Improved Miter System 6.
Smaller Size 7. Lighter Weight 8. Improved
Bevel System 9. Sustaining 305mm Share
Fence, bevel and detent plates
Rpm, Clamp Washer, Plate Thickness
25 Greater than the competition
Cam lock, detent plate, lock off
19 lt 708, only 8 gt 250mm saws
Improved center of gravity
Absolute domination
9 Positive stops
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2 Product Information
Features Benefits
2.3.1
DW718
Accuracy

• New Precise Mitre Bevel System

• New Step-Up Machined Fence Support

• New Rail Support Clamp System

Capacity

• New Design Delivers Best-in-Class Crosscut
  Capacity

• Tall Fence Design Delivers Highest Vertical
  Capacity in its Class (160mm Baseboard)

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2 Product Information
Features Benefits
2.3.2
DW718
Ease of Use

• DEWALT Laser Compatible

• Thumb Actuated Mitre Lock

• New Easy Access Bevel Lock

• New Bevel Detent System

Portability

• Smallest 305mm Slide Miter Saw
  Packs up Smaller than Hitachi 250mm Slide

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2 Product Information
Features Benefits
2.3.3
Accuracy Improvements - Improve fence
straightness - Fence perpendicularity -
Table post - Mitre detent spring Cut
Quality 0.1mm - ? blade washer size 66mm
- New DEWALT blade 2mm plate Horizontal
Cutting Capacity - At Base Fence 355mm
- At Secondary Fence 406mm Vertical Cutting
Capacity - At Fence 163mm - At Full
Extension 91mm Mitre System - Right
Capacity 60 - Left Capacity 50
- Detent System Hard
Size - Height 396mm
- Length 470mm - Width
770mm Weight
24.8kg Grooving 150mm Bevel
System - of Detents 9 -
Degree of Detents
0,22.5,33.9,45,48 - Detent Setting Location
Trunion - Scale Location
Trunion - Tightening Location
Trunion Rail System - Design
Horizontal - Diameter 25mm
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2 Product Information
Applications
2.4

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2 Product Information
Technical Information / Specifications
2.5
Voltage 230 115
Frequency 50 50
Armature / Rotor Resistance 0.95O 0.28O
Field / Stator Resistance Run 0.81O 0.17O
Field / Stator Resistance Brake 6.50O 1.55O
Initial Brush Length 21.5mm 21.5mm
No Load Speed / RPM 1900-3400 1900-3400
Input Watts 1600 1600
Output Watts 960 960

No Load Amps (Cordless Motors)
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3 Service Drawings
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3 Service Drawings

• Handle Wiring
• Motor Cable
• White - connects to Red from
• Electronic Module.
• Yellow - connects to Terminal 2 on
• switch Bottom.
• Red - connects to Terminal 2 on
• switch Top.
• Black connects to Terminal 1 on
• switch Top.
• Electronic Module
• Red - connects to White from the
• motor.
• White - connects to White from
• the connector block plus
• Black from the suppressor.
• Black - connects to Terminal 1 on

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4 Repair Instructions
Diagnosis and Root Cause
4.1

• Diagnosis
• Check the unit is not plugged in
• Check Cable
• Check whether blade is tight
• Check condition of blade
• Check condition of drive belt
• Check guard operation
• Plug unit in
• Quick test and check all functions
• Make a test cut
• Check for accuracy

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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2
Blade Removal
Hold guard in the up position and loosen the
guard plate screw. Hold in the spindle lock pin
and use spanner supplied to remove the blade
bolt. Undo bolt in a clockwise direction
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.1
Guard Removal
Remove 2 Torx 20 screws as shown by red arrows
and remove the guard linkage
Remove 2 Torx 20 screws as shown by red arrows
and remove the guard
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.2
Removal of Switch Handle
Remove 2 screws and lift off access panel. This
is where the laser plugs in. Remove 1 screw and
remove the handle. Remove ?? Screws and remove
handle cover. Note how handle is wired and
unplug/unscrew all connections. Remove handle.
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.3
Wiring Layout

• Motor Cable
• White - connects to Red from Electronic Module.
• Yellow - connects to Terminal 2 on switch
  Bottom.
• Red - connects to Terminal 2 on switch Top.
• Black connects to Terminal 1 on switch Top.
• Electronic Module
• Red - connects to White from the motor.
• White - connects to White from the connector
  block plus Black from the suppressor.
• Black - connects to Terminal 1 on switch - Bottom
  plus Black from the suppressor.
• White/Orange Plugs into the potentiometer.

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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.4
Removal of Belt cover Electronics
Belt cover can be removed Electronic module can
be removed by undoing 1 Torx 20 screw. Please
handle this component with care
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.5
Removal of Belt Motor
Measure belt at centre before removal appx 10
mm at centre. Slacken belt tension screw Remove
belt Remove 6 screws Remove motor
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.6
Motor Disassembly
Normal procedure to dismantle motor Note
condition of brushes and run time Appx 1mm of
wear per 10 hours
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.7
Motor Disassembly
1
2
3
1 Care to be taken with field leads 2 Field
inserts can be damaged 3 Cable clamp can be
released 4 Note black side to brushes
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.8
Motor Disassembly
Correct orientation of field and field case
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.9
Field Armature Checking resistances
Armature and field coil readings can be checked
per specifications
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.10
Arm Removal
Arm MUST be taken to the 90 degree
position Damaged will occur if this is note done
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.11
Arm Removal
Spring must be free
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.12
Arm Removal
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1
2
1.Loosen 2 grub screws 2. Return arm to 90
degree 3. Remove pin 4. Check condition of
washers
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.13
Pulley and Gear Removal

• Spindle and pulley is complete sub assembly

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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.14
Bevel Lock
Remove back cover to expose bevel lock system
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.15
Bevel Lock
Bevel detent lever and spring and how it works
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.16
Bevel Lock
Bevel detent lock removed
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.17
Bevel Lock
How the system works
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.18
Fence Removal
1
3
2
1 2 Remove 5 torx 40 screw to lift fence off 3.
New fence recess to aid fence set up in service
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.19
Mitre Latch
Mitre latch system
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.20
Mitre Latch
Correct layout
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4 Repair Instructions
Strip Down Guidelines / Procedures
4.2.21
Table Removal
Inner table removal
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5 Video Animation Instructions
Service Tooling Application and Use
5.3
Service Tool 559626-99 must be used to check and
reset if required the saw blade set up
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6 Summary Repair Notes
Useful Information
6.1