DeWalt 7700/3400 Instructions for use

© DeWAIX
instruction &
maintenance
manual
WARNING: FOR YOUR OWN SAFETY, READ THIS MANUAL BEFORE OPERATING TOOL
REVIEW SAFETY RULES AND OPERATING INSTRUCTIONS FREQUENTLY.
This booklet is provided, for your convenience
te the use and care of your new OeWait
Theses instructions include^ operation;
precautions, preventive maintenance, main-
tenancs and other pertinent data to assist you
in assuring long life and dependable service
fromyoursaw.
700 8" RADIAL ARM SAW
No. 7700/3400,120 VOLT. TYPE 5
No. 7700-01,220 VOLT, TYPE 5
Builetin No. 8814

INDEX
Uop^king, Set-Up.2»4
Machine Controls,.5
Intr^tcHon.^
Ryles for O^ration
and Maintenance.7*8
Alignments.943
Aligninefit Guide .. 14
PrecuttingWorkSurface.1547
Basic Cuts ..18-21
Saw Blades & Accessories,.... 22
Fancy Cuts.. 23-24
Parts Lists, Order Instruc.25-28
B^iD Service Centers ..32
UNPACKING & SET-UP INSTRUCTIONS
You can easily set up your new DeWALT Radial Arm Saw, one of America’s
most popular power tools. Handling is minimized because every machine
is partially assembled for shipment to you. The only tools required are the
wrenches furnished with the machine, Phillips screwdriver, regular
screwdriver, adjustable wrench, a good square, and a small amount of
grease or petroleum jelly. Just follow this easy step-by-step procedure on
pages 3 & 4 in setting up your new saw!
THIS IS THE
PARTS
ILLUSTRATION
MENTIONED
IN STEP 3
ON FACING
PAGE
NO. ITEM QUANTITY
1 3/8" Dia. Flat Hd. Screws 4
2 Lock Washers 4
3 3/8" Ola. Nuts 4
4 Large flange Hex Nuts 8
5 Self Tapping Screws 4
6 Thumb Screws 2
7 Cleat Brackets 2
8 Eyelets '2
9 Large Base Washer I
PARTS IDENTIFICATION
NO. ITEM QUANTITY
10 3/8* I.D. Washer 1
11 Base Clamp 1
12 Square Nut 1
13 1-3/4" Lg. Hex Bolt 1
14 Square Nut 1
15 Inserts 2
16 Handles 2
17 1/4-20 X1/2* Lg. Carriage Bolt 1
18 Guard Extension 1
NO. ITEM QUANTITY
19 Washer 1
20 Hex Nut 1
21 Anti-Kickback Device 1
22 Wing Bolt 1
23 Key I
24 • Arbor Washer 1
25 Spacer Washers 2
26 Arbor Screw* 1
27 & 28Wrencb« 2
"Assembled to Saw
2

Lay out conttnts of har^are bafs
in sequeixe illustrated in the piiot©^
graph on page two ( 2 ) , handy t® the
assembly area (item 26 is assem^
bled to saw artor). Familiarize your^
self with base and table assembly on
page 27 before asstmbling saw.
arm and motor assembly from carton.
Remove remainder of contents from carton.
^16
APPROX
Assmim tatJto frame (2 large channel pieces) to
the using <4) flat head .3/8* dia. saws, lock
voters and 3/8* dia. nuts. Tighten securely with
wrench. See page 27.
Attach the cleats to the underside of the table with
the seif-tapping screws. Note: Holes aie already
drilled fm" you. Tighten securely but do not strip the table
top.
Screw (4) large flange hex nuts onto the threaded
studs, of the table cleats m the studs extwd beyond
the nuts approximately 1-5/16*.
Instoll the table to the frame by putting cleat studs thru the elongated holes in
Screw (4) large flange hex nuts to the cleat studs and leave loose. These will be
the frame
tightened when you adjust the table 90® to the arm.
through the rectangular hole m the cleat. With one hand hold the eyelet against the
back board in line with the thumb screw while turning the thumb screw with the other hand to
force the stud Into the eyelet until it snaps in place. Repeat for the other side.
3

11 c Hold the large base washer at an angle and insert
It into the base from the bottom as shown.
IMPORTANT—the bottom of the arm should rest on this
thrust washer—see step 13.
17 8 Do not plug saw into receptacle at this time. Insert
Key in slot with notch down. Switch can now be
operated. Turn switch off and remove Key with upward
and outward motion.
« Remove the arm and motor assembly from the
packing. Lybri^te about 5’ of arm under miter
scale by applying grtaM over entire surface. Insert the
rear of the arm into the base as shown. Turn and “wig¬
gle” the end of the arm to ^se it in place. Pull the miter
locator pin m the arm goes all the way down to the base
washw.
15* Put the guard extension in place. Install the
1/4-20 X 1/2* carriage bolt into the rear square
hole of the saw guard with the bolt head inskie. Secure it
with a waidier and hex nut using the wrench provided.
18. MOUNT YOUR SAW ON A LEG STAND. STURDY
WORK BENCH, OR APPROPRIATE TABLE.
TABLE TOP OF SAW SHOULD PROTRUDE APPROX¬
IMATELY FOUR (4) INCHES OVER MOUNTING SUR¬
FACE. THIS UNIT WILL FIT A 35021 DELUXE MACHINE
STAND.
19, REFER NEXT TO MACHINE CONTROLS. IN¬
TRODUCTION AND ALIGNMENT PROCEDURES
ON FOLLOWING PAGES. YOUR SAW MUST BE COM¬
PLETELY ALIGNED BEFORE MAKING ANY CUTS
INSTALUNG BLADE
To install the blade rotate the saw to the out-rip p<Bitwfi
(see page6) at the end of the arm as shown. Make sure
saw is all the way to the out-rip petition (against front
bumper) and in its high^ elevated positiofi (see page
6). if saw is not against front bumper, it is slightly out of
phase with cover and arm. To correct, follow instructions
at bottom of page 12. Now raite the lower guard with the
lift tab provided and secure guard in raised position by
placing your fingers under the guard just atxive the artxsr
(see above illustration). Blade can new be installed or
removed without touching table top^ Wace blade on 3rt»r
following the illustration on the guard so the teeth of the
blade and direction arrow point in the proper dr^mn.
When tightening or lootening blade arbor %rew. the
blade can be held secure by inserting a siawdriver
through the hole in the blade, and alkwring scrawdriv** to
rest against the upper guard. A piece of scrap luml^
held against the blade teeth and resting on the up^r
guard will serve the same purpose. Do to Mitite
MaM wMi hami!
16 . Insert anti-kickback device in front end of the
guard and secure it with the wing bolt
IT IS RECOMMENOED THE TOOL BE CON¬
NECTED TO A SEPARATE CIRCUIT WITH AT
LEAST 15 AMP. CAPACITY. THIS CIRCUIT
SHOULD NOT BE CONNECTED TO THE LIGHT-
ING CIRCUIT. THE OUTLET MUST BE
GROUNDED. FOLLOW MOTOR OPERATING
AND GROUNDING INSTRUCTIONS ON PAGE
8. SEE INDEX FOR OPERATION AND
MAINTENANCE.
Plaite the large arbor washer on the outside the blade,
then (2) spacer wafers and arbor screw. Note: left
hand thread. CAUTION: Never assemble spi«r washers
m arbor setewdir«t% apinst blade.
IMWRTANT^CLWCM AOJUS»fNT:
T^ten artor screw until the spring washw* iatteni
Then bade off 1/6 turn (one flat on the h« head). This
ill^s blade to slip on spindle if It shmild jam in the
i blade jams stop saw immediately! Qutch will tm
funrtlon if the m:rm is not set pro^ly.
4

RADIAL ARM
YOKE^__
LOCATOR
PIN
ASSEMBLY
GUARD EXTENSION
ON-OFF
CONTROL
RIP
LOCK
OPERATING HANDLE
UPPER GUARD
MITER SCALE
GUIDE FENCE
mUMB SCREW
FRONT
LOWER
guard
BACK
board
CARRIAGE
.YOKE
CLAMP
HANDLE
KEY SWITCH
•YOKE
ELEVATION KNOB
BEVEL LOCK-
CLAMP
ANTI-KICKBACK DEVICE
MITER
LOCATOR PIN
NOVAPLY TOP'
REAR
LOWER GUARD

INTRODUCTION
You have now set up your saw by following the
preceding directions. But before plugging in the saw,
there are three important things you m ust do.
1 . Familiarize yourself thoroughly with the
principles of radial arm sawing. See Page 5 for
names of components.
2 . Familiarize yourself thoroughly with the rules
and instructions for operation on next two pages.
3. Carefully follow the alignment and adjustment
procedures.
The five basic movements are shown below. See
pages 18 to 20 for more details.
BEVELING —Elevate saw all the way up. Release
the bevel lock knob—rotate saw to desired angle.
(Saw automatically stops at 45®). Relock Knob.
ELEVATION— R elease wing nut with left hand and MITERING— R each around to base and release
turn black knob with right hand. This raises and clamp handle—pull miter pin and rotate saw to
lowers saw. Lock in position by tightening wing nut. desired angle. Let the pin fall in place and bear on the
arm slightly to the right. (Saw automatically stops at
45®). Lock base clamp.
CROSS CUTTING —Elevate saw until it clears
fence. Unlock riplock by turning counterclockwise —
pull saw back and forth. (If at anytime the saw does
not go all the way behind the fence or it does not hit
the front bumper refer to rollerhead adjustment on
page 12).
RIPPING —Release yoke clamp handle by pulling it
toward you. Rotate motor slightly clockwise (looking
down), and using left index finger depress index pin
handle and rotate saw to in-rip or out-rip position.
(See page 20). When pin clicks into place, lock yoke
clamp handle.

RULES FOR OPERATION
OF STATIONARY POWER TOOLS
1. ICMIlW' Yimil WMm TWL tli« owner's manual
oarefuily. L^am its applii»tion and limitation, as wail
as tlia'^speclio pAanial ha^nis ^ullar to this tool.
2. WEEP. IM and in iM^dcing order.
3. mmUMii Ali imis* ll t^ is quipped with three-
pronf plug, it should 1^ plu^^ Into a thme-hole
electrical i^irtacle. If an adapter Is used to accom¬
modate a tvwi-prong rmp^cle, the adapter wire must
he attached to a knoem piNfnii. remove the
third pron&
4 . nmmm msummm xiys and wrenches. Form
habit of checking to that ke^ and adfusting
wrenches are removed before turning on tool.
5. KSPIRIRIC AREA CLEAN. Cluttered areas and benches
invite accidente.
i. AVOID DANGEROUS ENVIRONMENT. Don't expose
imwm tools to rain. Don't use power tools in damp or
lotions. Keep your work area well illuminated.
7. USER CHILDRei AWAY. All visitors ^ould be kept a
sate distance from wodc area.
a. MAKE VKIIN^HOP iaDPm<B«--widi padltKdcs, master
^idttdies, or by removing sterter keys.
i. DON’T RNKB TML. it will do the job better and be
safer at the rate for whidi it was deigned.
ID. USE RIGHT TOOL. I^n't fonre fool or attachment to
do a job It was not designed for.
11. WEAR PROreR APPAREL. No loose clothing or jewelry
to get caught in moving parts. Rubber-soled footwear
is recommended for best footing,
12. USE PROTECTIVE GLASSES. Also use face or dust mask
if cudiing operation is dusty.
13. NEVER STAND ON TOOL. Serious injury could occur
if the tool is tipped or if the cutting tool is accidently
contained.
14. DONT OVERREACH. Keep your proper foofing and
balance at all times.
15. MAINTAIN TC^IS IN TOP CONDITION. Keep tools sharp
and clean for best performance. Follow instructions for
lubricating and changing accessories.
IS. DISCONNECT TOOLS before servicing and when chang¬
ing acc^sories such as blades, bits, cutters.
17. USE REIBMMENDED ACCESSORIES. Consult owner's
manual. Use of improper accessories may be hazard¬
ous.
IS. AWIO AMiOENTAL STARTING. Make sure switch is
l^fore plugging in cord.
19. KEEP HANDS AWAY FROM CUTTING AREA.
20. DO NOT OPSUITE electric tools in gaseous or explo¬
sive atmospheres. Motore In these tools normally
soark, and the sparks might Ignite fumes.
21. CHECK DAMAGED PARTS. Before further use of the
toot, a guard or other part that is damaged should be
carefully checked to assure 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 dam¬
aged should be properly repaired or replaced.
MAINTENANCE & OPERATION
1. Be sure blade rotates clockwise when facing arbor.
2. Secure table frame to a bench table, leg stand,
etc. before operating saw. It is recommended
that whatever saw support is used should slope
to the rear sufficiently to prevent the blade unit
from creeping forward due to gravity and it
should be securely anchored to the floor to pre¬
vent undesired movement.
3. Be sure all clamp handles are tight before start¬
ing any operation. Push back to tighten. Pull
to loosen.
4. Make sure blade and arbor collar are clean and col¬
lar is against blade. Tighten arbor screw securely,
and set clutch. (See clutch instructions). .
5. Keep the saw blade sharp and properly set.
6. Use anti-kickback device on guard; never re¬
move it.
7. Keep arm tracks and bearing surfaces clean and
dry. Periodically lubricate balls with a dry
lubricant.
8. Periodically recheck alignment (see alignment
chart).
9. Keep motor air slots clean and free of chips.
10. Do not attempt to operate saw on anything but
the designated voltage.
11. Do not use blades of larger diameter than 8".
12. Keep the saw blade sharp. Cracked or improper
type blades should not be used.
13. Never oil or grease arm tracks or the motor.
14. Do not wedge anything against fan to hold motor
shaft. .
15. Saw and table top should be kept away from
dampness.
16. Never force cutting action. Stalling or partial
stalling of the motor is dangerous and can cause
major damage to motor winding. If motor stalls
turn switch off immediately.
17. Do not remove ground prong from plug. Never
operate the saw unless it is properly grounded.
18. Be sure you are alert. If you are fatigued, rest
before you work.
19. Always use blade guard properly adjusted for
the operation you are performing. CAUTION: Do
not clean the lower plastic guard with solvents
or soaps. Use ONLY a cloth dampened with
water.
20. The motor and yoke should be safely behind the
guide fence before you start to cut. The saw
should always be returned to the rear of the
table after making a cut, and before you remove
any stock from the table.
21. Be certain the equipment is turned off before
making any adjustments.
22. When ripping, always feed the material past the
blade guard from the side opposite the anti¬
kickback device. Never stand in back, or in
direct line with the saw blade. Never rip from
the wrong end.
23. The saw blade or tool should be completely
stopped, and switch key removed, before you
leave the machine.
24. Always turn switch off before removing key.
7

INSTRUCTIONS
GROUNDING
This tool should be grounded while in use to protect the opera¬
tor from electric shock.
1, C ord-Connected Tools-~The tool is eciuipped with an ap¬
proved three-conductor cord and three-prong grounding type
plug to fit the proper grounding type receptacle. The green (or
green and yellow) conductor in the cord is the grounding wire.
Never connect the green (or green and yellow) wire to a live
terminal If your unit is for use on less than 150 volts, it has a
plug like that shown in Figure A. If it is for use on 150 to 250
volts, it has a plug like that shown in Figure 0. An adapter
Figures 8 and C, is available for connecting Figure A plugs to
two-prong receptacles. The green-colored rigid ear, lug, etc.,
must be connected to a permanent ground such as a properly
grounded outlet box. No adapter is available for a plug as
shown in Figure D. Adapter shown in Figures B and C is not
for use in Canada.
Ujre only 3-wire extension cords which have 3-prong type plugs
and 3-poie receptacles which accept the tool’s plug. Replace
or repair damaged or worn cord immediately.
If you replace the plug on the power cord, be sure to connect
the green wire only to the grounding (longest) prong, on a
3-prong plug.
EXTENSION CORD
When using the tool at a considerable distance from' power
source, a 3 conductor, grounding-type extension cord of ade¬
quate size must be used for safety and to prevent loss to power
and over-heating. Use the table below to determine the mini¬
mum wire size required.
Use only 3-wire extension cords which have 3-prong type plugs
and 3-pole receptacles which accept the tool’s plug. Replace or
repair damaged or worn cord immediately.
Anifi«re rating
0 to
2.10 to
a.ito
5.10 to
7.10 to
12.1 to
(on nameplate)
2.0
3.4
. 5.0
70
12 0
16.0
Ext. Cable -length
Wire Slie'<A.W.Q.)
2i ft
IS'
18
18
IS
16
14
so ft.
-18
18
18.
16
14
12
7S ft.
18
18
16
14
12
10
100 ft.
18
16
14
12
10
ISO ft
200ft.
li
li
14
14
12
12
12
10
11
MOTOR
Your DeWALT tool is powered by a B^D-built motor. Be sure your
power supply agrees with nameplate marking. Volts 50/^ Hz
means Alternating Current ONLY. Voltage variation of more than
10% will cause'loss of power and over-heating. All DeWALT tools
are factory-tested; if this tool does not operate, check the power
supply.
The use of a separate circuit independent of the'lighting circuit is
recommended.
MOTOR BRUSHES
It is recommended that the carbon brushes and the brush
springs be replaced when motor arcing becomes excessive.
If the surface of the commutator is pitted or grooved, we recom¬
mend the unit be taken to a DeWalt or Black 8i Decker Service
Center for repair. Otherwise, brushes and springs may be replac¬
ed as foJiows:
1. Unplug saw from powr supply.
2. Slide brush holder cover toward rear of motor housing
(hold hand in front of opening to prevent spring from
flying from opening). See photo below.
3. Remove spring along with terminal and lead wire.
4. Use a piece of stiff wire, such as an opened paper clip,
to reach inside the bmsh hoiders and pull brushes out.
5. insert new carbon brushes into the holder with the
radius tovi^rd the commutator.
6. Thread new springs into the temiinals and spring caps.
Insert Into brush holders and replace brush holder
covers.
7. Plug saw into power supply and allow saw to run Idle
for 15 minutes to seat the brushes.
For any other motor maintenance we recommend you take the
unit to a DeWalt or Black li Decker Service Center.
8

All MIV/ICT MT make certain saw is not connected to power source, now before going any
ML.I\JIIMIVII.IN I farther take time out to read the following important instructions, the
alignment of your new saw is most, important for making accurate cuts, the time spent here will add con¬
siderably TO YOUR OVERALL ENJOYMENT OF THIS FINE PRODUCT.
NOTE: SECURE TABLE FRAME OF UNIT TO A STURDY WORK BENCH, APPROPRIATE TABLE, OR LEG STAND, WITH SCREWS OR
BOLTS BEFORE MAKING ALIGNMENTS OR OPERATING.
ADJUSTING BASE TO ARM
Make certain the base is absolutely snug around the arm.
To do this refer to fig. A1 and adjust as follows:
1. Tighten the 5/16" bolt with a wrench until base is snug
around the arm and no appreciable play is noted.
2. Place the 3/8" I.D. Washer over the threaded end of the
base clamp (lubricate this washer and threads with a
small amount of grease). Install the base clamp in the
upper hole using the 3/8" square nut in the recess of
the base casting.
3. Position base clamp so that when it is locked the handle
position will be upright. If it is not, loosen the clamp rod
sufficiently to permit nut to come out of recess in
casting, then turn the nut 1/4 or 1/2 turn while holding
clamp rod. Retighten base clamp.
4. Place insert into plastic knob. Push knob on clamp
handle.
5. Release the base clamp by pulling it toward you, and
pull out the miter locator pin. You should now be able to
push the arm to the right and left and feel a slight drag.
6. If it is too hard to move, loosen the 5/16" bolt a little.
NOTE: The upper saw guard should be approx,
parallel with the table when the blade is touch¬
ing the table. If it is not, adjust the table by
turning the nuts on the table adjusting screws.
You will notice the mounting bolts, which hold the table to
the frame, are quite long. The large flange nuts, on the top
and bottom of the frame, suspend the table above the
frame about 1". There is an important reason for this con¬
struction. By turning these nuts up or down we can adjust
the table parallel to the arm. If the table is parallel to the
arm, then any groove you cut will be the same depth from
front to back. A simple method of adjusting the table to be
parallel with the arm is as follows:
1. With arm in cross cut position tighten base clamp
handle. Turn the anti-kickback rod on the guard upside-
down. The lower end of the rod will be
used as an indicator to determine if the entire table sur¬
face is the same distance from the arm.
2. Set the elevation adjustment so the end of the rod is
about 1/8" above the table top. Tighten elevating wing
nut. (Fig.A-2)
3. Push the saw all the way back. If the rod strikes the
surface, as you push it back, elevate it a little more so it
is 1/8" above as before.
4. Pull saw forward. Release base clamp handle, pull miter
locator pin and move the arm to your right until 30° is
indicated on the miter scale. As you move the arm, if the
end of the rod strikes the table, elevate it a little more
as before. With the arm 30° to the right, base clamp
handle tightened and the saw all the way back, turn the
height adjustment until the rod is just above the sur¬
face of the table and lock elevating wing nut.
5. Hand tighten the nuts on the back right table
suspension stud while still in 45° right position.
6. Pull the saw forward to the end of the track. If the end
of the rod strikes the table do not change the height ad¬
justment of the saw. Instead, lower the front right side
of the table by turning the upper nut on the suspension
stud up a few turns. You should now be able to push the
front right corner of the table down so the rod indicator
can pass over the surface without striking it.
7. Adjust the suspension stud nuts so the top of the table
on the front right side just touches the end of the anti-
kickback rod the same as the back. Tighten the nuts by
hand.
8. Release base clamp handle and swing the arm to the
left until 30° is indicated on the miter scale. Tighten
base clamp handle and check the height. If it is incor¬
rect, adjust the same as before. Do not change motor
height. Push the saw back and adjust the rear left side
of the table. Hand tighten adjusting nuts.
9. Replace kickback to its proper position.
Incidentally, you do not have to start the table adjust¬
ment with the right rear bolt. You can start with any one
of the bolts, if you find it more convenient. When check¬
ing any adjustments arm must always be locked in base.

ADJUSTING FOR SQUARE CROSS CUT
Install blade (See Page 4 for installation instruc¬
tions). Now you are ready to adjust the arm to be 90®
to the fence. You will notice the saw locates at 90®
when the tapered pin falls into the slotted hole on the
left side of the base. This is a spring loaded pin which
passes through (2) holes in the post The holes are
held to a close tolerance at the factory but they must
be large enough to enable the pin to be pulled out
without binding. If you locate the arm at 90® or 45®
you will be able to move the end of the arm to the
right and left about 1/2". This is due to the clearance
of the holes in the arm. In order to locate in the same
place each time, the hole clearance is taken up by
pushing the arm to the right until it stops. Lock the
base by pushing back on the base clamp. Make it a
habit of always locating the arm at 90* or the (2) 45*
locations by appro%hing the position from the left,
letting the pin fall in place and bear on the arm slight¬
ly to the right until it stops moving, and you always
have accurate cuts. As of now this does not mean the
arm is 90® to the fence. Checkit as follows:
1. Put the fence in its normal position, with the blade
in front of it and about 1/32* above the table.
2. Place a carpenter’s square against the fence on
the left side of the blade and against the blade
itself, not the guard. Raise the lower guard out of
the way.
3. Hold the square with your left hand and pull the
saw forward (Fig. A3). If the arm is 90® the blade
will stay against the square as you pull it out. If the
arm is too far to the right, the blade will move away
from the square. If it is too far to the left, it will
push the square to the left. In either case correc¬
tion is easy.
4. Since the nuts which hold the table to the frame
are not tight, you can shift the entire table in rela¬
tion to the arm by tapping the table corners with
your hand or lightly with a hammer (Fig. A4).
5. When table is located so the'fence is 90® to the
arm, tighten the adjusting nuts on the suspension
studs carefully so as not to change the adjustment
you just made.
a. ) Tighten the bottom nuts only. This will draw
the table down only slightly but the same
amount on each stud.
b. ) Prevent shifting by taking up on the first nut a
little and then proceed to the next taking it up
a little also.
c. ) After all (4) nuts are snug, take up on the first
again a little more and repeat on all the other
nuts
d. ) The third time around you should be able to
take them up tight without any shifting.
MAKING MITER ADJUSTMENT
When the arm is 90® to the table, set the miter scale
by loosening its set screw and turning the scale to
read0®. Tighten the set screw carefully making it just
tight enough to prevent the scale from turning (Fig.
A5). Once the saw has been set for 90®, it should be
automatically set for 45®; right and left.
Fig. A5
10