DeWalt DWS520 User manual

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INSTRUCTION MANUAL
GUIDE D'UTILISATION
MANUAL DE INSTRUCCIONES
INSTRUCTIVO DE OPERACION, CENTROS DE SERVICIOY POLIZA
DE GARANT[A. ADVERTENClA: LI_ASE ESTE INSTRUCTIVO ANTES
DE USAR EL PRODUCTO.
E ®
DWS520
Heavy-Duty Track Saw
Scie &rail industrielle
Sierra de Incisibn de Trabajo Pesado

fDefinitions: 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 which,
if not avoided, will result in death or serious injury.
i_,WARNING: Indicates apotentially hazardous situation which,
if not avoided, could result in death or serious injury.
i_ CAUTION: Indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
CAUTION: Used without the safety alert symbol indicates a
potentially hazardous situation which, 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
_ARNING! 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 toyour mains-operated
(corded) power tool or battery-operated (cordless) power tool
1) WORK AREA SAFETY
a) Keep 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 which may ignite the 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 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 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. Use of a cord suitable for
outdoor use reduces the risk of electric shock.

f) ff 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 mask, non-
skid safety shoes, hard hat, 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 power source and/
or battery pack, picking up or carrying the tool. Carrying
power tools with your finger on the switch or energising
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 sfuations.
f) Dress properly. Do not wear loose clothing or jewellery.
Keep your hair, clothing and gloves away from moving
parts. Loose clothes, jewellery or long hair can be caught in
moving parts.
g) ff devices are provided for the connection of dust
extraction and collection facilities, ensure these are
connected and properly used. 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 #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 cutting area and the
blade. Keep your second hand on auxiliary handle, or
motor housing. Ifboth 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 piece 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 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 cut and reduces the
chance of blade binding.
g) Always use blades with 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 loss
of control
h) Never use damaged or incorrect blade washers or bolt.
The blade washers and bolt 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.
-ff 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 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 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 into the material ff saw blade is binding, it
may walk up or kickback 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

theirownweight.Supportmustbeplacedunderthepanel
onbothsides,nearthelineofcutandneartheedgeofthe
panel
e) Do notusedullor damagedblade.Unsharpenedor
improperlysetbladesproducenarrowkerfcausingexcessive
friction,bladebinding,andkickback.
f) Bladedepthandbeveladjustinglockingleversmustbe
tightandsecurebeforemakingcut.Ifbladeadjustment
shiftswhilecutting,#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 ff guard does not move freely and
enclose the blade instantly. Never clamp or tie the guard
with the blade exposed. /f 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, ff 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.
Riving knife must be replaced after plunge cutting. Riving
knife causes interference during plunge cutting and can
create kickback. Model DWS520 does not require removal
of the riving knife because the riving knife retracts during a
plunge cut.
d) For the riving knife to work, #must be engaged in the
workpiece. The riving knife is ineffective in preventing
kickback during short cuts.
e) Do not operate the saw ff riving knife is bent. Even a 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 O.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.
Ampere
Rating
More Not
More
Than Than
0 6
6 10
10 12
12 16
MINIMUM GAUGE FOR CORD SETS
Volts Total Length of Cord in Feet (meters)
120V 25 (7,6) I50 (15,2) 100 (30,5) 150 (45,7)
240V 50 (15,2) I100 (30,5) 200 (61,0) 300 (91,4)
AWG
18 16 16 14
18 16 14 12
16 16 14 12
14 12 Not Recommended
•Air vents often cover moving parts and should be avoided.
Loose clothes, jewellery 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 over rated speed
can fly apart and cause injury. Accessory ratings must always be
above tool speed as shown on tool nameplate.
_WARNING: ALWAYS wear proper personal hearing protection
that conforms to ANSI $12.6 ($3.19) during use. Under some
conditions and duration of use, noise from this product may
contribute to hearing loss.
i_,WARNING: ALWAYS use safety glasses. Everyday eyeglasses
are NOT safety glasses. Also use face or dust mask ff cutting
operation is dusty. ALWAYS WEAR CERTIFIED SAFETY
EQUIPMENT:
• ANSI Z87.1 eye protection (CAN/CSA Z94.3),
• ANSI $12.6 ($3. 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, eyes, or lay on
the skin may promote absorption of harmful chemicals.
_WARNING: Use of this tool can generate and/or disburse
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.
•The label on your tool may include the following symbols. The
symbols and their definitions are as follows:
V. ........... volts
Hz.......... hertz
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
q., .......... alternating current
___.......... alternating or direct
............... current
no ........... no load speed
............ earthing terminal
........... safety alert symbol
.../min .....per minute
SAVE THESE INSTRUCTIONS
Motor
Be sure your power supply agrees with 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.
i_,CAUTION: Avoid contact with the blade teeth to prevent
personal injury.
COMPONENTS (Fig. 1-3, 8)
AWARNING: Never modify the power tool or any part of it.
Damage or personal injury could result.
A. Plunge trigger O. Outer flange
B. On/off switch
C. Main handle
D. Shoe
E. Bevel adjustment knob
E Depth adjustment knobs
G. Depth scale
H. Front handle
I. Dust extraction outlet
J. Track adjuster
K. Blade
L. Lock button
M. Lock lever
N. Blade clamping screw
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

FIG. 1
K
F
E
X
M
L
D
S
U
B
C
FIG. 2
M
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. Material build-up
may inhibit proper function of the plunge return, leaving the blade
exposed.
ADJUSTMENTS AND SET-UP
_WARNING: To reduce the risk of injury, turn unit off and
disconnect it from 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.Setthebevelanglebytiltingthesawshoe(D)untilthemark
indicatesthedesiredangleonthebevelscale(X).
3.Tightenthebeveladjustmentknobs(E).
FIG. 3
4. Turn the lock lever (M) counterclockwise until it stops.
5. Move the track saw back to top position.
FIG. 4
R
K
N 0
2-3 mm
Adjusting the Riving Knife (Fig. 3)
For the correct adjustment of the riving knife (Q), refer to the 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 an hex wrench (Z)
and set the riving knife as shown in Figure 3.
3. Tighten the riving knife screw (R).
Cutting Depth Adjustment (Fig. 4)
The cutting depth can be set at 0-2-5/16" (0-59 mm) without 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 unit off and
disconnect it from power source before installing and removing

accessories,beforeadjustingor whenmakingrepairs.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 unit off and
disconnect it from power source before installing and removing
accessories, before adjusting or when making repairs. An
accidental start-up can cause injury.
i_,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 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. Turn 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
i_ WARNING: Hands should be kept away from cutting area to
reduce the risk of injury.
AWARNING: 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.
FIG,5 RIGHT
SUPPORT WORK NEAR CUT
Figure 5 shows proper sawing position. Figure 6 shows an unsafe
condition. To avoid kickback, DO support 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.

FIG. 6 WRONG
MATERIAL BENDS ON
BLADE CAUSING HEAVY
LOADS OR KICKBACK
i_ 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 typical hand support of the
saw. FIG. 7 CH
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
i_ 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 service center for repair.
AWARNING: For maximum protection, effective control of this
powerful saw requires 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 over hanging material Use caution when
sawing material from below.
WARNING: Be sure that the saw is up to full speed before blade
contacts material to be cut. Starting the saw with blade against
material to be cut or pushed forward into 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 backwards towards you.
AWARNING: ALWAYS use the clamp (Fig. 8, AA) to hold the track
to the workpiece.
10

CAUTION: Do not operate your tool on a current on which the
voltage is not within correct limits. Do not operate tools rated AC
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
cutting depth and push it forward into cutting direction.
Push the saw forward at a speed which 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 over-heating of the motor.
Should the cut begin to go off the line, DO NOT try to force it back.
Release the switch and allow 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. IF
SAW STALLS, RELEASE THE TRIGGER, ALLOW THE BLADE
TO COME TO A COMPLETE STOP, AND BACK THE SAW UNTIL
IT IS LOOSE. BE SURE BLADE IS STRAIGHT IN THE CUT AND
CLEAR OF THE CUTTING EDGE BEFORE RESTARTING.
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.
FIG. 8
W
AA
PLUNGE CUTS (FIG. 1,8)
i_,WARNING: ALWAYS use the track when plunge cutting.
i_,WARNING: To avoid kickbacks, the following instructions MUST
be observed when plunge cutting:
11

1.Placethemachineontothetrackandreleasetheanti-kickback
knob(U)byturningitcounterclockwise.
2.Turnthemachineonandslowlypressthesawdownontothe
setcuttingdepthandpushforwardinthecuttingdirection.The
cutindicators(T)displaytheabsolutefrontandtheabsolute
rearcuttingpointsofthesawblade[dia.6-1/2"(165mm)]at
maximumcuttingdepthandusingthetrack.
3.If kickbackhappenedduringtheplungecut,turntheanti-
kickbackknob(U)counterclockwiseto releaseit fromthe
track.
4.Whenyouhavefinishedtheplungecut,turntheanti-kickback
knob(U)clockwiseintothelockposition.
CROSS-CUTTING
Cuttingdirectlyacrossthegrainofa pieceoflumberiscalled
crosscutting.Figures9 and10 illustratea crosscutoperation.
Positiontheworksothatthecutwillbeontheleft.
FIG. 9
FIG. 10
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.
12

KICKBACK
Whenthesawbladebecomespinchedortwistedinthecut,kickback
canoccur.Thesawisthrustrapidlybacktowardtheoperator.When
thebladeispinchedorboundtightlybythekerrclosingdown,the
bladestallsandthemotorreactiondrivestheunitbackward.When
thebladebecomestwistedormisalignedinthecut,theteethatthe
backedgeofthebladecandigintothetopsurfaceofthewoodcausing
thebladetoclimboutofthekerrandjumpbacktowardtheoperator.
Kickbackismorelikelytooccurwhenanyofthefollowingconditions
exist.
1.IMPROPERWORKPIECESUPPORT
A.Saggingor improperliftingofthecutoffpiececancause
pinchingofthebladeandleadtokickback.
B.Cuttingthroughmaterialsupportedattheouterendsonly
cancausekickback.Asthematerialweakensitsags,closing
downthekerrandpinchingtheblade.
C.Cuttingoffacantileveredoroverhangingpieceofmaterial
fromthebottomupinaverticaldirectioncancausekickback.
Thefallingcutoffpiececanpinchtheblade.
D.Cuttingofflongnarrowstrips(asin ripping)cancause
kickback.Thecutoffstripcansagortwistclosingthekerrand
pinchingtheblade.
E.Snaggingthelowerguardonasurfacebelowthematerial
beingcutmomentarilyreducesoperatorcontrol.Thesaw
canliftpartiallyoutofthecutincreasingthechanceofblade
twist.
2.IMPROPERDEPTHOFCUTSETTINGONSAW
Tomakethemostefficientcut,thebladeshouldprotrudeonly
farenoughtoexpose1/2ofa tooth.Thisallowstheshoeto
supportthebladeandminimizestwistingandpinchinginthe
material.SeethesectiontitledCutting 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 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 twist.
E. Backing up the saw to clear blade can lead to 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 twisting of the blade in the kerr. Worn blades
may also have insufficient body clearance which increases the
chance of binding and increased loading.
6. LIFTING THE SAW WHEN MAKING BEVEL CUT
Bevel cuts require special operator attention to proper cutting
techniques - especially guidance of the saw. Both blade angle
to the shoe and greater blade surface in the material increase
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
13

withthebladeinthekerr.Failuretodosocancausestallingand
kickback.
Anyotherconditionswhichcouldresultin pinching,binding,
twisting,ormisalignmentofthebladecouldcausekickback.Refer
to Adjustments And Set-Up and Operation for procedures and
techniques that will minimize the occurrence of kickback.
Blades
i_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 work piece such as wire or nails
can cause tips to crack or break. Only operate saw when proper
saw blade guard is in place. Mount blade securely in proper
rotation before using, and always use a clean, sharp blade.
i_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.
14
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 saw locks on track.
3. Rotate knob back until 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
instruction 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 3/16" (5 mm) cut depth.
4. Place the saw on the rear end of the track.

5.Turnthesawon,pressitdowntothesetcuttingdepthand
cuttheanti-splinterstripalongthefulllengthinonecontiuous
operation.Theedgeoftheanti-splinterstripnowcorresponds
exactlytothecuttingedgeoftheblade.
_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 optimise the cutting speed
to suit the material. Refer to the following chart for type of material
and speed range.
TYPE OF MATERIAL TO BE CUT SPEED RANGE
Solid wood (hard, soft) 3-5
Chipboards 4-5
Laminated wood, blockboards, 2-5
veneered and coated boards
Paper and carton 1-3
Wall Cutting (Fig. 11)
1. Place the track saw with the outer guard (V) on a clean, flat
floor.
FIG. 11 12 mm
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)
i_ 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.
Z¢WARNING: ALWAYS connect the track saw to a dust extractor!
AWARNING: ALWAYS use a dust extraction device designed in
accordance with the relevant regulations regarding dust emission.
Your tool is fitted with a dust extraction outlet (I).
MAINTENANCE
AWARNING: To reduce the risk of injury, turn unit off and dis-
connect it from power source before installing and removing
accessories, before adjusting or when making repairs. An acci-
dental start-up can cause injury.
i_,WARNING: ALWAYS USE SAFETY GLASSES. Everyday
eyeglasses are NOT safety glasses. Also use face or dust mask if
cutting operation is dusty. ALWAYS wear certified safety
equipment:
•ANSI Z87.1 eye protection (CAN/CSA Z94.3)
• ANSI $12.6 ($3.19) hearing protection
• NIOSH/OSHA respiratory protection.
Cleaning
i_ 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
15

injury, ALWAYS wear ANSI Z87.1 safety glasses while using
compressed air.
AWARNING: When cleaning, use only mild soap and a damp
cloth on plastic parts. Many household cleaners contain chemicals
which 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 into 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.
No 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 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. Use of the correct grade of brush is essential for proper
operation of electric brakes. New brush assemblies are available at
your local DEWALT certified service center.The tool should be allowed
to "run in" (run at no load without blade) for 10 minutes before use to
seat new brushes. This is especially important for saws equipped with
electric brakes, which may be erratic in operation untilthe brushes are
properly seated (worn in).
Accessories
A WARNING: Since accessories, other than those offered by
DEWALT, have not been tested with this product, use of such
accessories with this tool could be hazardous. To reduce the risk
of injury, only DEWALT, recommended accessories should be used
with this product.
i_,WARNING: DO NOT USE WATER FEED ATTACHMENTS
WITH THIS SAW
AWARNING: 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
Toassure 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 of warranty coverage and warranty repair
information, visit www.dewalt.com or call 1-800-4-DEWALT (1-800-
433-9258). This warranty does not apply to accessories or damage
caused where repairs have been made or attempted by others. This
16

warrantygivesyouspecificlegalrightsandyoumayhaveother
rightswhichvaryincertainstatesorprovinces.
Inadditiontothewarranty,DEWALTtoolsarecoveredbyour:
1YEARFREESERVICE
DEWALTwillmaintainthetoolandreplacewornpartscausedby
normaluse,forfree,anytimeduringthefirstyearafterpurchase.
90DAYMONEYBACKGUARANTEE
Ifyouarenotcompletelysatisfiedwiththeperformanceofyour
DEWALTPowerTool,Laser,orNailerforanyreason,youcanreturn
itwithin90daysfromthedateofpurchasewithareceiptforafull
refund- noquestionsasked.
LATINAMERICA:Thiswarrantydoesnotapplytoproductssold
inLatinAmerica.ForproductssoldinLatinAmerica,seecountry
specificwarrantyinformationcontainedeitherinthepackaging,call
thelocalcompanyorseewebsiteforwarrantyinformation.
FREEWARNINGLABELREPLACEMENT:Ifyourwarninglabels
becomeillegibleoraremissing,call1-800-4-DEWALTforafree
replacement.
DWS5206_/z°tle_mm)T.AcKsaw
SE&
KEEPHAN0SANDSOOVAWAY_ROmANOTOtHe SIDEOFTH_
_B LADE.CONTACTWiTH _LADE WILL RESULTiN SERIOUS INJURY.
TO _EDUCET_E RISKOF I_JUHY, USERMUST _EAOI_STRUC_
_ MA_IUAL.CHEC_GUARIII_IGSYSTEm.g MUST¢OV_RTHEBI_OE
I_ISTANTLY_HOLDSAW_ffltl3OTHHANDS.SUPPO_ANDCt_M_WORK.WEAREYE
Pn0TECTION.AtWAYSUSEPROPERRESPI_ATOR_"p_OTEC_0Pl.
FO_SERVICEINFO_MATIO_, CALLI-_08-4-D_WALT www.D_WALT,com
MANTE_GA LAS MANO$ Y _L
yA_ IA00O_L_a_S_A.E_CO_T_C_eCO_L__OJA
p_0VOC_L_S_0N_S_AVES.
_,_._PARA I{EO_J_R EL _iESGO
DELESi0NES, ELUSUA_I0
D E_L_ LEE_ EL MANUAL DE [_STRUCCiD_ES. VE_iFIQUE EL
SISTEMA DE P_OTECC_ON. OESE CtJ_IE LA HOJA EI_ FO_MA
_NSTANTA_EA. $OSTE_GA LA SIERRAco_ AMBAS MA_JO$.
SO POF_E Y SUJETE LAS PJEZAS [IE TRASAJO. Si]!MpR[ SE
DE,EllA LLEVAR LA pROTECCJON ApROpJA[IA pAliA LA VISTA
PA_ L_SVIA_e_SPIP_TOelAS.
= _ ,l TE_=R LE$ MAINS ET TOUTE AUTRE
PA_T_Eouco_PsE_0_G_EESDEL_
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LAME _[SQUE DE CAUSER DE GRAVES SLESSU_ES.
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BLESS_RES,LJR_LEG_JlDEI}'_TIt_SATION.VEP_RE_ LEDISP0SlTIF
DE PROTECTION, JL DOBT _ECOUV_I_ INSTA_T_ME_r LA
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PI_C£ A OUVRE_.BL FA_T TOUJOURS PORTER OE L'_[tUIPEMENT
Corian® is a registered trademark of E. I. du Pont de Nemours and
Company
17

FD_finitions : lignes
directrices en mati_re de s_curit_
Les d6finitions ci-dessous d6crivent le niveau de danger pour
chaque motindicateur employ& Lire le mode d'emploi et porter
une attention particuli_re & ces symboles.
ADANGER :indique une situation dangereuse imminente qui,
si elle n'est pas evit6e, entrainera la mort ou des blessures
graves
_&AVERTISSEMENT :indique une situation potentiellement
dangereuse qui, si elle n'est pas evit6e, pourrait entrMner la
mort ou des blessures graves
i_A TTENTION :indique une situation potentiellement dangereuse
qui, si elle n'est pas evit6e, pourrait entraTner des blessures
legeres ou moderees.
ATTENTION: utilise sans le symbole d'alerte de securite, indique
une situation potentiellement dangereuse qui, si elle n'est pas
_ 6vit6e, pourrait entraTner des dommages materiels. J
POUR TOUTE QUESTION OU REMARQUE AU SUJET DE CET
OUTIL OU DE TOUT AUTRE OUTIL DEWALT, COMPOSEZ LE
NUMI_RO SANS FRAIS : 1-800-4-DEWALT (1-800-433-9258).
_VERTISSEMENT :afin de reduire le risque de blessures,
life le mode d'emploi de Ibutil.
AVERTISSEMENTS DE SECURITE
GENERAUX POUR LES OUTILS
ELECTRIQUES
_AVERTISSEMENT! Lire tous les avertissements de securite
et toutes les directives. Le non-respect des avertissements et
des directives pourrait se solder par un choc electrique, un
incendie et/ou une blessure grave.
CONSERVER TOUS LES
AVERTISSEMENTS ET
TOUTES LES DIRECTIVES POUR
UN USAGE ULTERIEUR
Le terme ,, outil electrique, cite dans les avertissements se
rapporte a votre outil electrique a alimentation sur secteur (avec ill)
ou par piles (sans ill).
1) S#OURIT# DU LIEU DE TRAVAIL
a) Tenir I'aire de travail propre et bien eclairee. Les lieux
encombres ou sombres sont propices aux accidents.
b) Ne pas faire fonctionner d'outils electriques clans un
milieu deflagrant, tel qu'en presence de liquides, de gaz
ou de poussieres inflammables. Les outils electriques
produisent des etincelles qui pourraient enflammer la
poussibre ou les vapeurs.
c) Eloigner les enfants et les personnes aproximite pendant
I'utilisation d'un outil electrique. Une distraction pourrait
en faire perdre la maftrise a I'utilisateur.
2) S¢'CURIT¢' EN MATIERE D'C'LECTRICIT¢'
a) Les fiches des outils electriques doivent correspondre
la prise. Ne jamais modifier la fiche d'aucune fagon.
Ne jamais utiliser de fiche d'adaptation avec un outil
electrique mis a la terre. Le risque de choc electrique sera
reduit par I'utilisation de fiches non modifiees correspondant
la prise.
b) Eviter tout contact physique avec des surfaces mises a la
terre comme des tuyaux, des radiateurs, des cuisinieres
et des refrigerateurs. Le risque de choc electrique est plus
elev6 si votre corps est mis a la terre.
18

c) Ne pas exposer les outils electriques a la pluie ou
I'humidite. La penetration de I'eau dans un outil electrique
augmente le risque de choc electrique.
d) Ne pas utiliser le cordon de fa_on abusive. Ne jamais
utiliser le cordon pour transporter, tirer ou debrancher
un outil electrique. Tenir le cordon eloigne de la chaleur,
de I'huile, des bords tranchants et des pieces mobiles.
Les cordons endommages ou enchev6tres augmentent les
risques de choc electrique.
e) Pour I'utilisation d'un outil electrique a I'exterieur, se
servir d'une rallonge convenant a cette application.
L'utilisation d'une rallonge congue pour I'exterieur reduira les
risques de choc electrique.
f) S'il est impossible d'eviter I'utilisation d'un outil
electrique dans un endroit humide, brancher I'outil dans
une prise ou sur un circuit d'alimentation dotes d'un
disjoncteur de fuite ala terre (GFCl). L'utilisation de ce
type de disjoncteur redu# les risques de choc electrique.
3) SleCURITle PERSONNELLE
a) Etre vigilant, surveiller le travail effectue et faire preuve
de jugement Iorsqu'un outil electrique est utilise. Ne
pas utiliser d'outil electrique en cas de fatigue ou sous
I'influence de drogues, d'alcool ou de medicaments. Un
simple moment d'inattention en utilisant un outil electrique
peut entrafner des blessures corporelles graves.
b) Utiliser des equipements de protection individuelle.
Toujours porter une protection oculaire. L'utilisation
d'equipements de protection comme unmasque antipoussiere,
des chaussures antiderapantes, un casque de securite ou des
protecteurs auditifs Iorsque la situation le requiert reduira les
risques de blessures corporelles.
19
c) Emp6cher les demarrages intempestifs. S'assurer que
I'interrupteur se trouve a la position d'arr6t avant de
relier I'outil a une source d'alimentation et/ou d'inserer
un bloc-piles, de ramasser ou de transporter I'outil.
Transporter un outil electrique alors que le doigt repose sur
I'interrupteur ou brancher un outil electrique dont I'interrupteur
est a la position de marche risque de provoquer un accident.
d) Retirer toute cle de reglage ou cle avant de demarrer
I'outil. Une cle ou une cle de reglage attachee a une partie
pivotante de I'outil electrique peut provoquer des blessures
corporelles.
e) Ne pas trop tendre les bras. Conserver son equilibre en
tout temps. Cela permet de mieux mMtriser I'outil electrique
dans les situations imprevues.
f) S'habiller de maniere appropriee. Ne pas porter de
v6tements amples ni de bijoux. Garder les cheveux, les
v#tements et les gants a I'ecart des pieces mobiles. Les
v6tements amples, les bijoux ou les cheveux longs risquent
de rester coinces dans les pieces mobiles.
g) Si des composants sont fournis pour le raccordement de
dispositifs de depoussierage et de ramassage, s'assurer
que ceux-ci sont bien raccordes et utilises. L'uti/isation
d'un dispositif de depoussierage peut reduire les dangers
engendres par les poussieres.
4) UTILISATION ET ENTRETIEN D'UN OUTIL leLECTRIQUE
a) Ne pas forcer un outil electrique. Utiliser I'outil electrique
approprie a I'application. L'outil electrique approprie
effectuera un meilleur travail, de fa_on plus sore eta la
vitesse pour laquelle il a ete congu.
b) Ne pas utiliser un outil electrique dont I'interrupteur
est defectueux. Tout outil electrique dont I'interrupteur est
defectueux est dangereux et doit 6tre repare.