IF YOU SHOULD EXPERIENCE A PROBLEM WITH YOUR DEWALT PURCHASE, Before returning this product call 1-800-4-DEWALT CALL 1-800-4-DEWALT IN MOST CASES, A DEWALT REPRESENTATIVE CAN RESOLVE YOUR PROBLEM OVER THE PHONE. IF YOU HAVE A SUGGESTION OR COMMENT, GIVE US A CALL. YOUR FEEDBACK IS VITAL TO THE SUCCESS OF DEWALT’S QUALITY IMPROVEMENT PROGRAM. Questions? Visit us at www.dewalt.com Des questions ? Rendez nous visite à www.dewalt.com ¿Tiene preguntas? Visítenos en www.dewalt.
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.
English • REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure that the switch is in the “OFF” position before plugging in the power cord. In the event of a power failure, move the switch to the “OFF” position. An accidental start-up can cause injury. • Do not plug into or unplug from power source with wet hands. • USE RECOMMENDED ACCESSORIES. Use only accessories that are recommended by the manufacturer for your model.
KICKBACKS Kickbacks can cause serious injury. A kickback occurs when a part of the workpiece binds between the saw blade and the rip fence, or other fixed object, and rises from the table and is thrown toward the operator. Kickbacks can be avoided by attention to the following conditions. How to Avoid Them and Protect Yourself from Possible Injury a. Use the blade guard with splitter, or use the riving knife whenever possible. b. Be certain that the rip fence is parallel to the saw blade. c.
English WARNING: Use of this tool can generate and/or disperse dust, which may cause serious and permanent respiratory or other injury. Always use NIOSH/OSHA approved respiratory protection appropriate for the dust exposure. Direct particles away from face and body. FIG. 2 R 15 A 21-7/8" (556 mm) X 26-3/8" (669 mm) 30° L&R 0° to 45°L 10" (254 mm) 3-1/8" (79 mm) 2-1/4" (57 mm) 4800 Unpacking (Fig.
WARNING: Shock Hazard. To reduce the risk of serious personal injury, turn unit off and disconnect machine from power source before attempting to move it, change accessories or make any adjustments. An accidental start-up can cause injury. THIS SAW SHOULD BE ASSEMBLED IN THE FOLLOWING ORDER: (FIG, 2, 4) 1. Make sure blade is installed correctly and arbor nut is tight. Use wrenches (U) stored on the tool. Refer to Figure 3. 2. Install and lock throat plate (Q).
English 4. Loosen the rip scale indicator screws (GG) and set the rip scale indicator to read zero (0). Retighten the rip scale indicator screws. The yellow rip scale (top) reads correctly only when the fence is mounted on the right side of the blade and is in position 1 (for 0 to 24.5" ripping) [not the 32" rip position]. The white scale (bottom) reads correctly only when the fence is mounted on the right side of the blade and in position 2 (for 4" to 32.5" ripping).
1. Using a 6 mm hex wrench, loosen rear pivot bracket fasteners (LL) just enough to allow the bracket to move side-to-side. 2. Adjust the bracket until the blade is parallel to the miter gauge slot. 3. Tighten the rear pivot bracket fasteners to 110–120 in-lbs (12.5–13.6 Nm). BEVEL STOP AND POINTER ADJUSTMENT (FIG. 19, 20) 1. Raise the blade fully by rotating the blade height FIG. 19 adjustment wheel (F) clockwise until it stops. 2. Unlock the bevel lock lever (G) by pushing it up and to the right.
English POSITION 2 FENCE ALIGNMENT (FIG. 22, 23) 1. To align position 2 fence locator pins, ensure position 1 pins have been aligned, refer to Position 1 Fence Alignment. 2. Loosen the position 2 locator pins, then using the blade wrench holes as a guide for positioning, align the pins (Fig. 23). 3. Tighten the locator pins (front and rear). FIG. 23 FIG.
The riving knife provided with this saw is marked as follows (Fig. 27): OPERATION FIG. 27 All DEWALT blade body thickness and kerf widths are provided at www.dewalt.com. If a different blade is used and the body thickness FIG. 28 and kerf width dimensions are not provided, use the following procedure to determine the correct riving knife thickness: 1. Measure the body thickness of the blade. 2. Make a shallow cut in scrap material and measure the kerf width. 3. Select the riving knife (Fig. 28). 4.
English On-Off Switch (Fig. 29) WARNING: To reduce the risk of injury, be sure the switch is in the OFF position before plugging machine in. Push green button (H) in to turn this saw on and push down the red paddle to turn this saw off. FIG. 31 FIG. 29 LOCK OFF FEATURE INSTRUCTIONS A cover above the switch folds down for insertion of a padlock to lock the saw off. A padlock with a maximum diameter of 1/4" (6.35 mm) and minimum clearance of 3" (76.2 mm) is recommended. FIG.
Narrow Rip Auxiliary Fence (Fig. 35, 36) FIG. 33 FIG. 35 SS 4-3/4" (121 mm) CAUTION: The workpiece must have a straight edge against the fence and must not be warped, twisted or bowed. Keep both hands away from the blade and away from the path of the blade. See proper hand position in Figure 33. 4. Turn the saw on and allow the blade to come up to speed. Both hands can be used in starting the cut.
English 2. Place the push block (UU, Fig. 37) behind the material and ensure the lip of the block is flush to the narrow rip auxiliary fence (SS). 3. Once the push block is in place, continue feeding the material until the cut is complete making sure the push block remains flush to the narrow rip auxiliary fence at all times. IMPORTANT: The narrow rip auxiliary fence and the over hanging edge (W W, Fig. 36) should both be the same thickness.
FIG. 41 FIG. 40 24" (610 mm) 4" (102 mm) THE KERF SHOULD BE ABOUT 1/4" (6.4 mm) APART º 60 J 5" (127 mm) Miter Gauge Operation WARNING: Use featherboards for all non thru-sawing operations where the blade guard assembly, anti-kickback assembly and riving knife cannot be used. Always replace the blade guard assembly, anti-kickback assembly and riving knife when the non thrusawing operation is complete. Make sure the featherboard presses only on the portion of the workpiece in front of the blade.
English Motor Overload and Power Loss Reset Switch FIG. 45 If power is interrupted by a circuit breaker trip, or power is lost, the saw contains a power loss reset switch feature that will automatically reset to OFF position. Circuit breaker overload is often the result of a dull blade. Change your blade on a regular basis to avoid tripping your breaker. Disconnect the saw from power source and check your blade before re-setting the circuit breaker and continuing to saw. Lubrication (Fig. 44) 1.
FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are missing, call 1-800-4-DEWALT (1-800-433-9258) for a free replacement. Accessories XXX Repairs To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including brush inspection and replacement) should be performed by a DEWALT factory service center, a DEWALT authorized service center or other qualified service personnel. Always use identical replacement parts.
Parts List for DWE7491RS Type 1 Item Number Part Number Description Qty Required 1 5140136-09 SHOULDER SCREW 3 2 5140136-10 WASHER 3 3 5140136-11 SCREW 3 4 5140032-59 FLAT WASHER 3 5 5140134-60 SPRING CLIP 1 6 5140134-61 SCREW 2 7 5140134-62 STRAP CLAMP 1 8 5140134-63 OUTER RAIL 2 10 5140032-03 NUT 6 11 5140092-88 WAVE WASHER 1 12 5140134-65 POINTER 1 13 5140134-66 SCREW W/WASHER 2 14 5140134-67 SCREW W/WASHER 8 15 5140134-68 INNER RAIL 1 16 51401
Parts List for DWE7491RS Type 1 Item Number Part Number Description Qty Required 29 5140134-75 COMPRESSION SPRING 1 30 5140032-17 ADJUSTING SHAFT 1 31 5140134-76 HEX NUT 1 32 5140174-88 RAIL LOCK SHAFT ASSY 1 33 5140134-78 NYLOCK NUT 2 34 5140032-27 FLAT WASHER 3 35 5140134-79 FENCE KNOB 1 36 5140032-29 PINNION GEAR 2 37 5140134-80 BRACKET 2 38 5140134-81 GUARD 1 39 5140032-33 E-RING 4 40 5140032-34 DOWEL PIN 3 41 5140134-82 GEAR ROD 1 42 5140032-36
Parts List for DWE7491RS Type 1 Item Number Part Number Description Qty Required 56 5140134-92 RELEASE HANDLE 1 57 5140134-93 CLAMP 2 58 5140134-94 SPINDLE 1 59 5140134-95 KEY 1 60 5140033-10 GEAR CASE COVER 1 61 5140033-11 O-RING 1 62 5140117-79 BEARING 1 63 5140033-13 RING 1 64 5140134-96 RETAINING RING 1 65 5140134-97 GEAR 1 66 5140117-80 BEARING 1 67 5140033-16 O-RING 1 68 5140134-98 GEAR HOUSING BRACKET 1 69 5140033-18 O-RING 1 70 5140033-19
Parts List for DWE7491RS Type 1 Item Number Part Number Description Qty Required 83 5140034-68 GUARD 1 84 5140033-39 SCREW 4 85 5140135-05 SPLITTER 1 86 5140135-06 SHAFT 1 87 5140135-07 PIN 1 88 5140135-08 WIRE CLIP 1 89 5140135-09 PLATE 1 90 5140135-10 BUSHING 1 91 5140135-11 SET SCREW 3 92 5140135-12 COMPRESSION SPRING 1 93 5140135-13 FLAT WASHER 1 94 5140135-14 E-RING 1 95 5140135-15 BRACKET 1 96 5140135-16 SET SCREW 1 97 5140135-17 CAP SCREW
Parts List for DWE7491RS Type 1 Item Number Part Number Description Qty Required 110 5140135-29 SCREW AND WASHER 4 111 5140135-30 PIVOT BRACKET 1 112 5140135-31 SCREW AND WASHER 4 113 5140034-65 DUST COVER 1 114 5140135-32 TRUNNION 1 115 5140135-33 SCREW AND WASHER 2 116 5140032-69 CLAMP WASHER 1 117 5140131-58 BLADE NUT 1 118 5140135-34 TRUNION PLATE 1 119 5140135-35 COVER 1 120 5140135-36 FLAT WASHER 2 121 5140135-37 COMPRESSION SPRING 1 122 5140135-38
Parts List for DWE7491RS Type 1 Item Number Part Number Description Qty Required 137 5140135-51 BEVEL HANDLE 1 138 5140135-52 HANDWHEEL ASSEMBLY 1 142 5140032-52 RING 1 143 5140135-54 BUSHING 1 144 5140135-55 BRACKET 1 145 5140135-56 O-RING 2 146 5140135-57 SCREW 1 147 5140135-58 FLAT WASHER 2 148 5140135-59 LOCK NUT 1 149 5140135-60 SCREW AND WASHER 4 150 5140135-61 LOCK NUT 1 151 5140135-62 SHAFT 1 152 5140136-12 FRAME 1 153 5140135-64 SCREW AND WA
Parts List for DWE7491RS Type 1 Item Number Part Number Description Qty Required 169 5140135-78 BRACKET 1 170 5140135-79 SCREW 1 171 5140135-80 KNOB 1 172 5140135-81 PIN 1 173 5140135-82 FLAT WASHER 1 174 5140135-83 BAR 1 175 5140135-84 SHAFT 1 176 5140135-85 COMPRESSION SPRING 1 177 5140135-86 BRACKET 1 178 5140135-87 SCREW 1 179 5140135-88 FRONT PANEL 1 180 5140033-04 WASHER 2 181 5140135-89 SCREW 1 182 5140135-90 LOCKING PLATE 1 183 5140135-91
Parts List for DWE7491RS Type 1 Item Number Part Number Description Qty Required 197 5140136-15 LEFT FOOT 2 198 5140136-16 LEFT FOOT 2 200 5140135-99 SCREW 6 201 5140136-00 SCREW 2 202 5140136-01 SPRING BRACKET 1 203 5140136-02 SPRING PLATE 1 204 5140136-03 CAM LEVER 1 205 5140136-04 WASHER 2 206 5140136-05 BUSHING 2 207 5140136-06 SPRING BRACKET 1 208 5140136-07 SPRING PLATE 1 209 5140136-08 CAM LEVER 1 220 N276079 RATING LABEL 1 221 N196813 DEWALT
Parts List for DWE7491RS Type 1 Item Number Part Number Description Qty Required 256 5140131-57 WRENCH 2 856 DWE7402DI DADO INSERT 1 856 DWE74911 STAND ASSY 1 COPYRIGHT© 2005. All Rights Reserved. Parts list, pricing, and availability subject to change. Please visit www.dewaltservicenet.com for current parts information.