DENALI ACR5406B-00 Circular Saw Instruction Manual

ACR5406B-00 Circular Saw
Instruction Manual

US/Can: ACR5406B-00
EU/UK: ACR5406B-00E

WARNING
Read all safety warnings, instructions, illustrations and specifications provided with this power tool.
Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.

Tool Description

Intended Use

• This tool is intended for cutting through wood such as softwood, hardwood, wood composites to a maximum thickness of 2-1/8″ (54 mm).
• This tool is intended to be used on dry surfaces and areas only.
• This tool is intended for private use only.
• Usain well ventilated areas.

Before First Use

WARNING Risk of suffocation!
Keep any packaging materials away from children and pets — these materials area potential source of danger, e.g. suffocation.

• Remove all the packing materials.
• Remove and review all components before use.
• Check the tool for transport damages.
• Do not use the tool if it appears damaged.

Technical Terminology

RIP: A cut that travels in the same direction as the wood grain (Fig. 1).
CROSSCUT: A cut that travels across the wood grain (Fig. 1).
MITER CUT: Any cut that travel at an angle relative to the wood grain (Fig. 1).
BEVEL CUT: Any cut that travel at an angle so that the top of the wood is not perpendicular to the edges (Fig. 1).
BINDING THE BLADE: The blade stops cutting and binds with the workpiece.
KICKBACK: The tool suddenly is pushed back towards the operator.
KERF: The channel that has been cut up to a point.
RIP FENCE: A guide installed at the side of the workpiece so that the tool always travels at the same distance between the tool and the edge.

Preparation

5.1 Blades
NOTICE
The blade that comes with the tool is 6-1/2″ (165 mm) of diameter.
5.1.1 Blade parts
The following is the parts of a circular blade (Fig. 2):

5.1.2 Blade types
Here are the basic types of circular saw blades:

• Ripping saw blades are designed to cut in the same direction as the wood grain. Rip blades have a limited number of large and straight teeth which allows the dust from the cut to be cast off and removed efficiently.

• Crosscut saw blades are designed to cut perpendicular to the wood grain. A crosscut blade cuts with kerned teeth. Kerfeld teeth alternate from leaning left and leaning
  right.

• Combination saw blades are designed to cut both rips and crosscuts. Combination blades come with a variety of tooth counts. The difference between higher and lower tooth counts is the finish. The higher the number of teeth, the smoother the cut.

5.1.3 Blade rpm
Blades are designed to operate within a specific range of revolutions per minute ( R P M ). Operating these blades outside the effective RPM range can result in significant blade damage and can potentially cause severe injury or death to an operator or bystander if the blade shatters. Check the packaging of the blade to find if its blade rpm is
compatible with this tool.
5.2 Attaching the blade
CAUTION
Risk of injury!

• Take off the battery pack before attaching the blade (22) to prevent accidentally starting the tool.

• Use only the correct blades for wood-cutting operations. Do not use any abrasive wheels.

• Use only 6-1/2″ (165 mm) blades that are rated 4500/min (rpm) or greater. Never use a blade that is so thick that it prevents the outer flange from engaging with the
  flat side of the spindle. Using a blade not designed for the tool may result in serious personal injury and property damage.

• Wear protective work gloves whole handling the blade (22). The blade (22) can injure unprotected hands.

1. Fully close the base plate (8) and lock the depth of cut adjustment lever (18).

2.  Put the tool upside down with the auxiliary handle (14) and the front edge of the base plate (8) in contact with a flat and stable surface.

3. Set the base plate (8) so that the bevel gauge ( 1 3 ) is on the 0° marking and the bevel adjustment knob (12) fully tightened.

4. Press and hold the spindle lock button (15) to lock the spindle in place.

5. Turn the hex key (19) clockwise, and take off the blade bolt, the washer and the outer flange (Fig. 3).

6. Release the spindle lock button (15).

7. Do not remove the inner flange and verify it is installed correctly with the flat size facing outwards (Fig. 3).

8. Take off the protective tubing from the blade (22).

9. Identify which direction the blade ( 2 2 ) should be installed. Make sure that the saw teeth and the arrow on the blade point in the same direction as the arrow on the
   guards (5, 9) (Fig. 4).

10. Use the lower-guard lift lever (7) to retract and hold the lower guard (9) all the way up into the upper guard (5) (Fig. 5).

11. Slide the blade (22) through the slot in the base plate (8) and mount it against the inner flange on the shaft (Fig. 5).

12. Reinstall the outer flange then finger-tighten the assembly counter-clockwise with the blade bolt. The clamping surfaces of the inner a n d outer flanges must lay flush against the blade. Then tighten the blade bolt with an additional 1/8 turn (45°) with the hex key (19) (Fig. 5).

NOTICE
Do not over-tighten the blade bolt as it ensures slippage o f the blade (22) when it encounters excessive resistance, thus reducing motor overload and tool kickback.

5.3 Detaching the blade
CAUTION
Risk of injury

• Take off the battery pack before detaching the blade (22) t o prevent accidentally starting the tool.
• Wear protective work gloves whole handling the blade (22). The blade (22) can injure unprotected hands.

1. Fully close the base plate (8) and lock the depth of cut adjustment lever (18).
2. Put the tool upside down with the auxiliary handle ( 1 4 ) and the front edge of the base plate (8) i n contact with a flat and stable surface.
3. Set the base plate (8) so that the bevel gauge ( 1 3 ) is on the0° marking and the bevel adjustment knob (12) fully tightened.
4. Press and hold the spindle lock button (15) to lock the spindle in place.
5. Turn the h e x key ( 1 9 ) clockwise, and take off the blade bolt and the outer flange (Fig. 6).
6. Release the spindle lock button (15).
7. Use the lower-guard lift lever (7) to retract the lower guard (9) all the way up into the upper guard (5) (Fig. 6).
8. Slide the blade (22) off through the slot in the base plate (8) (Fig. 6).
9. Reinstall the outer flange then finger-tighten the assembly counter-clockwise with the blade bolt (Fig. 7).
10. Wrap the blade (22) in the provided protective tubing or in newspaper and tape.

5.4 Attaching vacuum adapter
CAUTION
Risk of fire and damage!
Do not use a regular/standard household vacuum cleaner to extract dust. The dust created during operation i s very fine, and it may damage/block the filter of the vacuum cleaner. If the dust enters the motor of the vacuum cleaner, it may cause fire from overheating.
It is highly recommended to always keep the vacuum adapter installed.
For easy cleaning of the operating area, the vacuum adapter (23) can connect the tool to a suitable vacuum cleaner/dust extractor t o catch most of the dust created during use.

1. Using a cross-head screwdriver (not included), attach the vacuum adapter (23) to the dust port (6) using the vacuum adapter screw (24) (Fig. 8).
2. Connect the vacuum cleaner/dust extractor to the vacuum adapter (23) (Fig. 9).

5.5 Detaching vacuum adapter
Using a cross-head screwdriver (not included), take out the vacuum adapter screw (24) to detach the vacuum adapter (23) from the tool (Fig. 10).

5.6 Depth of cut adjustment
CAUTION
Risk of injury!
Take off the battery pack before making adjustments to prevent accidentally starting the tool.
It is recommended that the tooth of the blade does not extend through the workpiece more than a full tooth approximate 1/4″ (6.35 mm).
The depth of cut adjustment lever ( 18 ) is used to set the depth of the cut.

1. Loosen the depth of cut adjustment lever (18).
2. Place the base plate (8) of the tool flat against the edge o f the workpiece.
3. Raise or lower the blade (22) with the main handle (3) (Fig. 11).• To avoid kickback and blade binding, do not set the cutting depth more than a tooth (1/4″ / 6.35 mm) lower than the workpiece.
4. When the   mark aligns with the desired cutting depth (0 – 5 1 mm) on the depth of cut gauge ( 2 1 ) , securely tighten the depth of cut adjustment lever (18) (Fig. 12).

5.7 Bevel adjustment
CAUTION
Risk of injury!

• Take off the battery pack before making adjustments to prevent accidentally starting the tool.
• Attempting to make bevel cuts without the bevel adjustment knob (12) securely tightened can result in serious injury.
• Because of the increased amount of blade engagement in the work while bevel cutting and decreased stability of the base plate, blade binding may occur. Keep the tool steady and the base plate (8) firmly on the workpiece.

NOTICE

• When bevel cutting, the depth of cut does not correspond with value on the depth of cut gauge (21).
• Since the blade thicknesses vary and different angles require different settings, always make a trial cut in scrap material along a guideline to determine how much to offset from the guideline on the workpiece to be cut.

The bevel adjustment knob (12) is used to set the cutting angle.

1. Loosen the bevel adjustment knob (12) by rotating it counterclockwise (Fig. 13).
2. Tilt the base plate (8) until the indicator mark reaches the desired angle (0° – 50°) on the bevel gauge (13) (Fig. 13).
3. Securely tighten the bevel adjustment knob (12) by rotating it clockwise (Fig. 13).

5.7.1 0° bevel check and adjustment
CAUTION
Risk of injury!
Take off the battery pack before making adjustments to prevent accidentally starting the tool.
0° bevel check:

1. Set the base plate (8) to the maximum depth of cut setting on the depth of cut gauge (21).
2. Set the tool to 0° bevel on the bevel gauge (13).
3. Turn the tool upside down and place it on a stable surface.
4. Use the straight angle on a speed square (not included) to check that the angle between the blade (22) and the underside of the base plate (8) is a 90° (Fig. 14).

0° bevel adjustment:
NOTICE
The tool. has been adjusted before shipment so that the base plate (8) is perpendicular (901 to the blade (22) at 0° bevel cutting. Only adjust this part of the tool if it did not pass the 0° bevel check.

1. Loosen the bevel adjustment knob (12).
2. Set the tool to 0° bevel on the bevel gauge (13)
3. Turn the tool upside down and place it on a stable surface.
   4 , Use a cross-head screwdriver (not included) to turn the bevel stop adjustment screw (16) until the base plate (8) is perpendicular (90°) t o the blade (22) (Fig. 15).
   After adjusting, perform the 0° bevel check again (Fig. 15).

5.8 Attaching the battery pack
CAUTION
Risk of injury!
Battery tools are always in operating condition. Therefore, take off the battery when the tool is not in use or when it is being carried.
NOTICE

• Use the tool with a fully charged battery pack that is suitable for this tool. Use this tool only with the provided battery pack (model ABY5197B-00, ABY5197B-00E, ABY5196B-00 or ABY5196B-00E) and charger. The tool can also be used with SKIL PWR CORE 20 battery pack. Use of non-compliant battery packs and chargers may cause risk of fire and/or explosion.
• When placing the battery pack on the tool, be sure that the raised rib on the battery pack aligns with the groove inside the tool and that the latches snap into place properly. Improper attachment of the battery pack can cause damage to internal components.

1. Align the raised ribs on the battery pack with the battery slot (4) on the tool.
2. Slide the battery pack onto the tool (Fig. 16). The battery pack snaps and locks into place.

5.9 Detaching the battery pack

1. Press and hold the battery-release button located on the front o f the battery pack to release it from the battery slot (4).
2. Slide the battery pack upwards off the tool (Fig. 17).

Use

6.1 Operating parts

The tool has the following parts that are often used during cutting (Fig. 18).
6.1.1 Lock off button

(1) The lock off button (1) prevents unintentionally pressing the power switch (2). The power switch (2) can only be activated if the lock-off button (1) Is pressed.

6.1.2 Power switch (2)
Pressing the power switch (2) starts the cutting action. The blade (22) starts spinning.
6.1.3 Main handle (3) and auxiliary handle (14)
Stand behind the tool and hold both the main handle (3) and auxiliary handle (14) while operating to ensure that no body parts are in the way of the cutting path of the tool. 6.1.4 Lower guard (9) with lower guard lift lever (7)
The lower guard (9) is spring-loaded, it automatically springs back to the closed position when a cut is finished to ensure the spinning blade (22) is exposed only during cutting. Always check that the lower guard (9) is closed before setting it down. The lower guard lift lever (7) is used to open the lower guard (9) manually for blade (22) replacement or plunge cuts.
CAUTION
Risk of injury!
Do not use the tool if the lower guard (9) is defective. The lower guard (9) is defective when it does not automatically spring back to the closed position when a cut is finished.
6.1.5 Saw line window (10)
The saw line window (10) shows the cutting path of the blade (22).

• For 0° bevel cuts, align the cutting line with the 0° notch.
• For 45° bevel cuts, align cutting line with the 45° notch.

NOTICE
The saw line window (10) can only give an approximate line of cut since the type and thickness of the blade varies. Make sample cuts in scrap lumber to verify the actual line of cut
6.1.6 LED light
The LED light located behind the upper guard (5). The LED light switches on when the power switch (2) is pressed, and switches off after the power switch (2) is released. It provides additional light on the blade (22) and the surface of the workpiece during operation in lower-light areas.
If the tool and/or battery pack becomes overloaded or too hot, the internal sensors will switch the tool off, and the LED light will rapidly flash. Rest the tool for a while or place the tool and battery pack separately under air flow for cooling.
6.2 Before each use
Wear personal protective equipment (PPE). Depending on the application, use face shield, safety goggles or safety glasses. As appropriate, wear dust mask, hearing protectors, gloves and full body suit capable o f stopping small abrasive or workpiece fragments (Fig. 19).

• Check the tool and its accessories for damage. Do not use the tool if it is damaged or worn out.
• Check for loose screws, misalignment or binding of moving parts, or any other condition that may affect the operation. If abnormal vibration or noise occurs, switch the tool off immediately and have the problem corrected before further use.
• Check that the vacuum cleaner hose is behind the tool, it should be clear of the cutting path and have enough length to avoid any tangles or getting caught by the workpiece or surrounding objects.
• Do not attempt to modify this tool or create accessories not recommended for use with this tool. Any such alteration or modification is misuse and could result in a hazardous condition leading to possible serious injury.
• Check the condition of the battery pack. Charge the battery pack if needed. Do not use the battery if it is bulging or hot.
• Always firmly hold the tool by its handles. Keep the tool clean and wear clean gloves to maintain a firm grip while in use.
• Check that the ventilation openings are not obstructed. Obstructed ventilation openings can cause overheating. Clean the tool with compressed dry air if needed.
• Stop operating the tool immediately if bystanders are interrupting the work. Never lay the tool down until the lower guard (9) is in the closed position. The spinning blade may grab the surface and pull the tool out of your control.
• Do not work continuously for extensive amounts of time with the tool. Take breaks in between work to ensure full concentration while using the tool. 1 Avoid using the tool in an inverted position.

6.3 Cutting tips
WARNING
Risk of injury!

• To make sawing easier and safer, always maintain proper control of the tool. Loss of control could cause an accident resulting in serious injury.
• Maintain a firm grip and operate the power switch with a decisive action. Never force the tool. Use light and continuous pressure.
• When lifting the tool from the workpiece, the blade is exposed on the underside of the tool until the lower blade guard closes. Make sure that the blade has stopped spinning and the lower blade guard is closed before setting the tool down.

To make the safest and best possible cut, follow these cutting tips:

• Prop up the workpiece to cut it.
• If needed, support the workpiece with spacers but do not put them too far apart as the workpiece may bend inwards.
• Prevent the workpiece from sliding by securing it with clamps. Do not attempt to hold a workpiece in place with hands or not at all.
• Draw a guideline along the desired cutting line before beginning the cut.
• Hold both the main handle (3) and auxiliary handle (14) firmly (Fig. 20).

• Never touch the workpiece while making a cut.
• Support the workpiece so that the cut is always to the user’s side and not directly in line with the user’s body.
• Apply even pressure on the tool while cutting and make sure the base plate (8) is flat and fully in contact with the workpiece.
• Rest the front edge of the base plate on the workpiece without touching the blade to the workpiece.
• Allow the blade to reach full speed before making the cut. 0 Always allow the blade to come to a complete stop before lifting the tool from the workpiece.

NOTICE

• Too much pressure on the tool may bind the blade to the cut (Fig. 21).
• When cutting is interrupted, to resume cutting: allow the blade to reach full speed before re-entering the cut slowly.
• When making a crosscut, the fibers of the wood have a tendency to tear and lift. Advancing the tool slowly can minimize this effect.

6.4 Starting/stopping the tool

• To start the tool: Press the lock off button (1) to the left or to the right, then press the power switch (2). (Fig. 22).
• To stop the tool: Release the power switch (2) (Fig. 22).

6.5 Making different cuts
CAUTION
Risk of injury!

• Always be sure that neither hand interferes with the free movement of the lower guard (9).
• After completing a cut and releasing the power switch (2), be aware of the necessary time it takes for the blade (22) to come to a complete stop. Do not allow the tool to brush against your leg or side. Since the lower guard (9) is retractable, it could catch on clothing and expose the blade (22). Be aware of the necessary blade (22) exposures that exist in both the upper guard (5) and lower guard (9) areas.

NOTICE

• Since the blade thicknesses vary and different angles require different settings, always make a trial cut in scrap material along a guideline to determine how much to offset from the guideline on the workpiece to be cut.
• The distance from the blade (22) to the tool base is approximately 1-3/8″ (35 mm) on the left side of the tool and 4-1/6″ (105 mm) on the right.

6.5.1 General cuts
The following instructions are suitable for cross-cuts, rip cuts and miter cuts.

1. Install the correct blade for the type of cut desired.
2. Secure the workpiece with clamps.
3. Adjust the tool bevel to 0° following 5.7 Bevel adjustment chapter. Make sure the bevel adjustment knob (12) is securely locked in place.
4. Adjust the tool to the desired depth of cut following 5.6 Depth of cut adjustment chapter. Make sure the depth of cut adjustment lever (18) is securely tightened.
5. Rest the front edge of the base plate (8) on the workpiece without touching the blade (22) to the workpiece.
6. Start the tool and allow the blade (22) to reach full speed.
7. Line up the 0° notch on the saw line window (10) with the drawn guideline to make the cut (Fig. 23).
8. Stop the tool and allow the blade (22) to come to a complete stop.
9. Lift the tool off the workpiece. 6.5.2 Cutting using a straight edge

NOTICE
A rip fence (not included) can be used as a guide instead of clamping a straight edge so that the tool always travels at the same distance between the tool and the edge.
The following instructions are suitable for cross-cuts, rip cuts and miter cuts.

1. Secure the workpiece with clamps.
2. Clamp a straight edge to the workpiece using clamps (not included).
3. Adjust the tool to the desired depth of cut following 5.6 Depth of cut adjustment chapter. Make sure the depth of cut adjustment lever (18) is securely tightened.
4. Rest the front edge of the base plate (8) on the workpiece without touching the blade (22) to the workpiece.
5. Start the tool and allow the blade (22) to reach full speed.
6. Following the straight edge, guide the tool into the workpiece to make the cut (Fig. 24).
7. Stop the tool and allow the blade (22) to come to a complete stop.
8. Lift the tool off the workpiece.

6.5.3 Bevel cut
NOTICE
When bevel cutting, the depth of cut does not correspond with value on the depth of cut gauge (21).
The following instructions are suitable for bevel cuts only.

1. Secure the workpiece with clamps.
2. Adjust the toot to the desired bevel angle following 5.7 Bevel adjustment chapter. Make sure the bevel adjustment knob (12) is securely locked in place.
3. Adjust the tool to the desired depth of cut following 5.6 Depth of cut adjustment chapter. Make sure the depth of cut adjustment lever (18) is securely tightened.
4. Rest the front edge of the base plate (8) on the workpiece without touching the blade (22) to the workpiece
5. Start the tool and allow the blade (22) to reach full speed.
6. Line up the 45° notch on the saw line window (10) with the drawn guideline to make the cut (Fig. 25).
7. Stop the tool and allow the blade (22) to come to a complete stop.
8. Lift the tool off the workpiece.

6.5.4 Plunge cut

1. Secure the workpiece with clamps.
2. Adjust the tool bevel to 0° following 5.7 Bevel adjustment chapter. Make sure the bevel adjustment knob (12) is securely locked in place.
3. Adjust the tool to the desired depth of cut following 5.6 Depth of cut adjustment chapter. Make sure the depth of cut adjustment lever (18) is securely tightened.
4. Holding the main handle (3) of the tool with one hand, tilt the tool forward and rest the front of the base plate (8) on the material to be cut.
5. Line up the 0° notch on the saw line window (10) with the drawn guideline.
6. With the other hand, raise the lower guard (9) using lower guard lift lever (7).
7. Position the blade (22) just clear of the material to be cut.
8. Start the tool and allow the blade (22) to reach full speed.
9. Using the front of the base plate (8) at a hinge point, gradually lower the back end of the tool into the material (Fig. 26).
10. Once the base plate (8) rests flat on the surface of the material, release the tower guard lift lever (7) and move the free hand to hold the auxiliary handle (14).
11. Proceed cutting in forward direction to end of the marked cut.
12. Stop the tool and allow the blade (22) to come to a complete stop.
13. Lift the tool off the workpiece.

NOTICE
If corners of the plunge cut are not completely cut through, use a jigsaw or hand saw to finish the corners.

Cleaning and Maintenance

NOTICE

• Detach the battery pack and the blade before cleaning, maintenance, storage, or transportation.
• Do not immerse the tool in water or other liquids. Never hold the tool under running water.

7.1 Cleaning the housing

• Clean the outer housing with soft, slightly damp cloth. Wipe dry after cleaning.
• Never use corrosive detergents, wire brushes, abrasive scourers, metal or sharp utensils to clean the tool.

NOTICE
The tool may be cleaned most effectively with compressed dry air. When doing so, do not exceed the pressure of 43 PSI (3 bar) and always wear safety goggles.
NOTICE
Certain cleaning agents and solvents damage plastic parts. Some of these are: gasoline, carbon tetrachloride, chlorinated cleaning solvents, ammonia and household detergents that contain ammonia. Do not use cleaning agents and solvents containing these, as they can damage the tool.
7.2 Cleaning the guarding system
Clean the guards and base plate using a soft brush.
7.3 Blade care

• Blades become dull after some use. If the tool has to be forced to go through a cut, the blade is dull or is not clean
• Clean the blade with soft, slightly damp cloth. Wipe dry after cleaning.
• Replace the blade if it has become dull.

7.4 Repair
This tool does not contain any parts that can be repaired by the user. Contact a professional repair center or a professional technician to have the tool checked out and repaired.
7.5 Transport

• Make sure the tool is secured safely for transit.
• Avoid vibrations and shocks.

7.6 Storage

• Clean the tool before storing.
• Store the tool in its original packaging in a dry area. Keep away from children and pets.
• Store the blade with the protective tubing.

7.7 Spare parts/replacement parts
CAUTION
Risk of injury!
Using parts that are not compatible with the tool may cause accidents that can result in serious injury.

and United Kingdom: ABY5197B-00E, ABY5196B-00E
Battery charger| North American market: ASC5358B-00 European market: ASCS358B- 00E United Kingdom: ASC5358B-00U

7.8 Maintenance
CAUTION
Risk of injury!
Maintenance performed by unauthorized personnel may result in misplacing of internal wires and components which could cause a serious injury.
Any other servicing than mentioned in this manual should be performed by a professional repair center.

Frequently Asked Questions

Check if the battery pack is attached to the tool properly.
Check if battery pack of correct type is connected (model ABY5197B-00, ABY5197B-00E, ABY5196B-00, ABY5196B-00E).
Burned out switch. Have the switch replaced by a professional repair center.
Blade does not come up to speed.| Motor is overheated. Switch off the tool, clean the ventilation openings and allow the motor to cool down before trying again.
Motor is overloaded. Reduce the pressure on the tool. Battery is low. Recharge the battery pack or use a fully charged battery pack.
Excessive vibration.| Blade out of balance. Replace with a new blade. Workpiece not clamped or supported properly. Clamp or support workpiece property.

MADE IN CHINA
**V02-09/22

**

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