INSTRUCTION MANUAL DWE575-XE 184 mm (7-1/4") CIRCULAR SAW Vibration total values (triax vector sum) determined according to EN 60745: Definitions: Safety Guidelines Vibration emission value ah cutting wood ah,W = Uncertainty K = The definitions below describe the level of severity for each signal word. Please read the manual and pay attention to these symbols. DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. NOTICE: Indicates a practice not related to personal injury which, if not avoided, may result in property damage. An estimation of the level of exposure to vibration should also take into account the times when the tool is switched off or when it is running but not actually doing the job. This may significantly reduce the exposure level over the total working period. Technical Data V W min-1 mm mm mm ˚C kg DWE575-XE 230 1600 5200 184 65 20 57˚ 4.0 LPA KPA LWA KWA dB(A) dB(A) dB(A) dB(A) 88 3 99 3 (sound pressure) (sound pressure uncertainty) (sound power) (sound power uncertainty) < 2.5 1.5 The vibration emission level given in this information sheet has been measured in accordance with a standardised test given in EN 60745 and may be used to compare one tool with another. It may be used for a preliminary assessment of exposure. WARNING: The declared vibration emission level represents the main applications of the tool. However if the tool is used for different applications, with different accessories or poorly maintained, the vibration emission may differ. This may significantly increase the exposure level over the total working period. IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL, CALL US AT: 1800 444 224 (Aust) or 0800 339 258 (NZ). Voltage Power input No-load speed Blade diameter Maximum depth of cut at 90˚ Blade bore Bevel angle adjustment Weight m/s² m/s² Identify additional safety measures to protect the operator from the effects of vibration such as: maintain the tool and the accessories, keep the hands warm, organisation of work patterns. SAFETY INSTRUCTIONS FOR POWER TOOLS When using power tools, always observe the safety regulations applicable in your country to reduce the risk of fire, electric shock and personal injury. Read the following safety instructions before attempting to operate this product. Keep these instructions in a safe place. WARNING: To reduce the risk of injury, user must read the instruction manual. GENERAL POWER TOOL SAFETY WARNINGS WARNING! Read all safety warnings and all instructions Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool. 1 SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE 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 situations. 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) 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 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 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) 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 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. 2 Safety Instructions for All Saws 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. a) b) c) d) e) Electrical Safety The electric motor has been designed for one voltage range only. Always check that the power supply corresponds to the voltage on the rating plate. 220–240 V AC means your tool will operate on alternating current. Operation at a voltage outside this range 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. Your DEWALT tool is double insulated, therefore no earth wire is required. • Young children and the infirm. This appliance is not intended for use by young children or infirm persons without supervision. – This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. – Children should be supervised to ensure that they do not play with the appliance. • Replacement of the supply cord. If the supply cord or plug is damaged, it must be replaced by the manufacturer or an authorised DEWALT Service Centre in order to avoid a hazard. f) g) h) DANGER: 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. Do not reach underneath the workpiece. The guard cannot protect you from the blade below the workpiece. 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. 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. 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. When ripping, always use a rip fence or straight edge guide. This improves the accuracy of cut and reduces the chance of blade binding. 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. 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. Further Safety Instructions for All Saws 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. Extension Cords CAUTION: Use only extension cords that are approved by the country’s Electrical Authority. Before using extension cords, inspect them for loose or exposed wires, damaged insulation and defective fittings. Replace the cord if necessary. 3 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: a) 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. 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 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. d) Support large panels to minimize 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. e) Do not use dull or damaged blades. 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. LOWER GUARD SAFETY INSTRUCTIONS a) Check lower guard for proper closing before each use. Do not operate the saw if lower guard does not move freely and close instantly. Never clamp or tie the lower guard into the open position. If saw is accidentally dropped, lower guard may be bent. Raise the lower guard with the retracting handle and make sure it moves freely and does not touch the blade or any other part, in all angles and depths of cut. b) Check the operation of the lower guard spring. If the guard and the spring are not operating properly, they must be serviced before use. Lower guard may operate sluggishly due to damaged parts, gummy deposits, or a build-up of debris. c) Lower guard should be retracted manually only for special cuts such as “plunge cuts” and “compound cuts.” Raise lower guard by retracting handle and as soon as blade enters the material, the lower guard must be released. For all other sawing, the lower guard should operate automatically. d) Always observe that the lower 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 Specific Safety Instructions for Circular Saws WARNING: Do not use abrasive wheels or blades. WARNING: Do not use water feed attachments. • Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body leaves it unstable and may lead to loss of control. • 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 (Refer to Causes and Operator Prevention of Kickback and Kickback). • Avoid cutting nails. Inspect for and remove all nails from lumber before cutting. • Accessories must be rated for at least the speed recommended on the tool warning label. Wheels and other accessories running over rated speed can fly apart and cause injury. Accessory ratings must always be above tool speed as shown on tool nameplate. • Always make sure the saw is clean before using. • Stop using this saw and have it properly serviced if any unusual noise or abnormal operation occcurs. • Always be sure all components are mounted properly and securely before using tool. • Always handle the saw blade with care when mounting or removing it. • Always wait until the motor has reached full speed before starting a cut. • Always keep handles dry, clean and free of oil and grease. Hold the tool firmly with both hands when in use. • Always be alert at all times, especially during repetitive, monotonous operations. Always be sure of position of your hands relative to the blade. 4 • Stay clear of end pieces that may fall after cutting off. They may be hot, sharp and/or heavy. Serious personal injury may result. • Replace or repair damaged cords. Make sure your extension cord is in good condition. Use only 3-wire extension cords that have 3-prong grounding-type plugs and 3-pole receptacles that accept the tool’s plug. • Air vents often cover moving parts and should be avoided. Loose clothes, jewelry or long hair can be caught in moving parts. WARNING: We recommend the use of a residual current device with a residual current rating of 30mA or less. WARNING: ALWAYS wear approved protective safety equipment complying with the following standards: • Eye protection: AS/NZS1337 Eye Protectors for Industrial Applications; • Hearing protection: AS/NZS1270 Acoustics – Hearing Protection; • Respiratory protection: AS/NZS1716 Respiratory Protective Devices. 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. 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 AS/NZS1716 approved respiratory protection appropriate for the dust exposure. Direct particles away from face and body. WARNING: Always wear proper personal hearing protection that conforms to AS/NZS1270 during use. Under some conditions and duration of use, noise from this product may contribute to hearing loss. • The label on your tool may include the following symbols. The symbols and their definitions are as follows: V ................. volts A ...............amperes Hz ............... hertz W ..............watts ...........alternating current min ............. minutes ........ direct current ...........alternating or direct current .............. Class I Construction no ..............no load speed ................... (grounded) .............earthing terminal .............. Class II Construction ..............safety alert symbol ................... (double insulated) BPM ..........beats per minute …/min ........ per minute RPM ..........revolutions per minute IPM ............. impacts per minute sfpm ..........surface feet per minute SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE COMPONENTS (Fig. 1) WARNING: Never modify the power tool or any part of it. Damage or personal injury could result. A. Trigger switch H. Foot plate B. Main handle I. Lower blade guard C. Blade lock J. Blade clamping screw D. End cap K. Lower guard lever E. Auxiliary handle L. Upper blade guard F. Bevel adjustment lever M. Trigger switch lock-off button G. Bevel angle adjustment mechanism 5 M FIG. 1 A FIG. 3 FIG. 2 B C K D L E K F I J H N TO INSTALL THE BLADE (FIG. 2–5) 1. Using the lower guard lever (K), retract the lower blade guard (I) and place blade on saw spindle against the inner clamp washer (N), making sure that the blade will rotate in the proper direction (the direction of the rotation arrow on the saw blade and the teeth must point in the same direction as the direction of rotation arrow on the saw). Do not assume that the printing on the blade will always be facing you when properly installed. When retracting the lower blade guard to install the blade, check the condition and operation of the lower blade guard to assure that it is working properly. Make sure it moves freely and does not touch the blade or any other part, in all angles and depths of cut. 2. Place outer clamp washer (O) on saw FIG. 4 spindle with the beveled edge facing out. C Make sure the 20 mm diameter on the blade side of the clamp fits into the 20 mm hole in the saw blade to ensure centering of the blade. 3. Thread blade clamping screw (J) into saw spindle by hand (screw has right-hand threads and must be turned clockwise to tighten). J I O G INTENDED USE This heavy-duty circular saw is designed for professional wood cutting applications. DO NOT use water feed attachments with this saw. DO NOT use abrasive wheels or blades. DO NOT use under wet conditions or in presence of flammable liquids or gases. This heavy-duty 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. ADJUSTMENTS Changing Blades WARNING: To reduce the risk of serious personal injury, turn tool off and disconnect tool from power source before making any adjustments or removing/ installing attachments or accessories. An accidental start-up can cause injury. 6 LOWER BLADE GUARD WARNING: The lower blade guard is a safety feature which reduces the risk of serious personal injury. Never use the saw if the lower guard is missing, damaged, misassembled or not working properly. Do not rely on the lower blade guard to protect you under all circumstances. Your safety depends on following all warnings and precautions as well as proper operation of the saw. Check lower guard for proper closing before each use as outlined in Additional Safety Rules for Circular Saws. If the lower blade guard is missing or not working properly, have the saw serviced before using. To assure product safety and reliability, repair, maintenance and adjustment should be performed by an authorized service center or other qualified service organization, always using identical replacement parts. CHECKING THE LOWER GUARD 1. Turn tool off and disconnect from power supply. 2. Rotate the lower guard lever (Fig. 1, K) from the fully closed position to the fully open position. 3. Release the lever and observe the guard (I) return to the fully closed position. The tool should be serviced by a qualified service center if it: • fails to return to the fully closed position, • moves intermittently or slowly, or • contacts the blade or any part of the tool in all angles and depth of cut. 4. Depress the blade lock (C) while FIG. 5 B turning the saw spindle with the blade wrench (P) stored underneath the main handle (B, Fig. 5), until the blade lock engages and the blade stops rotating. 5. Tighten the blade clamping screw firmly with the blade wrench. NOTE: 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. TO REPLACE THE BLADE (FIG. 2–5) P 1. To loosen the blade clamping screw (J), depress the blade lock (C) and turn the saw spindle with the blade wrench (P), stored underneath the main handle (B), until the blade lock engages and the blade stops rotating. With the blade lock engaged, turn the blade clamping screw counterclockwise with the blade wrench (screw has right-hand threads and must be turned counterclockwise to loosen). 2. Remove the blade clamping screw (J) and outer clamp washer (O). Remove old blade. 3. Clean any sawdust that may have accumulated in the guard or clamp washer area and check the condition and operation of the lower blade guard as previously outlined. Do not lubricate this area. 4. Select the proper blade for the application (refer to Recommended Blade Types under Blades). Always use blades that are the correct size (diameter) with the proper size and shape center hole for mounting on the saw spindle. Always assure that the maximum recommended speed (rpm) on the saw blade meets or exceeds the speed (rpm) of the saw. 5. Follow steps 1 through 5 under To Install the Blade, making sure that the blade will rotate in the proper direction. Cutting Depth Adjustment (Fig. 6–8) Your saw is equipped with a carbide tipped saw blade for long life and efficient cutting. Setting the saw at the proper cutting depth keeps blade friction to a minimum, removes sawdust from between the blade teeth, results in cooler, faster sawing and reduces the chance of kickback. FIG. 6 LOOSEN Q TIGHTEN 7 1. Hold the saw firmly. Raise the depth adjustment lever (Q) to loosen and move foot plate to obtain the desired depth of cut, as shown. Make sure the depth adjustment lever has been retightened (lowered) before operating the saw. 2. Align the appropriate mark on the Q depth adjustment strap (R) with notch FIG. 7 (S) on the upper blade guard. Your depth is set. 3. For the most efficient cutting action using a carbide tipped saw blade, set S the depth adjustment so that about one half of a tooth projects below the T surface of the wood to be cut. 4. A method of checking for the correct R cutting depth is shown in Figure 8. Lay a piece of the material you plan to cut along the side of the blade, as shown in the figure, and observe how much tooth projects beyond the material. 2. Adjust the depth adjustment lever by rotating it in the desired direction about 1/8 of a revolution. 3. Retighten nut. Bevel Angle Adjustment (Fig. 9) On the front of the saw is a bevel angle LOOSEN FIG. 9 adjustment mechanism (G) which F consists of an angle quadrant with a pointer (U) and a bevel adjustment lever (F). The angle quadrant allows for coarse adjustment. To achieve better accuracy in cutting, use the fine adjustment markings located on the pivot bracket (V). The full range of bevel adjustment is 0 to 57 degrees. TIGHTEN The pivot bracket is graduated in increments of 1 degree. 1. To set the saw for a bevel cut, raise the bevel adjustment U W V G lever (F) to loosen the bevel adjustment. 2. Tilt the foot plate to the desired angle by aligning the pointer (U) with the desired angle mark on the pivot bracket (V). 3. Retighten the bevel adjustment by lowering the lever. FIG. 8 Bevel Detent (Fig. 9) The DWE575-XE is equipped with a bevel detent feature. As you tilt the foot plate you will hear a click and feel the foot plate stop at both 22.5 and 4 degrees. If either of these is the desired angle, retighten the lever (F) by lowering it. If you desire another angle, continue tilting the foot plate until the coarse bevel pointer (W) or the fine pointer (U) aligns with the desired mark. ADJUSTING DEPTH ADJUSTMENT LEVER (FIG. 7) It may be desirable to adjust the depth adjustment lever (Q). It may loosen in time and hit the foot plate before tightening. To tighten the lever, follow the steps below. 1. Hold depth adjustment lever (Q) and loosen the locknut (T). Kerf Indicator (Fig. 10) The front of the saw foot plate has a kerf indicator for vertical and bevel cutting. This indicator enables you to guide the saw along cutting lines penciled on the material being cut. The indicator lines up with the left (inner) side of the saw blade which 8 makes the slot or “kerf” cut by the moving blade, fall to the right of the indicator. The markings on the front of the foot plate are in increments of 5 mm (1/5"). 45˚ FIG. 10 FIG. 12 0˚ Y X H OPERATION Cut Length Indicator (Fig. 11) The markings on the side of the foot plate show the length of the slot being cut into the material at the full depth of the cut. The markings are in increments of 5 mm (1/5"). WARNING: To reduce the risk of serious personal injury, turn tool off and disconnect tool from power source before making any adjustments or removing/ installing attachments or accessories. An accidental start-up can cause injury. FIG. 11 Proper Hand Position (Fig. 13) WARNING: To reduce the risk of serious personal injury, ALWAYS use proper hand position as shown. WARNING: To reduce the risk of serious personal injury, ALWAYS hold securely in anticipation of a sudden reaction. Proper hand position requires one hand on the main handle (B), with the other hand on the auxiliary handle (E). Mounting and Adjusting the Rip Guide (Fig. 12) The rip guide (X) is used for cutting parallel to the edge of the workpiece. MOUNTING 1. Slacken the rip guide adjustment knob (Y) to allow the rip guide to pass. 2. Insert the rip guide (X) in the foot plate (H) as shown. 3. Tighten the rip guide adjustment knob (Y). ADJUSTING 1. Slacken the rip guide adjustment knob (Y) and set the rip guide (X) to the desired width. The adjustment can be read on the rip guide scale. 2. Tighten the rip guide adjustment knob (Y). FIG. 13 B E Switching On and Off (Fig. 1) For safety reasons the trigger switch (A) of your tool is equipped with a lock-off button (M). Press the lock-off button to unlock the tool. To run the tool, press the trigger switch (A). As soon as the trigger switch is released, the lock-off switch is automatically activated to prevent unintended starting of the machine. 9 NOTICE: Do not switch the tool ON or OFF when the saw blade touches the workpiece or other materials. ALWAYS DISCONNECT SAW BEFORE MAKING ANY ADJUSTMENTS! 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. Workpiece Support (Fig. 14–17) WARNING: To reduce the risk of serious personal injury, support the work properly and hold the saw firmly to prevent loss of control. Figures 14 and 16 show proper sawing position. Figures 15 and 17 show an unsafe condition. Hands should be kept away from cutting area, and power cord is positioned clear of the cutting area so that it will not get caught or hung up on the work. Cutting WARNING: Never attempt to use this tool by resting it upside down on a work surface and bringing the material to the tool. Always securely clamp the workpiece and bring the tool to the workpiece, securely holding the tool with two hands as shown in Figure 16. Place the wider portion of the saw foot plate on that part of the work piece which is solidly supported, not on the section that will fall off when the cut is made. As examples, Figure 14 illustrates the RIGHT way to cut off the end of a board. 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. FIG. 14 FIG. 16 FIG. 17 FIG. 15 Be sure saw is up to full speed before blade contacts material to be cut. Starting saw with blade against material to be cut or pushed forward into kerf can result in kickback. 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 working without much decrease in speed. Forcing the saw can cause rough cuts, inaccuracy, kickback, and over-heating of the motor. Should your cut begin to To avoid kickback, ALWAYS support board or panel NEAR the cut (Fig. 14 and 16). DON’T support board or panel away from the cut (Fig. 15 and 17). When operating the saw, keep the cord away from the cutting area and prevent it from becoming hung up on the work piece. 10 go off the line, don’t try to force it back on. Release the switch and allow blade to come to a complete stop. Then you can withdraw the saw, sight anew, 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 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 telescoping guard will automatically close under the blade. Remember the blade is exposed until this occurs. Never reach under the work for any reason. When you have to retract the telescoping guard manually (as is necessary for starting pocket cuts) always use the retracting lever. NOTE: When cutting thin strips, be careful to ensure that small cutoff pieces don’t hang up on inside of lower guard. RIPPING (FIG. 18) Ripping is the process of cutting wider FIG. 18 boards into narrower strips – cutting grain lengthwise. Hand guiding is more difficult for this type of sawing and the use of a DEWALT rip guide (X) is recommended. POCKET CUTTING (FIG. 19) WARNING: Never tie the blade guard in a raised position. Never move the saw backwards when pocket cutting. This may cause the unit to X raise up off the work surface which could cause injury. A pocket cut is one that is made in a floor, wall or other flat surface. 1. Adjust the saw foot plate so the blade cuts at desired depth. 2. Tilt the saw forward and rest front of the foot plate on material to be cut. 3. Using the lower guard lever, retract lower blade guard to an upward position. Lower rear of foot plate until blade teeth almost touch cutting line. 4. Release the blade guard (its contact FIG. 19 with the work will keep it in position to open freely as you start the cut). Remove hand from guard lever and firmly grip auxiliary handle (E), as shown in Figure 19. Position your body and arm to allow you to resist kickback if it occurs. 5. Make sure blade is not in contact with E cutting surface before starting saw. 6. Start the motor and gradually lower the saw until its foot plate rests flat on the material to be cut. Advance saw along the cutting line until cut is completed. 7. Release trigger and allow blade to stop completely before withdrawing the blade from the material. 8. When starting each new cut, repeat as above. 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 (Fig. 15). 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. 11 2. 3. 4. 5. 6. 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 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 Further Safety Instructions for All Saws and Operation for procedures and techniques that will minimize the occurrence of kickback. 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. 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 as shown in Figure 8. This allows the foot plate to support the blade and minimizes twisting and pinching in the material. Refer to Cutting Depth Adjustment. 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 if it is not done carefully. 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) 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 kerf. Worn blades may also have insufficient body clearance which increases the chance of binding and increased loading. LIFTING THE SAW WHEN MAKING BEVEL CUTS Bevel cuts require special operator attention to proper cutting techniques – especially guidance of the saw. Both blade angle to the foot plate and greater MAINTENANCE WARNING: To reduce the risk of serious personal injury, turn tool off and disconnect tool from power source before making any adjustments or removing/ installing attachments or accessories. An accidental start-up can cause injury. Cleaning WARNING: Blow dirt and dust out of all air vents with clean, dry air at least once a week. To minimize the risk of eye injury, always wear AS/NZS51337 approved eye protection when performing this. WARNING: Never use solvents or other harsh chemicals for cleaning the non-metallic parts of the tool. These chemicals may weaken the plastic 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. LOWER GUARD The lower guard should always rotate and close freely from a fully open to fully closed position. Always check for correct operation before cutting by fully opening the guard and letting it close. If the guard closes slowly or not completely, it will need cleaning or servicing. Do not use the saw until it functions correctly. To clean the guard, use dry air or a soft brush to remove all accumulated sawdust or debris from the path of the guard and from around the guard spring. Should this not correct the problem, it will need to be serviced by an authorized service center. 12 Lubrication ADJUSTING BEVEL ADJUSTMENT LEVER (FIG. 21) It may be desirable to adjust the bevel adjustment lever. It may loosen in time and hit the foot plate before tightening. To tighten the lever, follow the steps below. 1. Hold bevel adjustment lever (F) and loosen the locknut (AA). 2. Adjust the bevel adjustment lever by rotating it in the desired direction about 1/8 of a revolution. 3. Retighten nut. Self lubricating ball and roller bearings are used in the tool and relubrication is not required. However, it is recommended that, once a year, you take or send the tool to a service center for a thorough cleaning, inspection and lubrication of the gear case. Repairs To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including brush inspection and replacement) should be performed by certified service centers or other qualified service organizations, always using identical replacement parts. Foot Plate Adjustment FIG. 20 Your foot plate has been factory set to assure that the blade is perpendicular to the foot plate. If after extended use you need to re-align the blade, follow the directions below: ADJUSTING FOR 90 DEGREE CUTS 1. Return the saw to 0 degrees bevel. 2. Place the saw on its side, and Z retract the lower guard. 3. Set the depth of cut at approximately 51 mm (2"). 4. Loosen the bevel adjustment lever (F). Place a square against the blade and the foot plate as shown in Figure 20. 5. Using a hex wrench, turn the set screw (Z) on the underside of the foot plate until the blade and the foot plate are both in flush contact with the square. Retighten the bevel adjustment lever. FIG. 21 F AA Blades 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. RECOMMENDED BLADE TYPES COMBINATION FRAMING 20 mm (5/8") Round arbor, 24 teeth All purpose fast rip and cross cuts PRESSURE TREATED/ 20 mm (5/8") Round arbor, 20 teeth WET LUMBER Coated - Resistant to gum build-up EXTREME DURABILITY 20 mm (5/8") Round arbor, 18 teeth Coated, rock carbide FINISHING 20 mm (5/8")Round arbor, 36 teeth More teeth for finer finish cuts FAST CUT FRAMING 20 mm (5/8") Round arbor, 18 teeth Fastest blade for rips and cross cuts 13 ACCESSORIES 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. Recommended accessories for use with your tool are available at extra cost from your local service center. If you need any assistance in locating any accessory, please contact Stanley Black & Decker, 82 Taryn Drive, Epping, VIC 3076 Australia or call 1800 444 224 or (NZ) 0800 339 258. DO NOT USE WATER FEED ATTACHMENTS WITH THIS SAW. VISUALLY EXAMINE CARBIDE BLADES BEFORE USE. REPLACE IF DAMAGED. 14 Stanley Black & Decker 82 Taryn Drive, Epping, VIC 3076 Australia • 1800 444 224 (Aust) or 0800 339 258 (NZ) www.dewalt.com.au • www.dewalt.co.nz (JUL12) Part No. N153695 DWE575-XE Copyright © 2012 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.