DEWALT D23620-XE HEAVY-DUTY CIRCULAR SAW

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.

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.

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 AT: 1800 654 155 (Aust) or 09 259 1111 (NZ).

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, 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.

SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE

The term "power tool" in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

1) WORK AREA SAFETY

• Keep work area clean and well lit. Cluttered or dark areas invite accidents.
• 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.
• Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

2) ELECTRICAL SAFETY

• 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.
• 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.
• Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
• 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.
• 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.
• 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

• 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.
• 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.
• 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.
• 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.
• Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
• 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.
• 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

• 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.
• 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.
• 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.
• 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.
• 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.
• Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
• 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

• 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.

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. 240 V AC means your tool will operate on alternating current. 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. 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. Young children should be supervised to ensure that they do not play with this appliance.
• Replacement of the supply cord. If the supply cord is damaged, it must be replaced by the manufacturer or an authorised DEWALT Service Centre in order to avoid a hazard.

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.

MINIMUM GAUGE FOR CORD SETS

• Do not use an extension cord unless it is absolutely necessary. Use of improper extension cord could result in risk of fire, electric shock, or electrocution.
• 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.
• 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.

Safety instructions for all saws

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 arbour 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.

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.

• 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.
• 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.
• 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.
• 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.
• Do not use dull or damaged blades. Unsharpened or improperly set blades produce narrow kerf causing excessive friction, blade binding and kickback.
• 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.
• 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 saws with a pendulum blade guard

• 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.
• 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.
• 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.
• 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 safety instructions for circular saws

• Wear ear protectors. Exposure to noise can cause hearing loss.
• Preferably wear a dust mask.
• 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. Use only the blades specified in this manual, complying with EN 847-1.
• Do not use distorted or cracked saw blades.
• Do not use a blade made of high-speed steel.
• Do not use a blade not in conformity with features as described in this manual.
• Do not exert lateral force to stop the blade.
• Do not set the movable guard in the open position.
• Ensure freely moving guard without binding.
• Ensure proper movement of retracting mechanism of all the protection system.
• Prior to blade replacement, adjustment or other maintenance, always unplug the tool.
• Never use any abrasive wheel unless a tool is specially designed for abrasive wheels.
• Do not use a blade with thinner blade body than the riving knife and tooth set.
• The riving knife must be adjusted not more than 5 mm from the blade tooth circle, and the tooth length below the lower edge of the riving knife shall not be bigger than 5 mm.
• Always use the riving knife except when plunge cutting.
• Never use abrasive cut-off wheels.

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 NIOSH/OSHA approved respiratory protection appropriate for the dust exposure. Direct particles away from face and body.

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 S12.6 (S3.19) hearing protection
• NIOSH/OSHA/MSHA respiratory protection.

WARNING:

ALWAYS wear proper personal hearing protection that conforms to ANSI S12.6 (S3.19) during use. Under some conditions and duration of use, noise from this product may contribute to hearing loss.

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

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

Package contents

• 1 Circular Saw (with 185 mm blade fitted)
• 1 Parallel fence
• 1 Saw blade wrench
• 1 Instruction manual
• 1 Exploded drawing

Description (Fig. 1, 2)

WARNING:

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

INTENDED USE

The D23620-XE circular saw is designed for professional sawing of wood and plastic. 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.

FIG. 1

• A. On/off switch
• B. Lock-off button
• C. Spindle lock
• D. Dust extraction outlet
• E. Shoe
• F. Lower guard retracting lever
• G. Lower blade guard
• H. Saw blade
• I. Bevel adjustment knob
• J. Mark for bevel cut
• K. Mark for straight cut
• L. Depth adjustment knob (Fig. 2)
• M. Parallel fence (Fig. 2)

Depth of cut adjustment (Fig. 2, 3)

1. Loosen the depth adjustment knob (L).
2. Move the shoe (E) to obtain the correct depth of cut.
3. Tighten the depth adjustment knob (L).

WARNING:

For optimal results, allow the saw blade to protrude from the workpiece by about 3 mm (see inset in Figure 3).

Bevel adjustment (Fig. 4)

The bevel angle can be adjusted between 0° and 50°.

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

Shoe adjustment for 90° cuts (Fig. 2)

1. Adjust the saw to 0° bevel.
2. Retract the blade guard using the lever (F) and place the saw on the blade side.
3. Loosen the bevel adjustment knob (I).
4. Place a square against the blade and shoe to adjust the 90° setting. Adjust the stop (N) using an hex key.

Replacing the saw blade (Fig. 5)

1. Engage the blade lock button (C) and unscrew the blade clamping screw (O) by turning counterclockwise using the spanner (P) supplied with the tool.
2. Retract the lower blade guard using the lever (F) and replace the blade (H). Reinstall the washers (Q, R) in the correct position.
3. Check the direction of rotation of the blade.
4. Thread on the blade clamping screw (O) by hand to hold the washer in position. Turn clockwise.
5. Press the blade lock button (C) while turning the spindle until the blade stops rotating.
6. Tighten the blade clamping screw firmly using the spanner.

Mounting and adjusting the parallel fence (Fig. 6)

The parallel fence (M) is used for cutting parallel to the edge of the workpiece.

Mounting

1. Slacken the locking screw (S) as to allow the parallel fence to pass.
2. Insert the parallel fence (M) in the saw shoe (E) as shown.
3. Tighten the locking screw (S).

Adjusting

1. Slacken the locking screw (S) and set the parallel fence (M) to the desired width.
2. Tighten the locking screw (S).

Prior to operation:

• Make sure the guards have been mounted correctly. The saw blade guard must be in closed position.
• Make sure the saw blade rotates in the direction of the arrow on the blade.
• Do not switch the tool on or off when the saw blade touches the workpiece or other materials.
• Do not operate the spindle lock while the tool is running.

OPERATION

WARNING:

• Always observe the safety instructions and applicable regulations.
• Ensure the material to be sawn is firmly secured in place.
• DO NOT use your saw for pocket cuts.
• Apply only a gentle pressure to the tool and do not exert side pressure on the saw blade.
• Avoid overloading.
• Do not use excessively worn saw blades.

Switch (Fig. 1)

To operate the tool, depress the lock-off button (B) then depress the on/off switch (A). Once the tool is running, release the lock-off button. Turn the tool off by releasing the trigger.

Holding and guiding the tool (Fig. 1)

1. Hold the tool by the main grip to guide the saw properly.
2. For optimum results, clamp the workpiece bottom up. Follow the line drawn on the workpiece using the mark (K).
3. In case of a bevel angle of 50° follow the line drawn on the workpiece using the mark (J).
4. Lead the cord away in line with the rear of the tool.

WARNING:

Do not use a vacuum extractor without proper spark protection when sawing metal.

MAINTENANCE

WARNING:

Shock Hazard. 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.

Cleaning

CAUTION:

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.

Lubrication

Your tool was properly lubricated before leaving the factory. In from two to six months, depending upon use, take or send your tool to an authorized service center for a complete cleaning, inspection and lubrication. Tools used constantly on production jobs will need relubrication more often. Also, tools "out of service" for long periods should be relubricated before being put back to work.

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.

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 DEWALT Industrial Tool Co., 20 Fletcher Road, Mooroolbark, VIC 3138 Australia or call 1800 654 155 or (NZ) 09 259 1111.

Guarantee

Applicable to hand held Power Tools, Lasers and Nailers.

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. Please return the complete unit, transportation prepaid, to any DEWALT Service Centre, or any authorised service station.

For warranty repair information, call (AUS) 1800 654 155 or (NZ) 09 259 1111.

This warranty does not apply to:

• Accessories
• Damage caused where repairs have been made or attempted by others.
• Damage due to misuse, neglect, wear and tear, alteration or modification.

This warranty gives you specific legal rights and you may have other rights under the provisions of the Consumer Guarantee Act 1993 (New Zealand only), Trade Practices Act 1974 and State Legislation (Australia only).

In addition to the warranty, DEWALT tools are covered by our:

FREE ONE YEAR SERVICE CONTRACT

DEWALT will also maintain the tool for free at any time during the first year of purchase. This includes labour, parts and lubrication required to restore the product to sound mechanical and/or electrical condition. Normal wear parts are not covered in this service. Carbon brushes worn more then 50% will be replaced.

NOTE: Three Year Warranty is not applicable to items deemed as consumables. Radial arm saws are covered by a one (1) year warranty only. DEWALT Reserves the right to review its warranty policy prior to launch of any new business development products.

30 DAY NO SATISFACTION GUARANTEE

If you are dissatisfied with any DEWALT power tool, laser or nailer, for any reason, simply return it to the point of purchase with your sales receipt within 30 days for a replacement unit or a full refund.

FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are missing, call (AUS) 1800 654 155 or (NZ) 09 259 1111 for a free replacement.

SPECIFICATIONS

DEWALT Industrial Tool Co., 20 Fletcher Road, Mooroolbark, VIC 3138 Australia (03 8720 5100) • 5 Te Apunga Place, Mt Wellington, New Zealand (09 259 1111)

(SEP07) Form No. 656145-00 D23620-XE Copyright © 2007 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.