DeWalt DWS520 Manual

Technical data

ASSEMBLY AND ADJUSTMENTS

Prior to assembly and adjustment, always unplug the tool.

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 depth scale (g).
3. Tighten the bevel adjustment knobs (e).

Changing the saw blade (fig. 2, 3)

1. Press the lock button (l).
2. Press the plunge 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) anti-clockwise 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.
   NOTE: The direction of rotation of the saw blade and the rotation of the plunge saw MUST be the same.
8. Tighten the blade clamping screw firmly using the Allen key.
9. Turn the lock lever (m) anti-clockwise until it stops.
10. Move the plunge saw back to top position.
11. Push plunge trigger (a) forward, to lock saw blade change.

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. FollowChanging the Saw Blade steps 1–4.
2. Loosen the riving adjustment screw (r) with an Allen key and set the riving knife as shown in figure 3.
3. Tighten the riving knife screw (r).
4. Turn the lock lever (m) anti-clockwise until it stops.
5. Move the plunge saw back to top position.

Depth of cut adjustment (fig. 4)
The cutting depth can be set at 0 – 59 mm without guide rail attached; with the guide rail attached: 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 3 mm (fig. 4).

OPERATION

Before using the plunge saw, ALWAYS make sure all functions are working properly!

Instructions for use

Always observe the safety instructions and applicable regulations.

Switching on and off (fig. 1)
Press the on/off switch to turn the plunge saw on.

Holding and guiding the tool (fig. 5, 6)

• ALWAYS secure the workpiece in such a manner that it cannot move while sawing.
• ALWAYS push the machine forwards. NEVER pull the machine backwards towards you.
• ALWAYS use the plunge saw with both hands. Put one hand on the main handle (c) and the second hand on the front handle (h) as shown in figure 5.
• ALWAYS use the clamp to hold the rail to the workpiece as shown in figure 6.
• M ake sure the cord is not in the path of the saw.
• Hold the tool by the main handle (c) and the front handle (h) to guide the saw properly.
• The cutting indicator (t) displays the cutting line for 0° and 47° cuts (without guide rail).
• The blade position indicator (y) shows the blade position for full plunge.
• For optimum results, clamp the workpiece bottom up.

CUTTING

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 switch (a) forward, press the saw down to set cutting depth and push it forward into cutting direction.

PLUNGE CUTS

To avoid kickbacks, the following in-structions MUST be observed when plunge cutting:

• Place the machine onto the guide rail and release the anti-kickback knob (u) by turning it anti-clockwise.
• 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. 165 mm) at maximum cutting depth and using the guide rail.
• I f kickback happened during the plunge cut, turn the anti-kickback knob (u) anti-clockwise to release it from the rail.
• When you have finished the plunge cut, turn the anti-kickback knob (u) clockwise into the lock position.

Guide system (fig. 1, 5)
The guide rails, 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, mitre cuts and fitting work can be completed with the guide rail system.
Securing the workpiece with clamps ensures a secure hold and safe working.
The guide clearance of the plunge saw must be very small for best cutting results and can be set with the two rail adjusters (j).

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

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

SPLINTERGUARD
The guide rail is equipped with a splinterguard, which has to be cut to size before the first use:

ALWAYS read and follow the guide system instruction before cutting the splinterguard!

1. Set the speed of the plunge saw to level 5.
2. Place the guide rail on a scrap piece of wood.
3. Set the plunge saw on 5 mm cut depth
4. Place the saw on the rear end of the guide rail.
5. Turn the saw on, press it down to the set cutting depth and cut the splinterguard along the full length in one contiuous operation. The edge of the splinterguard now corresponds exactly to the cutting edge of the blade.
   
   To reduce the risk of injury, ALWAYS secure the guide rail (w) with a clamp (x).

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.

Door cutting (fig. 7)

1. Place the plunge saw with the outer guard (v) on a clean, flat floor.
2. Press the shoe (d) with the front side on the door against the adjusted depth stop.

Dust extraction (fig. 1)
Your tool is fitted with a dust extraction outlet (i).

ALWAYS connect the plunge saw to a dust extractor!

ALWAYS use a dust extraction device designed in accordance with the relevant regulations regarding dust emission.

MAINTENANCE

Your DEWALT power tool has been designed to operate over a long period of time with a minimum of maintenance. Continuous satisfactory operation depends upon proper tool care and regular cleaning.

To reduce the risk of injury, turn unit off and disconnect machine from power source before installing and removing accessories, before adjusting or changing set-ups or when making repairs. Be sure the trigger switch is in the OFF position. An accidental start-up can cause injury.

If the saw blade is worn replace it with a new sharp blade.

Lubrication
Your power tool requires no additional lubrication.

Cleaning

Blow dirt and dust out of the main housing with dry air as often as dirt is seen collecting in and around the air vents. Wear approved eye protection and approved dust mask when performing this procedure.

Never use solvents or other harsh chemicals for cleaning the non-metallic parts of the tool. These chemicals may weaken the materials used in these parts. Use a cloth dampened only with water and mild soap. Never let any liquid get inside the tool; never immerse any part of the tool into a liquid.

Optional accessories

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.
DEWALT offers saw blades specially designed for your plunge saw.
Consult your dealer for further information on the appropriate accessories.

Definitions: Safety Guidelines

The definitions below describe the level of severity for each signal word. Please read the manual and pay attention to these symbols.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
Denotes risk of electric shock.
Denotes risk of fire.

The declared vibration emission value has been measured in accordance with a standard test method and may be used for comparing one tool with another.
The declared vibration emission value may also be used in a preliminary assessment of exposure.

The vibration emission value during actual use of the power tool can differ from the declared value depending on the ways in which the tool is used. This could lead to a significant underestimate of exposure when the tool is used regularly in such a way.
An estimation of the level of exposure to vibration experienced during a given period of work should also take into account the times when the tool is switched off and when it is running idle in addition to the trigger time.
This may significantly reduce the exposure level over the total working period.


To reduce the risk of injury, read the instruction manual.

General Power Tool Safety Warnings

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 batteryoperated (cordless) power tool.

1. WORK AREA SAFETY
   1. Keep work area clean and well lit. Cluttered or dark areas invite accidents.
   2. 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.
   3. Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.
2. ELECTRICAL SAFETY
   1. 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.
   2. 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.
   3. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
   4. 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.
   5. 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.
   6. If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.

3. PERSONAL SAFETY
   1. 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.
   2. 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.
   3. 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.
   4. 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.
   5. Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
   6. 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.
   7. If 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
   1. 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.

2. 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.
3. 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.
4. 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.
5. 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.
6. Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
7. 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
   1. 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

1. 
   Keep hands away from cutting area and the blade. Keep your second hand on auxiliary handle, or motor housing. If both hands are holding the saw, they cannot be cut by the blade.
2. Do not reach underneath the workpiece. The guard cannot protect you from the blade below the workpiece.
3. 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.
4. 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.
5. Hold power tool by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring. Contact with a "live" wire will also make exposed metal parts of the power tool "live" and shock the operator.
6. When ripping always use a rip fence or straight edge guide. This improves the accuracy of cut and reduces the chance of blade binding.
7. Always use blades with correct size and shape (diamond versus round) of arbour holes. Blades that do not match the mounting hardware of the saw will run eccentrically, causing loss of control.
8. 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;
• 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 saw misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below:

1. Maintain a firm grip with both hands on the saw and position your arms to resist kickback forces. Position your body to either side of the blade, but not in line with the blade. Kickback could cause the saw to jump backwards, but kickback forces can be controlled by the operator, if proper precautions are taken.
2. 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.
3. When restarting a saw in the workpiece, centre the saw blade in the kerf and check that saw teeth are not engaged into the material. If saw blade is binding, it may walk up or kickback from the workpiece as the saw is restarted.
4. Support large panels to minimise the risk of blade pinching and kickback. Large panels tend to sag under their own weight. Supports must be placed under the panel on both sides, near the line of cut and near the edge of the panel.
5. Do not use dull or damaged blades. Unsharpened or improperly set blades produce narrow kerf causing excessive friction, blade binding and kickback.
6. 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.
7. 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

1. 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.
2. 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.
3. 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.
4. 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

1. 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.
2. Adjust the riving knife as described in this instruction manual. Incorrect spacing, positioning and alignment can make the riving knife ineffective in preventing kickback.
3. For the riving knife to work, it must be engaged in the workpiece. The riving knife is ineffective in preventing kickback during short cuts.
4. Do not operate the saw if riving knife is bent. Even a light interference can slow the closing rate of a guard.

Additional safety instructions for plunge-type 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.
• Do not use blades of larger or smaller diameter than recommended. For the proper blade rating refer to the technical data. Use only the blades specified in this manual, complying with EN 847-1.
• Never use abrasive cut-off wheels.

Residual risks

• In spite of the application of the relevant safety regulations and the implementation of safety devices, certain residual risks cannot be avoided.

These are:

• Impairment of hearing.

• Risk of accidents caused by the uncovered parts of the rotating cutting disc.
• Risk of injury when changing the disc.
• Risk of dust inhalation from materials that when cut, can be harmful.

Labels on tool
In addition to the pictographs used in this manual, the labels on the tool show the following pictographs:
Maximum depth of cut
Blade diameter

Package contents

The package contains:
1 Plunge saw
1 Rail clamp
1 Allen key
1 Instruction manual
1 Exploded drawing

• Check for damage to the tool, parts or accessories which may have occurred during transport.
• Take the time to thoroughly read and understand this manual prior to operation.

Description (fig. 1–3)

Never modify the power tool or any part of it. Damage or personal injury could result.

INTENDED USE
The DWS520 plunge saw is designed for professional sawing applications and cutting wood products.
DO NOT use under wet conditions or in presence of flammable liquids or gases.
This heavy-duty plunge saw is a professional power tool. DO NOT let children come into contact with the tool. Supervision is required when inexperienced operators use this tool.

1. plunge trigger
2. on/off switch
3. main handle
4. shoe
5. bevel adjustment knob
6. depth adjustment knobs
7. depth scale
8. front handle
9. dust extraction outlet
10. rail adjuster
11. blade
12. lock button
13. lock lever
14. blade clamping screw
15. outer flange
16. inner flange
17. riving knife
18. riving knife adjustment screws
19. speed wheel
20. cutting indicator
21. anti-kickback knob
22. outer guard
23. guide rail
24. clamp
25. blade position indicators

Electrical safety

The electric motor has been designed for one voltage only. Always check that the power supply corresponds to the voltage on the rating plate.

Your DEWALT tool is double insulated in accordance with EN 60745; therefore no earth wire is required.
If the supply cord is damaged, it must be replaced by a specially prepared cord available through the DEWALT service organization.

Mains plug replacement (U.K. & Ireland only)

• Should your mains plug need replacing and you are competent to do this, proceed as instructed below. If you are in doubt, contact an authorized DEWALT repair agent or a qualified electrician.
• Disconnect the plug from the supply.
• Cut off the plug and dispose of it safely; a plug with bared copper conductors is dangerous if engaged in a live socket outlet.
• Only fit 13 Amperes BS1363A approved plugs fitted with the correctly rated fuse (1).
• The cable wire colours, or a letter, will be marked at the connection points of most good quality plugs. Attach the wires to their respective points in the plug (see below). Brown is for Live (L) (2) and Blue is for Neutral (N) (4).
• Before replacing the top cover of the mains plug ensure that the cable restraint (3) is holding the outer sheath of the cable firmly and that the two leads are correctly fixed at the terminals crews.
  

NEVER use a light socket.
NEVER connect the live (L) or neutral (N) wires to the earth pin marked E or .
For 115 V units with a power rating exceeding 1500 W, we recommend to fit a plug to BS4343 standard.

115 V units have to be operated via a fail-safe isolating transformer with an earth screen between the primary and secondary winding.

Using an extension cable
If an extension cable is required, use an approved extension cable suitable for the power input of this tool (see technical data).
The minimum conductor size is 1.5 mm². When using a cable reel, always unwind the cable completely. Also refer to the table below.