DEWALT DWS520KT Plunge Circular Saw 1300W Instruction Manual

DWS520KT Plunge Circular Saw 1300W
Instruction Manual

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1-800-4-DEWALT
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INSTRUCTION MANUAL
DWS520
Heavy-Duty Track Saw

Definations: Safety Guidelines
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 that, if not avoided, will result in death or serious injury.
WARNING: Indicates a potentially hazardous situation that, 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.
CAUTION: Using without the safety alert symbol indicates a potentially hazardous situation that, if not avoided, may result in property damage.
IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL, CALL US TOLL FREE AT:
1-800-4-DEWALT (1-800-433-9258).
WARNING: To reduce the risk of injury, read the instruction manual.

GENERAL POWER TOOL SAFETY

WARNINGS
WARNING! Read all safety warnings and instructions
Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.
1) WORK AREA SAFETY
a) Keep the work area clean and well-lit. Cluttered or dark areas invite accidents.
b) Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks that may ignite dust or fumes.
c) Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.
2) ELECTRICAL SAFETY
a) Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and
matching outlets will reduce the risk of electric shock.
b) Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges, and refrigerators. There is an increased risk of electric shock if your body is earthed
or grounded.
c) Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
d) Do not abuse the cord. Never use the cord for carrying, pulling, or unplugging the power tool. Keep the cord away from heat, oil, sharp edges or moving parts. Damaged or
entangled cords increase the risk of electric shock.
e) When operating a power tool outdoors, use an extension cord suitable for outdoor use. The use of a cord suitable for outdoor use reduces the risk of electric shock.
f) If operating a power tool in a damp location is unavoidable, use a ground fault circuit interrupter (GFCI) protected supply. Use of a GFCI reduces the risk of electric shock. 3) PERSONAL SAFETY
a) Stay alert, watch what you are doing, and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.
b) Use personal protective equipment. Always wear eye protection. Protective equipment such as dust masks, nonskid safety shoes, hard hats, or hearing protection used for appropriate conditions will reduce personal injuries. c) Prevent unintentional starting. Ensure the switch is in the off position before connecting to a power source and/ or battery pack, picking up, or carrying the tool. Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.
d) Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.
e) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
f) Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
g) If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. The use of dust collection can reduce dust-related hazards.
4) POWER TOOL USE AND CARE
a) Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.
b) Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
c) Disconnect the plug from the power source and/or the battery pack from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.
d) Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.
e) Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
g) Use the power tool, accessories and tool bits etc., in accordance with these instructions taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.
5) SERVICE
a) Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

ADDITIONAL SPECIFIC SAFETY RULES

Safety Instructions for All Saws
a) DANGER: Keep hands away from the cutting area and the blade. Keep your second hand on the auxiliary handle, or motor housing. If both hands are holding the saw, they cannot be cut by the blade.
b) Do not reach underneath the workpiece. The guard cannot protect you from the blade below the workpiece.
c) Adjust the cutting depth to the thickness of the workpiece. Less than a full tooth of the blade teeth should be visible below the workpiece.
d) Never hold pieces being cut in your hands or across your leg. Secure the workpiece to a stable platform. It is important to support the work properly to minimize body exposure, blade binding, or loss of control.
e) Hold the power tool by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord. Contact with a “live” wire will also make exposed metal parts of the power tool “live” and shock the operator.
f) When ripping always use a rip fence or straight-edge guide. This improves the accuracy of the cut and reduces the chance of blade binding.
g) Always use blades with the correct size and shape (diamond versus round) of arbor holes. Blades that do not match the mounting hardware of the saw will run eccentrically, causing a loss of control.
h) Never use damaged or incorrect blade washers or bolts. The blade washers and bolts were specially designed for your saw, for optimum performance and safety of operation.

CAUSES AND OPERATOR PREVENTION OF KICKBACK
– Kickback is a sudden reaction to a pinched, bound or misaligned saw blade, causing an uncontrolled saw to lift up and out of the workpiece toward the operator.
– When the blade is pinched or bound tightly by the kerf closing down, the blade stalls, and the motor reaction drives the unit rapidly back toward the operator.
– If the blade becomes twisted or misaligned in the cut, the teeth at the back edge of the blade can dig into the top surface of the wood causing the blade to climb out of the kerf and jump back toward the operator. Kickback is the result of tool misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below:
a) Maintain a firm grip with both hands on the saw and position your body and arm to allow you to resist kickback forces. Kickback forces can be controlled by the operator, if proper precautions are taken.
b) When the blade is binding, or when interrupting a cut for any reason, release the trigger and hold the saw motionless in the material until the blade comes to a complete stop. Never attempt to remove the saw from the work or pull the saw backward while the blade is in motion or kickback may occur. Investigate and take corrective actions to eliminate the cause of blade binding.
c) When restarting a saw in the workpiece, center the saw blade in the kerf and check that the saw teeth are not engaged in the material. If the saw blade is binding, it may walk up or kick back from the workpiece as the saw is restarted.
d) Support large panels to minimize the risk of blade pinching and kickback. Large panels tend to sag under their own weight. Support must be placed under the panel
on both sides, near the line of cut and near the edge of the panel.
e) Do not use dull or damaged blade. Unsharpened or improperly set blades produce narrow kerf causing excessive friction, blade binding, and kickback.
f) Blade depth and bevel adjusting locking levers must be tight and secure before making cut. If blade adjustment shifts while cutting, it may cause binding and kickback.
g) Use extra caution when making a “Plunge Cut” into existing walls or other blind areas. The protruding blade may cut objects that can cause kickback.
Safety Instructions for Plunge-Type Saws
a) Check guard for proper closing before each use. Do not operate the saw if guard does not move freely and enclose the blade instantly. Never clamp or tie the guard with the blade exposed. If saw is accidentally dropped, guard may be bent. Check to make sure that guard moves freely and does not touch the blade or any other part, in all angles and depths of cut.
b) Check the operation and condition of the guard return spring. If the guard and the spring are not operating properly, they must be serviced before use. Guard may operate sluggishly due to damaged parts, gummy deposits, or a build- up of debris.
c) Assure that the guide plate of the saw will not shift while performing the “plunge cut” when the blade bevel setting is not at 90°. Blade shifting sideways will cause binding and likely kickback.
d) Always observe that the guard is covering the blade before placing saw down on bench or floor. An unprotected,  coasting blade will cause the saw to walk backwards, cutting
whatever is in its path. Be aware of the time it takes for the blade to stop after switch is released.
Additional Safety Instructions for All Saws with Riving Knife
a) Use the appropriate riving knife for the blade being used. For the riving knife to work, it must be thicker than the body of the blade but thinner than the tooth set of the blade.
b) Adjust the riving knife as described in this instruction manual. Incorrect spacing, positioning, and alignment can make the riving knife ineffective in preventing kickback.
c) Always use the riving knife except when plunge cutting.
The Riving knife must be replaced after plunge cutting. A Riving knife causes interference during plunge cutting and can create kickback. Model DWS520 does not require the removal of the riving knife because the riving knife retracts during a plunge cut.
d) For the riving knife to work, it must be engaged in the workpiece. The riving knife is ineffective in preventing kickback during shortcuts.
e) Do not operate the saw if the riving knife is bent. Even light interference can slow the closing rate of a guard.
Additional Safety Instructions for Saws

• Wear ear protectors. Exposure to noise can cause hearing loss.
• Wear a dust mask. Exposure to dust particles can cause breathing difficulty and possible injury.
• Use only recommended blades. The saw is designed for use with 6-1/2″ (165 mm) diameter blades that have a 0.79″ (20 mm) diameter bore. Blades must be rated for 6000 RPM operation (or higher).
• Never use abrasive cut-off wheels.
• Keep your body positioned to either side of the blade, but not in line with the saw blade. kickback could cause the saw to jump backwards (see Causes and Operator Prevention of Kickback and kickback).
• CAUTION: Blades coast after turn off. Serious personal injury may result.
• Avoid cutting nails. In spect for and remove all nails from lumber before cutting.

EXTENSION CORDS
An extension cord must have adequate wire size (AWG or American Wire Gauge) for safety. The smaller the gauge number of the wire, the greater the capacity of the cable, that is 16 gauge has more capacity than 18 gauge. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating.
When using more than one extension to make up the total length, be sure each individual extension contains at least the minimum wire size. The following table shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

MINIMUM GAUGE FOR CORD SETS

Ampere Rating| Volts| Total Length of Cord in Feet (meters)
120V| 25 (7.6)| 50 (15.2)| 100 (30.5)| 150 (45.7)
240V| 50 (15.2)| 100 (30.5)| 200 (61.0)| 300 (91.4)
More Than| Not more than| AWG
0| 6| | 18| 16| 16| 14
6| 10| 18| 16| 14| 12
10| 12| 16| 16| 14| 12
12| 16| 14| 12| Not Recommended

• Air vents often cover moving parts and should be avoided. Loose clothes, jewelry or long hair can be caught in moving parts.
• Accessories must be rated for at least the speed recommended on the tool warning label. Accessories running at rated speed can fly apart and cause injury. Accessory ratings must always be above tool speed as shown on the tool nameplate.

WARNING: ALWAYS wear proper personal hearing protection that conforms to ANSI S12.6 (S3.19) during use. Under some conditions and duration of use, noise from this product may contribute to hearing loss.
WARNING: ALWAYS use safety glasses. Everyday eyeglasses are NOT safety glasses. Also, use a face or dust mask if the cutting operation is dusty.
ALWAYS WEAR CERTIFIED SAFETY EQUIPMENT:

• ANSI Z87.1 eye protection (CAN/CSA Z94.3),
• ANSI S12.6 (S3.19) hearing protection,
• NIOSH/OSHA/MSHA respiratory protection.

WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

• lead from lead-based paints,
• crystalline silica from bricks and cement and other masonry products, and
• arsenic and chromium from chemically-treated lumber (CCA).

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well-ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

• Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling, and other construction activities. Wear protective clothing and wash exposed areas with soap and water. Allowing dust to get into your mouth and eyes, or lay on the skin may promote the absorption of harmful chemicals.

WARNING: Use of this tool can generate and/or disburse dust, which may cause serious and permanent respiratory or another injury. Always use NIOSH /OSHA-approved respiratory protection appropriate for dust exposure. Direct particles away from the face and body.

• The label on your tool may include the following symbols. The symbols and their definitions are as follows:

V …………volts A
Hz ……….hertz W
min ……..minutes
………….. …..direct current
 ……….Class I Construction (grounded)
……….Class II Construction (double insulated)
BPM ……beats per minute
RPM ……revolutions per minute
A ………….amperes
W …………watts
……….alternating current
……….alternating or direct current
………..no load speed
…………earthing terminal
………..safety alert symbol
…/min …..per minute

SAVE THESE INSTRUCTIONS
Motor
Be sure your power supply agrees with the nameplate marking. As little as 10% lower voltage can cause loss of power and can result in overheating. All DEWALT tools are factory-tested; if this tool does not operate, check the power supply.
WARNING: Accessories must be rated for at least the speed recommended on the tool warning label. Accessories running over rated speed can fly apart and cause injury. Accessory ratings must always be above tool speed as shown on tool nameplate.
CAUTION: Avoid contact with the blade teeth to prevent personal injury.
COMPONENTS (Fig. 1–3, 8)
WARNING: Never modify the power tool or any part of it. Damage or personal injury could result.

A. Plunge trigger
B. On/off switch
C. Main handle
D. Shoe
E. Bevel adjustment knob
F . Depth adjustment knobs
G. Depth scale
H. Front handle
I. Dust extraction outlet
J. T rack adjuster
K. Blade
L. Lock button
M. Lock lever| N. Blade clamping screw
O. Outer flange
P . Inner flange
Q. Riving knife
R. Riving knife adjustment screws
S. Speed wheel
T . Cutting indicator
U. Anti-kickback knob
V . Outer guard
W. Track
X. Bevel scale
Y . Blade position indicators
Z. Hex wrench
---|---

INTENDED USE

The DWS520 track saw is designed to cut wood. Do not use this saw to cut solid-surface countertops (i.e., Corian®).
WARNING: To reduce the risk of serious personal injury, do not use this saw to cut solid-surface countertops. The material build-up may inhibit the proper function of the plunge return, leaving the blade exposed.

ADJUSTMENTS AND SET-UP

WARNING: To reduce the risk of injury, turn the unit off and disconnect it from the power source before installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.
WARNING: Before using the track saw, ALWAYS make sure all functions are working properly!
Bevel Adjustment (Fig. 1)
The bevel angle can be adjusted between 0° and 47°.

1. Loosen the bevel adjustment knobs (E).
2. Set the bevel angle by tilting the saw shoe (D) until the mark indicates the desired angle on the bevel scale (X).
3. Tighten the bevel adjustment knobs (E).

Adjusting the Riving Knife (Fig. 3)
For the correct adjustment of the riving knife (Q), refer to Figure 3. Adjust the clearance of the riving knife after changing the saw blade or whenever necessary.

1. Follow Changing the Saw Blade steps 1–4.
2. Loosen the riving adjustment screw (R) with a hex wrench (Z) and set the riving knife as shown in Figure 3.
3. Tighten the riving knife screw (R).
4. T urn the lock lever (M) counterclockwise until it stops.
5. Move the track saw back to top position.

Cutting Depth Adjustment (Fig. 4)
The cutting depth can be set at 0–2-5/16″ (0–59 mm) without a track attached; with the track attached: 0–2-1/8″ (0–55 mm).

1. Loosen the depth adjustment knob (F) and move the pointer to obtain the correct depth of cut.
2. Tighten the depth adjustment knob (F).

NOTE: For optimal results, allow the saw blade to protrude from the workpiece by about 1/8″ (3 mm).

OPERATION

WARNING: To reduce the risk of injury, turn the unit off and disconnect it from the power source before installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.
Switching On and Off (Fig. 1)
Pull the On/off switch (B) to turn the motor on. Releasing the trigger turns the motor off. This tool has no provision to lock the switch in the on position, and should never be locked on by any other means.
Changing the Saw Blade (Fig. 1–3)
WARNING: To reduce the risk of injury, turn the unit off and disconnect it from the power source before installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.
CAUTION: Avoid contact with the blade teeth to prevent personal injury.
CAUTION: Never engage the blade lock while saw is running or engage in an effort to stop the tool. Never turn the saw on while the blade lock is engaged. Serious damage to your saw will result.

1. Press the lock button (L).

2. Press the track saw down to stop (blade change position).

3. Turn the lock lever (M) clockwise until it stops.

4. Press the lock lever (M) down and rotate the blade until the lock position is found.
   NOTE: The blade (K) is now locked and cannot be turned by hand.

5. Turn the blade clamping screw (N) counterclockwise to remove.

6. Remove the outer flange (O) and used the blade (K). Place the new blade on the inner flange (P).

7. Replace the outer flange (O) and blade clamping screw (N). Turn the screw clockwise by hand.
   CAUTION: The direction of rotation of the saw blade and the rotation of the track saw MUST be the same.

8. Tighten the blade clamping screw firmly using the hex wrench (Z).

9. T urn the lock lever (M) counterclockwise until it stops.

10. Move the track saw back to top position.

11. Push plunge trigger (A) forward, to lock saw blade change.

Workpiece Support

WARNING: Hands should be kept away from cutting area to reduce the risk of injury.
WARNING: The power cord should be positioned clear of the cutting area so that it will not get caught or hung up on the work and to prevent electric shock.
Figure 5 shows proper sawing position. Figure 6 shows an unsafe condition. T o avoid kickback, DO support the board or panel NEAR the cut. DON’T support board or panel away from the cut.
WARNING: When operating the saw, keep the cord away from the cutting area to prevent electric shock.

WARNING: It is important to support the work properly and to hold the saw firmly to prevent loss of control which could cause personal injury. Figure 7 illustrates the typical hand support of the saw.

Place the work with its “good” side – the one on which appearance is most important – down. The saw cuts upward, so any splintering will be on the work face that is up when you saw it.

Cutting

DANGER: Risk of electrical shock. Keep the cord away from the cutting area to prevent electrocution.
WARNING: If the guard binds or is sluggish, return the saw to your nearest authorized DEWALT T service center for repair.
WARNING: For maximum protection, effective control of this powerful saw requires a two-handed operation. support the work properly and hold the saw firmly to prevent loss of control which could cause injury. Refer to Figure 7 for the proper way to hold the saw.
WARNING: Stay alert and maintain a firm grip on the saw. Release the switch immediately if the blade binds or the saw stalls. Keep your blade sharp. Properly support panels (Fig. 5, 6). Use the track when ripping. DO NOT force the tool. DO NOT remove the saw from the workpiece while the blade is moving.
WARNING: To help reduce the risk of personal injury, always clamp work. Don’t try to hold short pieces by hand! Remember to support cantilevered and overhanging material. Use caution when sawing material from below.
WARNING: Be sure that the saw is up to full speed before the blade contacts the material to be cut. Starting the saw with a blade against the material to be cut or pushed forward into the kerf can result in kickback and personal injury.
**WARNING: ALWAYS secure the workpiece in such a manner that it cannot move while sawing. For optimum results, clamp the workpiece bottom up.
WARNING: ALWAYS push the machine forwards. NEVER pull the machine backward towards you.
WARNING:** ALWAYS use the clamp (Fig. 8, AA) to hold the track to the workpiece.
CAUTION: Do not operate your tool on a current on which the voltage is not within the correct limits. Do not operate tools rated only on DC current. To do so may seriously damage the tool.

1. Place the machine with the front part of the saw base on the workpiece.
2. Press the on/off switch to turn the saw on.
3. Push the plunge trigger (A) forward, press the saw down to set the cutting depth, and push it forward into the cutting direction.

Push the saw forward at a speed that allows the blade to cut without laboring. Hardness and toughness can vary even in the same piece of material, and knotty or damp sections can put a heavy load on the saw. When this happens, push the saw more slowly, but hard enough to keep it working without much decrease in speed. Forcing the saw can cause rough cuts, inaccuracy, kickback, and overheating of the motor.
Should the cut begin to go off the line, DO NOT try to force it back? Release the switch and allow the blade to come to a complete stop, then withdraw the saw, realign, and start a new cut slightly inside the wrong one.
In any event, withdraw the saw if you must shift the cut. Forcing a correction inside the cut can stall the saw and lead to kickback. I SAWEST ALLS, RELEASE THE TRIGGER, ALLOW THE BLADE TO COME TO A COMPLETE STOP, AND BACK THE SAW UNTIL IT IS LOOSE. BE SURE THE BLADE IS STRAIGHT IN THE CUT AND CLEAR OF THE CUTTING EDGE BEFORE REST RATING.
As you finish a cut, release the trigger and allow the blade to stop before lifting the saw from the work. As you lift the saw, the spring-tensioned guard will automatically close around the blade. Remember the blade is exposed until this occurs, never reach under the work for any reason whatsoever. Always use a track, fence, or straight-edge guide when ripping.
NOTE: When cutting thin strips, be careful to ensure that the narrow strips do not feed up into the inside of the blade enclosure.
NOTE: The tracks, available in different lengths, allow for precise, clean cuts and simultaneously protect the workpiece surface against damage.

PLUNGE CUTS (FIG. 1, 8)
WARNING: ALWAYS use the track when plunge cutting.
WARNING: To avoid kickbacks, the following instructions MUST be observed when plunge cutting:

1. Place the machine onto the track and release the anti-kickback knob (U) by turning it counterclockwise.
2. Turn the machine on and slowly press the saw down onto the set cutting depth and push forward in the cutting direction. The cut indicators (T) display the absolute front and the absolute rear cutting points of the saw blade [dia. 6-1/2″ (165 mm)] at maximum cutting depth and using the track.
3. If kickback happened during the plunge cut, turn the antikickback knob (U) counterclockwise to release it from the track.
4. When you have finished the plunge cut, turn the anti-kickback knob (U) clockwise into the lock position.

CROSS-CUTTING
Cutting directly across the grain of a piece of lumber is called crosscutting. Figures 9 and 10 illustrate a crosscut operation. Position the work so that the cut will be on the left.

RIPPING
Ripping is cutting wood lengthwise. This operation is performed in the same manner as crosscutting with the exception of supporting the workpiece. If the workpiece is supported on a large table, bench, or floor, several pieces of scrap stock approximately 1″ (25.4 mm) thick should be placed beneath the material to allow clearance for the portion of the saw blade that extends thru the workpiece. Large sheets of paneling or thin plywood supported on saw horses should have 2 x 4’s placed lengthwise between the horses and the workpiece to prevent it from sagging in the center.
BEVEL CUTTING
Make your bevel cuts in the same manner as crosscuts and rip cuts, but set the blade at an angle between 0° and 47°. The bevel cut made at an angle to the edge of a board is called a compound cut.

KICKBACK

When the saw blade becomes pinched or twisted in the cut, kickback can occur. The saw is thrust rapidly back toward the operator. When the blade is pinched or bound tightly by the kerf closing down, the blade stalls, and the motor reaction drives the unit backward. When the blade becomes twisted or misaligned in the cut, the teeth at the back edge of the blade can dig into the top surface of the wood causing the blade to climb out of the kerf and jump back toward the operator. Kickback is more likely to occur when any of the following conditions exist.

1. IMPROPER WORKPIECE SUPPORT
   A. Sagging or improper lifting of the cut-off piece can cause pinching of the blade and lead to kickback.
   B. Cutting through material supported at the outer ends only can cause kickback. As the material weakens it sags, closing down the kerf and pinching the blade.
   C. Cutting off a cantilevered or overhanging piece of material from the bottom up in a vertical direction can cause kickback. The falling cut-off piece can pinch the blade.
   D. Cutting off long narrow strips (as in ripping) can cause kickback. The cut- off strip can sag or twist closing the kerf and pinching the blade.
   E. Snagging the lower guard on a surface below the material being cut momentarily reduces operator control. The saw can lift partially out of the cut increasing the chance of blade twist.

2. IMPROPER DEPTH OF CUT SETTING ON SAW
   To make the most efficient cut, the blade should protrude only far enough to expose 1/2 of a tooth. This allows the shoe to support the blade and minimizes twisting and pinching in the material. See the section titled Cutting Depth Adjustment.

3. BLADE TWISTING (MISALIGNMENT IN CUT)
   A. Pushing harder to cut through a knot, a nail, or a hard grain area can cause the blade to twist.
   B. Trying to turn the saw in the cut (trying to get back on the marked line) can cause a blade twist.
   C. Over-reaching or operating the saw with poor body control (out of balance), can result in twisting the blade.
   D. Changing hand grip or body position while cutting can result in blade twists.
   E. Backing up the saw to clear the blade can lead to a twist.

4. MATERIALS THAT REQUIRE EXTRA ATTENTION
   A. Wet lumber
   B. Green lumber (material freshly cut or not kiln-dried)
   C. Pressure-treated lumber (material treated with preservatives or anti-rot chemicals)

5. USE OF DULL OR DIRTY BLADES
   Dull blades cause increased loading of the saw. To compensate, an operator will usually push harder which further loads the unit and promotes the twisting of the blade in the kerf. Worn blades may also have insufficient body clearance which increases the chance of binding and increased loading.

6. LIFTING THE SAW WHEN MAKING A BEVEL CUT
   Bevel cuts require special operator attention to proper cutting techniques – especially the guidance of the saw. Both blade angle to the shoe and greater blade surface in the material increases the chance for binding and misalignment (twist) to occur.

7. RESTARTING A CUT WITH THE BLADE TEETH JAMMED AGAINST THE MATERIAL
   The saw should be brought up to full operating speed before starting a cut or restarting a cut after the unit has been stopped with the blade in the kerf. Failure to do so can cause stalling and kickback.

Any other conditions which could result in pinching, binding, twisting, or misalignment of the blade could cause kickback. Refer to Adjustments And Set- Up and Operation for procedures and techniques that will minimize the occurrence of kickback.

Blades

WARNING: To minimize the risk of eye injury, always wear ANSI Z87.1-approved eye protection. Carbide is a hard but brittle material. Foreign objects in the workpiece such as wire or nails can cause tips to crack or break. Only operate the saw when the proper saw blade guard is in place. Mount the blade securely in the proper rotation before using it, and always use a clean, sharp blade
WARNING: NEVER cut ferrous metals (those with any iron or steel content), masonry, glass or tile with this saw. Damage to the saw and personal injury may result. A dull blade will cause inefficient cutting, overload on the saw motor, excessive splintering, and increase the possibility of kickback. Change blades when it is no longer easy to push the saw through the cut, when the motor is straining, or when excessive heat is built up in the blade. It is a good practice to keep extra blades on hand so that sharp blades are available for immediate use. Dull blades can be sharpened in most areas; see SAWS- SHARPENING in the yellow pages. Hardened gum on the blade can be removed with kerosene, turpentine, or oven cleaner. Anti-stick-coated blades can be used in applications where excessive build-up is encountered, such as pressure-treated and green lumber. BLADE SELECTION
Your DEWALT track saw is designed for use with 6-1/2″ (165 mm) diameter blades that have a 0.79″ (20 mm) diameter bore. Blades must be rated for 6000 RPM operation (or higher). DO NOT use any abrasive wheels.
A combination blade is furnished with your saw and is an excellent blade for all general ripping and crosscutting operations. Use a fine-tooth blade for cutting plywood.
**WARNING: VISUALLY EXAMINE CARBIDE BLADES BEFORE USE. REPLACE IF DAMAGED.
Track Saw System (Fig. 1)**
The tracks, which are available in different lengths, allow for precise, clean cuts and simultaneously protect the workpiece surface against damage.
In conjunction with additional accessories, exact angled cuts, miter cuts, and fitting work can be completed with the track saw system. Securing the workpiece with clamps ensures a secure hold and safe working.
The guide clearance of the track saw must be very small for best cutting results and can be set with the two-track adjusters (J).

1. Release the screw inside the track adjuster to adjust the clearance.
2. Adjust the knob until the saw locks on track.
3. Rotate the knob back until the saw slides easily.
4. Hold the track adjuster in position and lock the screw again.

NOTE: ALWAYS readjust the system for use with other tracks.

Anti-splinter Strip

The track is equipped with an anti-splinter strip, which has to be cut to size before the first use:
IMPORTANT: ALWAYS read and follow the track saw system instructions before cutting the anti-splinter strip!

1. Set the speed of the track saw to level 5.
2. Place the track on a scrap piece of wood.
3. Set the track saw on a 3/16″ (5 mm) cut depth.
4. Place the saw on the rear end of the track.’
5. Turn the saw on, press it down to the set cutting depth, and cut the anti-splinter strip along the full length in one continuous operation. The edge of the anti-splinter strip now corresponds exactly to the cutting edge of the blade.

WARNING: To reduce the risk of injury, ALWAYS secure the track (W) with a clamp.
Speed Adjustment (Fig. 1)
The speed can be regulated between 1750 and 4000/min using the speed wheel (S). This enables you to optimize the cutting speed to suit the material. Refer to the following chart for the type of material and speed range.

Wall Cutting (Fig. 11)
1. Place the track saw with the outer guard (V) on a clean, flat floor.

2. Press the shoe (D) with the front side on the wall against the adjusted depth stop.
NOTE: The minimum cut between wall and workpiece is 12 mm. Dust Extraction (Fig. 1)
WARNING: DO NOT direct sawdust toward yourself or others. To avoid injury from flying sawdust, keep the exhaust nozzle either in the forward position or in the closed position. DO NOT insert foreign objects into the exhaust opening.
WARNING: ALWAYS connect the track saw to a dust extractor!
WARNING: ALWAYS use a dust extraction device designed in accordance with the relevant regulations regarding dust emission. Y our tool is fitted with a dust extraction outlet (I).

MAINTENANCE

**WARNING: To reduce the risk of injury, turn unit off and disconnect it from the power source before installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.
WARNING:** ALWAYS USE SAFETY GLASSES. Everyday eyeglasses are NOT safety glasses. Also, use a face or dust mask if the cutting operation is dusty. ALWAYS wear certified safety equipment:

• ANSI Z87.1 eye protection (CAN/CSA Z94.3)
• ANSI S12.6 (S3.19) hearing protection
• NIOSH/OSHA respiratory protection.

Cleaning

**WARNING: Periodically blowing dust and chips out of the motor housing using clean, dry compressed air is a suggested maintenance procedure. To reduce the risk of serious personal injury, ALWAYS wear ANSI Z87.1 safety glasses while using compressed air.
WARNING:** When cleaning, use only mild soap and a damp cloth on plastic parts. Many household cleaners contain chemicals that could seriously damage plastic. Also, do not use gasoline turpentine, lacquer or paint thinner, dry cleaning fluids or similar products which may seriously damage plastic parts. Never let any liquid get inside the tool; never immerse any part of the tool in a liquid. Lubrication This tool has been lubricated with a sufficient amount of high-grade lubricant for the life of the unit under normal operating conditions further lubrication is necessary.

Brushes

WARNING: To reduce the risk of injury, DO NOT TIE, TAPE, OR OTHERWISE LOCK THE ON/OFF SWITCH ON while “running in”.HOLD BY HAND ONLY
. Inspect carbon brushes regularly by unplugging the tool, removing the brush inspection cap, and withdrawing the brush assembly. Keep brushes clean and sliding freely in their guides. Always replace a used brush in the same orientation in the holder as it was prior to removal.Carbon brushes have varying symbols stamped into their sides, and if the brushes are worn down to the line closest to the spring, they must be replaced. Use only identical DEWALT brushes. Always replace both brushes. The use of the correct grade of the brush is essential for the proper operation of electric brakes. New brush assemblies are available at your local DEWALT-certified service center. The tool should be allowed “run in” (run at no load without blade) for 10 minutes before use to set new brushes. This is especially important for saws equipped with electric brakes, which may be erratic in operation until the brushes are properly seated (worn in).

Accessories

WARNING: Since accessories, other than those offered by DEWALT T, have not been tested with this product, use of such accessories with this tool could be hazardous. T o reduce the risk of injury, only DEWALT T, recommended accessories should be used with this product.
** WARNING : DO NOT USE WATER FEED A TT ATTACHMENT WITH THIS SAW. WARNING: VISUALLY EXAMINE CARBIDE BLADES BEFORE USE. REPLACE IF DAMAGED.** Recommended accessories for use with your tool are available at extra cost from your local dealer or authorized service center. If you need assistance in locating any accessory, please contact DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286, call 1-800-4-DEWALT (1-800-433-9258) or visit our website www.dewalt.com.

Repairs

To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustments (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.

Three-Year Limited Warranty

DEWALT will repair, without charge, any defects due to faulty materials or workmanship for three years from the date of purchase. This warranty does not cover part failure due to normal wear or tool abuse. For further detail on warranty coverage and warranty repair information, visit www.dewalt.com or call 1-800-4-DEWALT (1-800433-9258). This warranty does not apply to accessories or damage caused where repairs have been made or attempted by others. This warranty gives you specific legal rights and you may have other rights which vary in certain states or provinces.
In addition to the warranty, DEWALT tools are covered by our:
1 YEAR OF FREE SERVICE
DEWALT will maintain the tool and replace worn parts caused by normal use, for free, any time during the first year after purchase.
90-DAY MONEY-BACK GUARANTEE
If you are not completely satisfied with the performance of your DEWALT Power Tool, Laser, or Nailer for any reason, you can return it within 90 days from the date of purchase with a receipt for a full refund – no questions asked.
LATIN AMERICA: This warranty does not apply to products sold in Latin America. For products sold in Latin America, see country-specific warranty information contained either in the packaging, call the local company or see the website for warranty information.
FREE WARNING LABEL REPLACEMENT : If your warning labels become illegible or are missing, call 1-800-4-DEWALT for a free replacement.
DWS520 6 1/2″ (165mm) TRACK SAW
SER.
DANGER
KEEP HANDS AND BODY AWAY FROM AND TO THE SIDE OF THE BLADE. CONTACT WITH BLADE WILL RESULT IN SERIOUS INJURY.
WARNING
TO REDUCE THE RISK OF INJURY, USERS MUST READ THE INSTRUCTION MANUAL. CHECK GUARDING SYSTEM. IT MUST COVER THE BLADE INSTANTLY! HOLD THE SAW WITH BOTH HANDS. SUPPORT AND CLAMP WORK. WEAR EYE PROTECTION. ALWAYS USE PROPER RESPIRATORY PROTECTION.
DEWALT INDUSTRIAL TOOL CO., BALTIMORE, MD 21286 U.S.A. FOR SERVICE INFORMATION, CALL 1-800-4-DEWALT www.DEWALT.com
Corian® is a registered trademark of E. I. du Pont de Nemours and Company

Para servicioy ventas consulte
“HERRAMIENTAS ELECTRICAS”
en la sección amarilla.
SOLAMENTE P ARA PROPÓSITO DE MÉXICO:
IMPORT ADO POR: DEWALT S.A. DE C.V .
BOSQUES DE CIDROS, ACCESO RADIA T AS NO.42
3A. SECCIÓN DE BOSQUES DE LAS LOMAS
DELEGACIÓN CUAJIMALP A,
05120, MÉXICO, D.F .
TEL. (52) 555-326-7100
R.F .C.: BDE810626-1W7
DEWALT Industrial T ool Co., 701 East Joppa Road, Baltimore, MD 21286 (AUG08)
Part No. 492114-01 DWS520 Copyright © 2008 DEWALT
The following are trademarks for one or more DEWALT power tools: the yellow and black color scheme; the “D” shaped air intake grill; the array of
pyramids on the handgrip; the kit box configuration; and the array of lozenge- shaped humps on the surface of the tool.

References

• 2helpU
• Autorizovaný servis elektrického nářadí, půjčovna nářadí, prodejna nářadí
• BANDSERVIS
• Elektrické nářadí | Úložné systémy | Zahrada | DEWALT Česko
• Elektrické náradie | Úložné systémy | Terénne úpravy | DEWALT Slovensko

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