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REPAIR INFORMATION
DW708
MITRE SAW
JUNE 1998
DW708 MITRE SAW - STRIDOWN PROCEDURE
The machine consists of two main assemblies, the motor and guard (Head Assy.)
and the rotary table and base (Table Assy.). These elements are connected by
means of a bevel housing, that also supports the crosscut pull bars.
The procedure that follows is intended only as a guide, and the product can be
repaired or taken apart in a different sequence if required. Before commencing any
stripdown or repair work you should refer to the use Instruction manual to familiarise
yourself with the major components of the product. You should read and pay
particular attention to the safety Instructions in the manual.
The Instruction manual also contains useful advise on the setting up procedure to
ensure accuracy of cut following any repair work.
Make sure the tool is unplugged before commencing any repairs or
adjustment.
MOTOR & GUARD ASSEMBLY.
Before starting remove the blade (if fitted) as follows :
Press down on the handle (101) and pull out the head lock pin (118) to allow the
head assy. to come up into the normal cutting position when you depress the guard
lock lever (180).
This will now allow you to access the blade cover plate screw (10).
Loosen the screw and swing the plate up so that you can see the blade bolt (12).
Undo the left hand threaded blade bolt, remove the outer clamp washer (77) and
take off the blade. You can now remove the inner clamp (79).
Before removing the motor from the body of the machine you must free up the motor
cable.
Take off the cable cover plate (97) by removing the screws (26).
Now lock the head assy. back down in the transit position to make it easier to work
on.
Remove the switch handle cover screws (30,11) and lift off the cover. You can now
remove the handle to casting fixing screw (9), the handle can now be moved free
from the casting, and also allow the cable to be moved as required.
At this point you can also access the switch, leads, and capacitor. Before
disconnecting any of the leads make a note of the connections (also refer to the
wiring diagram attached). Note also that the leads are retained and routed in the
handle by plastic fins to prevent them being trapped upon reassembly.
Now take off the belt cover (104) by removing the screw (7) and remove the belt by
pulling, and at the same time feeding it off the pulley.
The motor is detached from the arm casting (102) by first removing the six fixing
screws (8).
Take off the motor, which can now be worked on further as required.
To remove the armature and field take out the four screws (1) that fix the fieldcase
to the bearing housing (94), and take the motor apart.
The armature pulley (69) is fixed to the armature with two keys (74), a screw (4),
lockwasher (39), and a flat washer (38). The pulley position on the armature is
maintained by a circlip (44).
When taking the motor apart take care not to lose the dust seals (103).
Page 1
When re-assembling the motor, carefully position the motor cable in the correct
position so that it cannot be trapped.
Note that the two "lugs" on the bearing housing (94) fit into the two larger slots of
the arm casting assy. (102) when putting the motor back onto this housing. (see
drawing "A").
The pulley belt tension is adjusted by the adjusting screw (19) located in the
bearing housing (94).
If the guard or gearcase parts need to be removed proceed as follows :
Release the head lock and guard lock levers to allow the head to come up into the
normal cutting position.
To remove the upper guard casting (105) undo the screws (31) and lift off the
casting, this will now allow you access to the linkage (110) and lower guard (109).
The linkage is removed by undoing the screw (16), then taking off the bush (113).
Remove the screw (27), washer (36), and bush (114) at the other end of the linkage,
and then lift the linkage clear. When re-assembling the linkage ensure that the
roller goes over the "runner" part of the casting (102), and not under it. (drawing "B")
To remove the plastic guard (109) undo the screws (6) and lift off the plate (82),
taking care as the tension of the guard spring (54) will be released as you undo the
screw ! The guard can now be taken off of the machine.
By removing the plate (82) you can now take off the gearcase, and replace any
components inside as required.
When re-assembling the plastic guard, the spring (54) must be located in the hole in
the guard, and the hole in the plate (82). Push the guard and plate up to the
gearcase and turn the plate to position the screw holes to line up with the screw
holes in the gearcase, whilst ensuring that the spring is still located in he holes of
both the guard and plate.
HEAD TORSION SPRING REMOVAL.
Before moving onto the table assembly the motor and head assy. casting (102)
needs to be removed from the bevel housing support (130).
Lock the head down, and then remove the screws (17) that hold the pin (115) in
position. You can now release the head lock after undoing the screws.
Remove the grub screws (13), release the cable clamp (128) from the end cap
housing, this is done by using a pair of pliers to nip the plastic clamp together, and
then pulling the clamp out of the end cap housing (127).
The end cap can be carefully tapped off the bars (12) making sure that you do not
damage either the end cap or bars.
Loosen the screws (15) that fix the guide bushes (123), and slacken the rail lock
lever (126) to allow the bars (121) to be pulled out of the support housing (130).
The complete bar assembly can now be pulled through the support housing.
Once removed turn this assembly over so that it is upside down, enabling you to see
the underneath of the spring(60). It will be easier if you clamp the assembly in a
vice whilst working on this section.
With the screws (17) released you can now knock the pin (115) out of the bracket
(121), (drawing "C") this will release the tension of the spring which can then be
removed together with the plastic bushes (116). Note which way around the plastic
bushes are fitted.
Page 2
Take care not to lose or damage the two plastic shims (42) when removing the
bracket part of the casting (102) from the bar and bracket (121).
To re-assemble, make sure that the plastic shims (42) are fitted to the arm assembly
casting (102).
Position the bars and bracket (121) over the casting (102).
Use a spare pin (115) to assist in this next part of the assembly.
Knock the original and spare pin into both ends of the brackets to align them, with
the pins flush with the inner faces of the brackets. This will make it easier to knock
the original pin through the assembly once the spring and plastic bushes are fitted.
Put the two plastic bushes (116) inside the spring (60) and place the spring inside
the casting (102)..
When you put the spring in the casting you must ensure that the two ends of the
spring are located into the appropriate slots, one in the casting (102), and one in the
bars bracket (121).
Knock the pin carefully all the way through the brackets, spring, and plastic bushes.
(check that the pin does not foul on the plastic bushes as it is knocked through).
Refit the complete bar assembly to the support housing (130) and fit/tighten the
screws (17) to lock the pin in place.
FIXED & ROTARY TABLES.
Before taking the tables apart remove the base fences (157, 158).
Remove the back fence (156) - note that the fixing screws (28) are very tight and an
impact wrench may be required to remove them.
Undo the nut (33) and remove the bolt (32) and washer (34) together with the
washer (36) fitted between the fixed and rotary tables, enabling the two tables to be
separated.
Once separated make sure that the wear plates (154) are correctly located on the
fixed table, and not stuck onto the rotary table. This will make the re-assembly
easier (also note that the wear plates are fitted into the slots of the fixed table, and
can only be fitted the one way).
The adjustable scale (140) can be removed if required by taking out the screws (10).
If you only need to replace the mitre lock lever (143, 144) this can be done without
having to take the tables apart.
Knock out the pin (142) - note that one end of the pin is knurled, and therefore
should only be knocked out from the opposite end of the pin.
The lever (143) and spring (56) will come free with the pin (142) removed.
To take off the trigger (144) you need to grip the rod (145) witha pair of pliers, then
unscrew the trigger and pivot pin (146) by turning this assembly until it unscrews off
of the rod.
The rod and spring plates (148) can be removed by taking out the screws (7), the
complete assembly is available as a spare part item 173.
When re-assembling make sure that the pin (142) is knocked back in the correct
way, so that the knurled part of the pin is in the same position as it was taken out,
do not knock the knurled part through the non knurled part of the table bracket (137)
(drawing "D").
Page 3
ADJUSTMENT.
Please refer to the Instruction manual for details on how to adjust the blade to the
fence, the mitre pointer, mitre lock adjustment, and bevel adjustments.
To adjust the bevel stop there are three bevel stop pins :
*Top right (as you face the machine) is to adjust the blade 90 degrees to the fence.
*Top left is to adjust the 45 degrees left bevel angle.
*Bottom right is to adjust the 45 degree right cut angle.
As stated previously it is important that you read the Instruction manual, and in
particular the Safety Instructions. The procedure is only a preliminary guide, and
modifications to the drawing, parts lists, components may take place during the
products life.
Page 4
TYP.
DW708
1998
A
B
C
D
TYP.
DW708
1
03 / 06 / 98
E12374 / 234444
85
91
84
3
170
90
165
164
106
108
10
6
31
39
105
107
110
111
113
16
20
10
83
92
89
87
61
88
2
45
44
62
19
94
12
77
79
6
82
54
81
10
66
75
76
48
67
72
47
112
109
100
11
30
29
99
9
101
24
96
180
181
182
93
177
179
178
176
97
26
103
119
58
8
50
69
71
104
7
102
70
4
39
38
74
46
73
55
37
1
183
TYP.
1
03 / 06 /98
E12498 / 234444
DW708
5
131
163
95
133
130
126
123
15
127
129
128
13
125
41
22
6
136
18
124
22
41
125
124
52
171
40
68
134
121
115
13
135
57
118
42
51
17
116
60
120
43
23
6
9836
27
114
157
158
167
28
159
156
138
5
149
33
34
36
174
5
132
5
141
86
137
139
32
175
5
154
166
168
152
153
10
140
7
142
146
148
147
145
144
56
143
49
53
35
173
TYP.
DW708 WIRING DIAGRAM
1
03 / 06 / 98
E12540
ARMATURE
FIELD COIL FIELD COIL
CAPACITOR
BLUE MAINS
BROWN MAINS
CONNECTOR
BLOCK
WHITE
CONNECTOR
LEAD
BLACK
CAPACITOR LEADS
BLACK
CONNECTOR
LEAD
SCHEMATIC WIRING DIAGRAM
WHITE
FIELD LEAD BLACK
CAPACITOR
LEAD
WHITE
CONNECTOR LEAD
BLACK
FIELD LEAD
BLACK
CAPACITOR
LEAD
BLACK
CONNECTOR LEAD
MAINS CORD
ELECTRICAL
CORD
BROWN
MAINS LEAD
BLACK
CONNECTOR LEAD
BLUE
MAINS LEAD
BLACK
FIELD LEAD
CAPACITOR
WHITE
FIELD LEAD
WHITE CONNECTOR
LEAD
BLACK
CAPACITOR LEAD
ENGLISH FRENCH ITALIAN
GERMAN
BLACK NOIR NERO SCHWARZ
WHITE BLANC BIANCO WEISS
BROWN BRUN MARRONE BRAUN
BLUE BLEU BLU BLAU
RED ROUGE ROSSO ROT
YELLOW JAUNE GIALLO GELB
GREEN VERT VERDE GRUN
ORANGE ORANGE ARANCIO ORANGE
GREY GRIS GRIGIO GRAU
COLOUR KEY
CLEAR
.
.
KLAR
DW708-----A 23/06/98
-------------------------------------------------------------------
ITEMDESCRIPTION PART NO. QTY VARIANT DESCRIPTION
1 SCREW 98094-55 4
2 SCREW 330019-19 2
3 SCREW 330019-20 2
4 SCREW 153778-00 2
5 SCREW 330045-05 10
6 SCREW 330045-13 8
7 SCREW 330045-14 3
8 SCREW 330045-15 6
9 SCREW 330045-18 1
10 SCREW.TEMP 330045-23 10
11 SCREW 330045-20 3
12 SCREW 145344-01 1
13 SCREW 153666-00 4
15 SCREW 153637-00 2
16 SCREW 153720-00 1
17 SCREW 150075-00 2
18 SCREW 153576-00 2
19 SCREW 153625-00 1
20 SCREW.SPECIAL 144949-00 1
22 SCREW 151799-00 2
23 SCREW 153639-00 1
24 SCREW TERMINAL 791707-00 4
26 SCREW.TEMP 330045-06 4
27 SCREW 330045-47 1
28 SCREW 330045-33 4
29 SCREW 330019-03 1
30 SCREW 330019-14 4
31 SCREW 330045-24 3
32 SCREW 153787-00 1
33 NUT 153794-00 1
34 WASHER 153792-00 1
35 WASHER 62487-00 1
36 WASHER 153781-00 2
37 WASHER 153559-00 1
38 WASHER 153782-00 2
39 WASHER 98198-05 5
40 WASHER 153769-00 2
41 WASHER 153586-00 2
42 WASHER 148296-00 2
43 WASHER 153655-00 1
44 CIRCLIP 144803-00 1
45 RETAINER 380245-00 1
46 O RING 153753-00 1
47 RING 142273-00 2
48 O RING 153752-00 1
49 O RING 153763-00 1
50 O RING 153783-00 1
51 SEAL 34158-00 1
52 O RING 385717-00 1
53 SPRING 140733-00 1
54 SPRING 153604-00 1
55 SPRING 448176-00 1
56 SPRING 96723-00 1
DW708-----A 23/06/98
-------------------------------------------------------------------
ITEMDESCRIPTION PART NO. QTY VARIANT DESCRIPTION
57 SPRING 88165-00 1
58 SPRING 168507-00 1
60 SPRING 153596-01 1
61 BEARING 330003-09 1
62 BEARING 330003-48 1
66 BEARING 131790-00 1
67 BEARING 330003-47 1
68 BEARING 65786-00 1
69 DRIVE PULLEY 153554-00 1
70 PULLEY 153556-00 1
71 BELT 153555-00 1
72 GASKET 153560-00 1
73 LOCKING PIN 153561-00 1
74 KEY 153638-00 3
75 GEARCASE COVER 153754-00 1
76 SHAFT 153553-00 1
77 BLADE CLAMP 152635-01 1 M-AT-BE-DE-ES-FR-GR-IT
77 BLADE CLAMP 153645-01 1 M-B1
77 BLADE CLAMP 152635-01 1 M-CH
77 BLADE CLAMP 152635-01 1 M-DK-FI-NO-SE-PT
77 BLADE CLAMP 152635-01 1 M-GB
77 BLADE CLAMP 153645-01 1 M-XD
77 BLADE CLAMP 153645-01 1 M-XE
77 BLADE CLAMP 152635-01 1 T-GB115V
79 ARBOR 153645-00 1
81 SLEEVE 153649-00 1
82 COVER 153563-00 1
83 FIELDCASE 146709-02 1
84 END CAP 148678-01 1
85 NAMEPLATE 149521-01 1
86 STOP 153788-00 3
87 SLEEVE 137382-01 1
88 ARMATURE 230V 153646-03 1 M-AT-BE-DE-ES-FR-GR-IT
88 ARMATURE 230V 153646-03 1 M-B1
88 ARMATURE 230V 153646-03 1 M-CH
88 ARMATURE 230V 153646-03 1 M-DK-FI-NO-SE-PT
88 ARMATURE 230V 153646-03 1 M-GB
88 ARMATURE 230V 153646-03 1 M-XD
88 ARMATURE 230V 153646-03 1 M-XE
88 ARMATURE 115V 153646-02 1 T-GB115V
89 FIELD 144798-01 1 M-AT-BE-DE-ES-FR-GR-IT
89 FIELD 144798-01 1 M-B1
89 FIELD 144798-01 1 M-CH
89 FIELD 144798-01 1 M-DK-FI-NO-SE-PT
89 FIELD 144798-01 1 M-GB
89 FIELD 144798-01 1 M-XD
89 FIELD 144798-01 1 M-XE
89 FIELD 115V 144797-03 1 T-GB115V
90 BRUSH & HOLDER 147097-06 2 M-AT-BE-DE-ES-FR-GR-IT
90 BRUSH & HOLDER 147097-06 1 M-B1
90 BRUSH & HOLDER 147097-06 2 M-CH
90 BRUSH & HOLDER 147097-06 2 M-DK-FI-NO-SE-PT
90 BRUSH & HOLDER 147097-06 2 M-GB
DW708-----A 23/06/98
-------------------------------------------------------------------
ITEMDESCRIPTION PART NO. QTY VARIANT DESCRIPTION
90 BRUSH & HOLDER 147097-06 1 M-XD
90 BRUSH & HOLDER 147097-06 1 M-XE
90 BRUSH HOLDER 147097-05 2 T-GB115V
91 NAMEPLATE 384838-00 1 M-AT-BE-DE-ES-FR-GR-IT
91 NAMEPLATE 384838-01 1 M-CH
91 NAMEPLATE 384838-00 1 M-DK-FI-NO-SE-PT
91 NAMEPLATE 384838-03 1 M-GB
91 NAMEPLATE 384838-02 1 T-GB115V
92 BAFFLE 146723-01 1 M-AT-BE-DE-ES-FR-GR-IT
92 BAFFLE 146723-01 1 M-B1
92 BAFFLE 146723-01 1 M-CH
92 BAFFLE 146723-01 1 M-DK-FI-NO-SE-PT
92 BAFFLE 146723-01 1 M-GB
92 BAFFLE 146723-01 1 M-XD
92 BAFFLE 146723-01 1 M-XE
92 BAFFLE 383064-00 1 T-GB115V
93 LEAD SA 381740-00 1 M-AT-BE-DE-ES-FR-GR-IT
93 LEAD SA 381740-00 1 M-B1
93 LEAD SA 381740-00 1 M-CH
93 LEAD SA 381740-00 1 M-DK-FI-NO-SE-PT
93 LEAD SA 381740-00 1 M-GB
93 LEAD SA 381740-00 1 M-XD
93 LEAD SA 381740-00 1 M-XE
93 LEAD 385561-00 1 T-GB115V
94 PLATE SA 153564-00 1
95 CORDSET 330048-10 1 M-AT-BE-DE-ES-FR-GR-IT
95 CABLE 380651-07 1 M-B1
95 CABLE & PLUG 330048-31 1 M-CH
95 CORDSET 330048-10 1 M-DK-FI-NO-SE-PT
95 CORDSET (M/PLUG) 330060-02 1 M-GB
95 CORDSET (M/PLUG) 330060-02 1 M-XD
95 CABLE SA 330048-38 1 M-XE
95 CORDSET 330061-03 1 T-GB115V
96 CONNECTOR 32114-06 1
97 COVER 153647-00 1
98 CORD CLAMP 153669-00 1
99 SWITCH 153749-01 1 M-AT-BE-DE-ES-FR-GR-IT
99 SWITCH 153749-01 1 M-B1
99 SWITCH 153749-01 1 M-CH
99 SWITCH 153749-01 1 M-DK-FI-NO-SE-PT
99 SWITCH 153749-01 1 M-GB
99 SWITCH 153749-01 1 M-XD
99 SWITCH 153749-01 1 M-XE
99 SWITCH 115V 153609-00 1 T-GB115V
100 PLUG 153756-00 1
101 CLAMSHELL PAIR 153755-01 1
102 ARM LINK 383331-01 1 M-AT-BE-DE-ES-FR-GR-IT
102 ARM LINK 383331-00 1 M-B1
102 ARM LINK 383331-01 1 M-CH
102 ARM LINK 383331-01 1 M-DK-FI-NO-SE-PT
102 ARM LINK 383331-01 1 M-GB
102 ARM LINK 383331-00 1 M-XD
102 ARM LINK 383331-00 1 M-XE
DW708-----A 23/06/98
-------------------------------------------------------------------
ITEMDESCRIPTION PART NO. QTY VARIANT DESCRIPTION
102 ARM LINK 383331-01 1 T-GB115V
103 FOAM 153721-00 2
104 BELT COVER 153562-00 1
105 GUARD UPPER 153648-01 1
106 IDENTITY LABEL 149365-01 1
107 DUST EXTRACTOR 153567-00 1
108 TUBE UPPER 151949-00 1
109 GUARD LOWER 153602-02 1
110 LINKAGE SA 153719-00 1
111 BUMPER 145318-00 1
112 ROLLER 146774-00 1
113 SLEEVE 146740-00 1
114 BUSHING 146753-00 1
115 SHAFT 146751-00 1
116 SPACER 153593-00 2
118 LOCKING PIN 153600-00 1
119 KNOB 153677-00 1
120 STOP 153603-00 1
121 ARM HORIZONTAL 383332-00 1
123 GUIDE 153582-00 4
124 WIPER 153590-00 4
125 COVER 153583-00 2
126 KNOB 147107-03 1
127 END CAP 153584-00 1
128 BUSHING 33821-00 1
129 BUSHING 153667-00 1
130 HOUSING 153568-00 1
131 SCALE 153578-00 1
132 POINTER 153575-00 1
133 HANDLE 146767-00 1
134 SPACER 385708-01 1
135 PIN 153570-00 1
136 PLATE 153793-00 1
137 TABLE 153617-01 1
138 SHAFT 385709-00 1
139 PIN 153640-00 1
140 DETENT 153620-03 1
141 POINTER 153624-00 1
142 PIN 153632-00 1
143 HANDLE 153621-00 1
144 TRIGGER 153722-00 1
145 LOCKING PIN 153622-00 1
146 LEVER 153626-00 1
147 COLLAR 153760-00 1
148 SPRING SA 153768-00 1
149 PLATE SA 153616-02 2
152 BASE SA 153765-00 1
153 FOOT 153612-00 4
154 PLATE THRUST 153614-00 3
156 FENCE SA 153627-00 1
157 FENCE LH 153766-03 1
158 FENCE RH 153767-03 1
159 KNOB LOWER 147107-02 1
DW708-----A 23/06/98
-------------------------------------------------------------------
ITEMDESCRIPTION PART NO. QTY VARIANT DESCRIPTION
163 WRENCH 153636-00 1
164 BRUSH SPRING 145323-02 2
165 BRUSH CAP 448084-01 2
166 WARNING LABEL 143861-00 2
167 WARNING LABEL 380179-00 1 M-AT-BE-DE-ES-FR-GR-IT
167 WARNING LABEL 148524-01 1 M-B1
167 WARNING LABEL 380179-00 1 M-CH
167 WARNING LABEL 380179-00 1 M-DK-FI-NO-SE-PT
167 WARNING LABEL 380179-00 1 M-GB
167 WARNING LABEL 148524-01 1 M-XD
167 WARNING LABEL 148524-01 1 M-XE
167 WARNING LABEL 380179-00 1 T-GB115V
168 SUPPORT. REAR 153764-00 2
170 PLUG 87205-00 2
171 WASHER 385750-00 1
173 LOCK SA 385652-00 1
174 PLUG 153799-00 1
175 INSERT 153608-00 1
176 CAPACITOR 115V 148679-04 1
177 TERMINAL BLOCK 320078-00 1
178 LEAD SA BLACK 151644-00 1
179 LEAD 385235-00 1
183 GREASE 790206-00 1
CAPACITY 119/305MM
VOLTAGE #1 230
AMPERE #1 7
INPUT WATTS #1 1700
RPM #1 4000
FREQUENCY #1 50HZ
/