1. go to: INDEX - PREVIOUS - NEXT DW718 EUROPEAN SERVICE REPAIR TRAINING DW718 – Mitre Saw

2. go to: INDEX - PREVIOUS - NEXT DW718 Service Tooling Application and Use5.3 Illustrated Tips5.4 6Summary Repair Notes Useful Information 6.1 Strip Down / Repair / After Repair 6.2 Safety Notes 6.3 7Modifications & Product Updates Engineering News 7.1 Quality Changes 7.2 8Additional Training Information Battery Performance 8.1 Battery Tester 8.2 Hammer Mechanism 8.3 Good Practices 8.4 Cordless Motor test unit8.5 EUROPEAN SERVICE REPAIR TRAINING 2Product Information Customer Requirements2.1 Marketing Information2.2 Features & Benefits2.3 Applications2.4 Technical Information/Specifications 2.5 3Service Drawings 4Repair Instructions Diagnosis and Root Cause4.1 Strip Down Guidelines/Procedures4.2 Repair Assembly Guide4.3 5Video & Animation Instructions Disassembly5.1 Re-assembly5.2 Contents

3. go to: INDEX - PREVIOUS - NEXT DW718 2Product Information Customer Requirements 2.1 Slide Mitre Saw CTQ Research Finish = Cut Quality Ease of Use = Fence System Bevel Detents

4. go to: INDEX - PREVIOUS - NEXT DW718 2Product Information Marketing Information 2.2 DW718-QS DW718-GB DW718-LX DW718V-QS DW718V-GB DW718V-LX DW718-B4 DW718-XE V indicates factory fitted laser system DW708 WILL BE DISCONTINUED FROM AUGUST 2005

5. go to: INDEX - PREVIOUS - NEXT DW718 2Product 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

6. go to: INDEX - PREVIOUS - NEXT DW718 2Product 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 19% 250mm saws Improved center of gravity 9 Positive stops Absolute domination Cam lock, detent plate, lock off

7. go to: INDEX - PREVIOUS - NEXT DW718 2Product Information Features & Benefits 2.3.1 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) DW718

8. go to: INDEX - PREVIOUS - NEXT DW718 2Product Information Features & Benefits 2.3.2 Ease of Use Portability DW718 Thumb Actuated Mitre Lock New Easy Access Bevel Lock New Bevel Detent System DEWALT Laser Compatible Smallest 305mm Slide Miter Saw – Packs up Smaller than Hitachi 250mm Slide

9. go to: INDEX - PREVIOUS - NEXT DW718 2Product Information Features & Benefits 2.3.3 Accuracy Improvements: - Improve fence straightness - Fence perpendicularity - Table post - Mitre detent spring Cut Quality:0.1mm -  blade washer size66mm - New DEWALT blade2mm 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

10. go to: INDEX - PREVIOUS - NEXT DW718 2Product Information Applications 2.4

11. go to: INDEX - PREVIOUS - NEXT DW718 2Product Information Technical Information / Specifications 2.5 Voltage230115 Frequency50 Armature / Rotor Resistance0.95Ω0.28Ω Field / Stator Resistance Run0.81Ω0.17Ω Field / Stator Resistance Brake6.50Ω1.55Ω Initial Brush Length21.5mm No Load Speed / RPM1900-3400 Input Watts1600 Output Watts960 No Load Amps (Cordless Motors)

12. go to: INDEX - PREVIOUS - NEXT DW718 3Service Drawings

13. go to: INDEX - PREVIOUS - NEXT DW718 3Service 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 switch - Bottom plus Black from the suppressor. White/Orange – Plugs into the potentiometer.

14. go to: INDEX - PREVIOUS - NEXT DW718 4Repair 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

15. go to: INDEX - PREVIOUS - NEXT DW718 4Repair 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

16. go to: INDEX - PREVIOUS - NEXT DW718 4Repair 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

17. go to: INDEX - PREVIOUS - NEXT DW718 4Repair 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.

18. go to: INDEX - PREVIOUS - NEXT DW718 4Repair 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.

19. go to: INDEX - PREVIOUS - NEXT DW718 4Repair 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

20. go to: INDEX - PREVIOUS - NEXT DW718 4Repair 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

21. go to: INDEX - PREVIOUS - NEXT DW718 4Repair 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

22. go to: INDEX - PREVIOUS - NEXT DW718 4Repair Instructions Strip Down Guidelines / Procedures 4.2.7 Motor Disassembly 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 1 2 3 4

23. go to: INDEX - PREVIOUS - NEXT DW718 4Repair Instructions Strip Down Guidelines / Procedures 4.2.8 Motor Disassembly Correct orientation of field and field case

24. go to: INDEX - PREVIOUS - NEXT DW718 4Repair Instructions Strip Down Guidelines / Procedures 4.2.9 Field & Armature – Checking resistances Armature and field coil readings can be checked per specifications

25. go to: INDEX - PREVIOUS - NEXT DW718 4Repair 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

26. go to: INDEX - PREVIOUS - NEXT DW718 4Repair Instructions Strip Down Guidelines / Procedures 4.2.11 Arm Removal Spring must be free

27. go to: INDEX - PREVIOUS - NEXT DW718 4Repair Instructions Strip Down Guidelines / Procedures 4.2.12 Arm Removal 1 2 3 4 1.Loosen 2 grub screws 2. Return arm to 90 degree 3. Remove pin 4. Check condition of washers

28. go to: INDEX - PREVIOUS - NEXT DW718 4Repair Instructions Spindle and pulley is complete sub assembly Strip Down Guidelines / Procedures 4.2.13 Pulley and Gear Removal

29. go to: INDEX - PREVIOUS - NEXT DW718 4Repair Instructions Strip Down Guidelines / Procedures 4.2.14 Bevel Lock Remove back cover to expose bevel lock system

30. go to: INDEX - PREVIOUS - NEXT DW718 4Repair Instructions Strip Down Guidelines / Procedures 4.2.15 Bevel Lock Bevel detent lever and spring and how it works

31. go to: INDEX - PREVIOUS - NEXT DW718 4Repair Instructions Strip Down Guidelines / Procedures 4.2.16 Bevel Lock Bevel detent lock removed

32. go to: INDEX - PREVIOUS - NEXT DW718 4Repair Instructions Strip Down Guidelines / Procedures 4.2.17 Bevel Lock How the system works

33. go to: INDEX - PREVIOUS - NEXT DW718 4Repair Instructions Strip Down Guidelines / Procedures 4.2.18 Fence Removal 1 2 3 1 & 2 Remove 5 torx 40 screw to lift fence off 3. New fence recess to aid fence set up in service

34. go to: INDEX - PREVIOUS - NEXT DW718 4Repair Instructions Strip Down Guidelines / Procedures 4.2.19 Mitre Latch Mitre latch system

35. go to: INDEX - PREVIOUS - NEXT DW718 4Repair Instructions Strip Down Guidelines / Procedures 4.2.20 Mitre Latch Correct layout

36. go to: INDEX - PREVIOUS - NEXT DW718 4 Repair Instructions Table Removal Inner table removal 4.2.21 Strip Down Guidelines / Procedures

37. go to: INDEX - PREVIOUS - NEXT DW718 5Video & 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

38. go to: INDEX - PREVIOUS - NEXT DW718 Make a note of the type number and date code. Carry out a quick test and check all functions before dismantling (charge the battery). Understand the root cause of the failure's). Before Dismantling 6Summary Repair Notes Useful Information 6.1 Keep your workbench/Station absolutely clean. Check spare parts for dirt, dust and corrosion. Exchange all parts showing wear. Use only original spare parts. Always use service tooling where available. During the Repair After repair run in the unit and quick test all functions. In drill position the clutch has to lock Make sure that the unit goes back to the customer in a clean condition, with the tool tag attached and the box is complete. After the Repair