DeWalt DC390 Instruction manual

DC390
18.0 Volt Cordless Circular Saw
L
3700 RPM
A
B
K
J
A.
B.
C.
D.
E.
F.
I
C
H
G
F
E
G.
H.
I.
J.
K.
L.
SWITCH LOCK-OFF BUTTON
TRIGGER SWITCH
BATTERY PACK
DEPTH ADJUSTMENT KNOB
SHOE
LOWER GUARD
RETRACTING LEVER
LOWER GUARD
BLADE CLAMPING SCREW
KERF INDICATOR
BEVEL ADJUSTMENT KNOB
(not shown)
BLADE LOCK BUTTON
(not shown)
AUXILARY HANDLE
DC390-XE
CORDLESS CIRCULAR SAW
INSTRUCTION MANUAL
D
DEWALT Industrial Tool Co.,
701 East Joppa Road, Baltimore, MD 21286 • 20 Fletcher Road, Mooroolbark, VIC 3138 Australia
(SEP04)
Form No. 625099-00
DC390-XE
Copyright © 2004 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.
IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL, CALL US AT: 1800 654 155 (Aust)
or 09 526 2556 (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.
General Safety Rules
WARNING! Read all instructions. Failure to follow all instructions listed below may result in electric shock, fire and/or
serious injury. The term “power tool” in all of the warnings listed below refers to your mains operated (corded) power tool
or battery operated (cordless) power tool.
SAVE THESE INSTRUCTIONS
1. WORK AREA
a. Keep work area clean and well lit. Cluttered and 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.
3. PERSONAL SAFETY
a. Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a
power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.
b. Use safety equipment. Always wear eye protection. Safety equipment such as dust mask, non-skid safety
shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.
c. Avoid accidental starting. Ensure the switch is in the off position before plugging in. Carrying power tools
with your finger on the switch or plugging in 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 these devices 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 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 tools 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 and in the manner intended for the particular type of power tool, 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. BATTERY TOOL USE AND CARE
a. Ensure the switch is in the off position before inserting battery pack. Inserting the battery pack into power
tools that have the switch on invites accidents.
b. Recharge only with the charger specified by the manufacturer. A charger that is suitable for one type of battery pack may create a risk of fire when used with another battery pack.
c. Use power tools only with specifically designated battery packs. Use of any other battery packs may create a
risk of injury and fire.
d. When battery pack is not in use, keep it away from other metal objects like paper clips, coins, keys, nails,
screws, or other small metal objects that can make a connection from one terminal to another. Shorting the
battery terminals together may cause burns or a fire.
e. Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact accidentally
occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the battery
may cause irritation or burns.
6. 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.
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 saw 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.
Additional Safety Instructions
DANGER: Keep hands away from cutting area and 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.
• Keep your body positioned to either side of the blade, but not in line with the saw blade. KICKBACK could cause
the saw to jump backwards (see KICKBACK).
• Do not reach underneath the work. The guard can not protect you from the blade below the work.
• Check lower guard for proper closing before use. Do not operate 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 and condition 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 buildup of debris.
• Lower guard should be retracted manually only for special cuts such as “Pocket Cuts” and “Compound Cuts.”
Raise lower guard by Retracting Handle. As soon as blade enters the material, 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.
• NEVER hold piece being cut in your hands or across your leg. It is important to support the work properly to
minimize body exposure, blade binding, or loss of control.
• Hold tool by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring. Contact with a “live” wire will make exposed metal parts of the 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 for blade binding.
• Always use blades with correct size and shape (diamond vs. round) 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 bolts. The blade washers and bolt were specially designed for
your saw, for optimum performance and safety of operation.
• Avoid cutting nails. Inspect for and remove all nails from lumber before cutting.
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 operator.
• Kickback is the result of tool misuse and/or incorrect operating procedures or conditions and can be avoided by
taking proper precautions as given below:
• Maintain a firm grip with both hands on the saw and position your body and arm to allow you to resist kickback forces. Kickback forces can be controlled by the operator, if proper precautions are taken.
• 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, center the saw blade in the kerf and check that the 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 minimize the risk of blade pinching and kickback. Large panels tend to sag under their
own weight. Support must be placed under the panel on both sides, near the line of cut and near the edge of the
panel.
• Do not use dull or damaged blade. 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 “Pocket Cut” into existing walls or other blind areas. The protruding blade
may cut objects that can cause kickback.
WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains
chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:
• lead from lead-based paints,
• crystalline silica from bricks and cement and other masonry products, and
• arsenic and chromium from chemically-treated lumber (CCA).
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these
chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are
specially designed to filter out microscopic particles.
• Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling, and other construction activities. Wear protective clothing and wash exposed areas with soap and water. Allowing dust to get into your
mouth, eyes, or lay on the skin may promote absorption of harmful chemicals.
WARNING: Use of this tool can generate and/or disburse dust, which may cause serious and permanent respiratory or
other injury. Always use NIOSH/OSHA approved respiratory protection appropriate for the dust exposure. Direct particles
away from face and body.
WARNING: Always use eye protection. All users and bystanders must wear eye protection that conforms to ANSI Z87.1.
CAUTION: When not in use, place tool on its side on a stable surface where it will not cause a tripping or falling
hazard. Some tools with large battery packs will stand upright on the battery pack but may be easily knocked over.
CAUTION: Wear appropriate personal hearing protection during use. Under some conditions and duration of use,
noise from this product may contribute to hearing loss.
CAUTION: When sawing into walls, floors, or wherever “live” electrical wires may be encountered, do not touch any
metal parts of the tool! Hold the saw only by its plastic handles to prevent electric shock if you accidentally saw into a live
wire.
• 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
min..............minutes
..........alternating current
no..............no load speed
..........direct current
..............Class II Construction
............earthing terminal
..............safety alert symbol
.../min........revolutions per minute
Important Safety Instructions for Battery Packs
Your tool uses an 18 Volt DEWALT battery pack. When ordering replacement battery packs, be sure to include catalog
number and voltage: Extended Run-Time battery packs deliver 25% more run-time than standard battery packs.
NOTE: Your tool will accept either standard or Extended Run Time battery packs. However, be sure to select proper voltage. Batteries slowly lose their charge when they are not on the charger, the best place to keep your battery is on the
charger at all times.
The battery pack is not fully charged out of the carton. Before using the battery pack and charger, read the safety
instructions below. Then follow charging procedures outlined.
READ ALL INSTRUCTIONS
• Do not incinerate the battery pack even if it is severely damaged or is completely worn out. The battery pack
can explode in a fire.
• A small leakage of liquid from the battery pack cells may occur under extreme usage or temperature conditions.
This does not indicate a failure. However, if the outer seal is broken and this leakage gets on your skin:
a. Wash quickly with soap and water.
b. Neutralize with a mild acid such as lemon juice or vinegar.
c. If battery liquid gets into your eyes, flush them with clean water for a minimum of 10 minutes and seek immediate
medical attention. (Medical Note: The liquid is 25–35% solution of potassium hydroxide.)
• Charge the battery packs only in DEWALT chargers.
• DO NOT splash or immerse in water or other liquids.
• Do not store or use the tool and battery pack in locations where the temperature may reach or exceed 105°F
(40˚C) (such as outside sheds or metal buildings in summer).
DANGER: Never attempt to open the battery pack for any reason. If battery pack case is cracked or damaged, do not insert
into charger. Electric shock or electrocution may result. Damaged battery packs should be returned to service center for recycling.
NOTE: Battery storage and carrying caps are provided for use wheneverthe battery is out of the tool or
charger. Remove cap before placing battery in charger or tool.
WARNING: Do not store or carry battery so that metal objects can contact exposed battery terminals.
For example, do not place battery in aprons, pockets, tool boxes, product kit boxes, drawers, etc. with loose
nails, screws, keys, etc. without battery cap. Without cap in place, battery could short circuit causing fire or
burns or damage to battery.
CAUTION: Battery pack must be securely attached to tool. If battery pack is detached, personal injury may result.
The RBRC™ Seal
The RBRC™ (Rechargeable Battery Recycling Corporation) Seal on the nickel-cadmium battery (or battery
pack) indicates that the costs to recycle the battery (or battery pack) at the end of its useful life have
already been paid by DEWALT. In some areas, it is illegal to place spent nickel-cadmium batteries in the
trash or municipal solid waste stream and the RBRC program provides an environmentally conscious
alternative.
RBRC™ in cooperation with DEWALT and other battery users, has established programs in the United States to facilitate
the collection of spent nickel-cadmium batteries. Help protect our environment and conserve natural resources by
returning the spent nickel-cadmium battery to an authorized DEWALT service center or to your local retailer for recycling.
You may also contact your local recycling center for information on where to drop off the spent battery.
RBRC™ is a registered trademark of the Rechargeable Battery Recycling Corporation.
Important Safety Instructions for Battery Chargers
SAVE THESE INSTRUCTIONS: This manual contains important safety instructions for battery chargers.
• Before using charger, read all instructions and cautionary markings on charger, battery pack, and product using battery pack.
DANGER: 240 volts are present at charging terminals. Do not probe with conductive objects. Electric shock or electrocution may result.
WARNING: Do not allow any liquid to get inside charger. Electric shock may result.
CAUTION: To reduce the risk of injury, charge only DEWALT nickel cadmium rechargeable batteries. Other types of batteries may burst causing personal injury and damage.
CAUTION: Under certain conditions, with the charger plugged in to the power supply, the exposed charging contacts
inside the charger can be shorted by foreign material. Foreign materials of a conductive nature such as, but not limited
to, steel wool, aluminum foil, or any buildup of metallic particles should be kept away from charger cavities. Always
unplug the charger from the power supply when there is no battery pack in the cavity. Unplug charger before attempting
to clean.
• DO NOT attempt to charge the battery pack with any chargers other than the ones in this manual. The charger
and battery pack are specifically designed to work together.
• These chargers are not intended for any uses other than charging DEWALT rechargeable batteries. Any other
uses may result in risk of fire, electric shock or electrocution.
• Do not expose charger to rain or snow.
• Pull by plug rather than cord when disconnecting charger. This will reduce risk of damage to electric plug and
cord.
• Make sure that cord is located so that it will not be stepped on, tripped over, or otherwise subjected to damage
or stress.
• 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.
• 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.
When using more than one extension to make up the total length, be sure each individual extension contains at least
the minimum wire size.
Recommended Minimum Wire Size for Extension Cords
Total Length of Cord
25 ft.
50 ft.
75 ft.
100 ft.
125 ft.
150 ft.
175 ft.
7.6 m 15.2 m 22.9 m
30.5 m
38.1 m
45.7 m
53.3 m
Wire Size AWG
18
18
16
16
14
14
12
• Do not place any object on top of charger or place the charger on a soft surface that might block the ventilation slots and result in excessive internal heat. Place the charger in a position away from any heat source. The
charger is ventilated through slots in the top and the bottom of the housing.
• Do not operate charger with damaged cord or plug — have them replaced immediately.
• Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged in any way. Take it
to an authorized service center.
• Do not disassemble charger; take it to an authorized service center when service or repair is required.
Incorrect reassembly may result in a risk of electric shock, electrocution or fire.
• Disconnect the charger from the outlet before attempting any cleaning. This will reduce the risk of electric
shock. Removing the battery pack will not reduce this risk.
• NEVER attempt to connect 2 chargers together.
• The charger is designed to operate on standard household electrical power (240 Volts). Do not attempt to use
it on any other voltage. This does not apply to the vehicular charger.
Using Automatic Tune-Up™ Mode
The Automatic Tune-Up™ Mode equalizes or balances the individual cells in the battery pack allowing it to function at
peak capacity. Battery packs should be tuned up weekly or after 10 charge/discharge cycles or whenever the pack no
longer delivers the same amount of work. To use the Automatic Tune-Up™, place the battery pack in the charger and
leave it for at least 8 hours. The charger will cycle through the following modes.
1. The red light will blink continuously indicating that the 1-hour charge cycle has started.
2. When the 1-hour charge cycle is complete, the light will stay on continuously and will no longer blink. This indicates that the pack is fully charged and can be used at this time.
3. Whenever the pack is left in the charger after the initial 1-hour charge, the charger will begin the Automatic TuneUp™ Mode. This mode continues up to 8 hours or until the individual cells in the battery pack are equalized. The battery pack is ready for use and can be removed at any time during the Tune-Up™ Mode.
4. Once the Automatic Tune-Up™ Mode is complete the charger will transition to a maintenance charge; the indicator
light shuts off when the automatic Tune-Up™ Mode is complete.
SAVE THESE INSTRUCTIONS FOR FUTURE USE
Chargers
FIG. 1
Your tool uses a 18.0 Volt DEWALT Charger. Your battery can be
charged in DEWALT 1 Hour Chargers, 15 Minute Chargers or
Vehicular 12 volt charger. Be sure to read all safety instructions
before using your charger. Consult the chart on the back cover of
this manual for compatibility of chargers and battery packs.
Charging Procedure (Fig. 1)
DANGER: 240 volts are present at charging terminals. Do not probe with conductive objects. Electric shock or electrocution may result.
1. Plug the charger into an appropriate outlet.
2. Insert the battery pack into the charger. The red (charging) light will blink continuously indicating that the charging
process has started.
3. The completion of charge will be indicated by the red light remaining ON continuously. The pack is fully charged
and may be used at this time or left in the charger.
Indicator Light Operation
PACK CHARGING...................
FULLY CHARGED...................
HOT/COLD PACK DELAY........
REPLACE PACK......................
PROBLEM POWER LINE........
Charge Indicators
Some chargers are designed to detect certain problems that can arise with battery packs. Problems are indicated by the red
light flashing at a fast rate. If this occurs, reinsert battery pack into the charger. If the problem persists, try a different battery
pack to determine if the charger is OK. If the new pack charges correctly, then the original pack is defective and should be
returned to a service center or other collection site for recycling. If the new battery pack elicits the same trouble indication as
the original, have the charger tested at an authorized service center.
HOT/COLD PACK DELAY
Some chargers have a Hot/Cold Pack Delay feature: when the charger detects a battery that is hot, it automatically
starts a Hot Pack Delay, suspending charging until the battery has cooled. After the battery has cooled, the charger
automatically switches to the Pack Charging mode. This feature ensures maximum battery life. The red light flashes
long, then short while in the Hot Pack Delay mode.
PROBLEM POWER LINE
Some chargers have a Problem Power Line indicator. When the charger is used with some portable power sources such as
generators or sources that convert DC to AC, the charger may temporarily suspend operation, flashing the red light with two
fast blinks followed by a pause. This indicates the power source is out of limits.
LEAVING THE BATTERY PACK IN THE CHARGER
The charger and battery pack can be left connected with the red light glowing indefinitely. The charger will keep the battery pack fresh and fully charged.
NOTE: A battery pack will slowly lose its charge when kept out of the charger. If the battery pack has not been kept on
maintenance charge, it may need to be recharged before use. A battery pack may also slowly lose its charge if left in a
charger that is not plugged into an appropriate AC source.
WEAK BATTERY PACKS: Chargers can also detect a weak battery. Such batteries are still usable but should not be
expected to perform as much work. In such cases, about 10 seconds after battery insertion, the charger will beep
rapidly 8 times to indicate a weak battery condition. The charger will then go on to charge the battery to the highest
capacity possible.
Important Charging Notes
1. Longest life and best performance can be obtained if the battery pack is charged when the air temperature is
between 65°F and 75°F (18°- 24°C). DO NOT charge the battery pack in an air temperature below +40°F (+4.5°C),
or above +105°F (+40.5°C). This is important and will prevent serious damage to the battery pack.
2. The charger and battery pack may become warm to touch while charging. This is a normal condition, and does not
indicate a problem. To facilitate the cooling of the battery pack after use, avoid placing the charger or battery pack
in a warm environment such as in a metal shed, or an uninsulated trailer.
3. If the battery pack does not charge properly:
a. Check current at receptacle by plugging in a lamp or other appliance
b. Check to see if receptacle is connected to a light switch which turns power off when you turn out the lights.
c. Move charger and battery pack to a location where the surrounding air temperature is approximately 65°F - 75°F
(18° - 24°C).
d. If charging problems persist, take the tool, battery pack and charger to your local service center.
4. The battery pack should be recharged when it fails to produce sufficient power on jobs which were easily done previously. DO NOT CONTINUE to use under these conditions. Follow the charging procedure. You may also charge a
partially used pack whenever you desire with no adverse affect on the battery pack.
5. Under certain conditions, with the charger plugged into the power supply, the exposed charging contacts inside the
charger can be shorted by foreign material. Foreign materials of a conductive nature such as, but not limited to, steel
wool, aluminum foil, or any buildup of metallic particles should be kept away from charger cavities. Always unplug the
charger from the power supply when there is no battery pack in the cavity. Unplug charger before attempting to clean.
6. Do not freeze or immerse charger in water or any other liquid.
WARNING: Don't allow any liquid to get inside charger. Electric shock may result.
CAUTION: Never attempt to open the battery pack for any reason. If the plastic housing of the battery pack breaks or cracks,
return to a service center for recycling.
FIG. 2
FIG. 3
A
B
M
Installing and Removing the Battery Pack (Fig. 2)
NOTE: Make sure your battery pack is fully charged.
CAUTION: Make certain the switch lock-off button (A) is engaged to prevent switch actuation before removing or
installing battery.
To install the battery pack into the tool handle, align the base of the tool with the notch inside the tool’s handle and
slide the battery pack firmly into the handle until you hear the lock snap into place.
To remove the battery pack from the tool, press the release buttons and firmly pull the battery pack out of the tool handle. Insert it into the charger as described in the charger manual.
OPERATION
Switch
Release switch lock-off button (A) by pressing button as shown (Fig. 3). Pull the trigger switch (B) to turn the motor ON.
Releasing the trigger switch turns the motor OFF. Releasing the trigger switch also automatically actuates lock-off button.
NOTE: This tool has no provision to lock the switch in the ON position, and should never be locked ON by any other
means.
Changing Blades
CAUTION: TURN OFF TOOL AND REMOVE BATTERY PACK FROM SAW BEFORE CHANGING ACCESSORIES OR MAKING ANY ADJUSTMENTS.
TO INSTALL THE BLADE
1. Place inner clamp washer (N) on saw spindle spindle with the large flat surface facing out toward the blade (Fig. 4).
2. Retract the lower blade guard (G) and place blade on saw spindle against the inner clamp washer, 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.
3. Place outer clamp washer (O) on saw spindle with the large flat surface against the blade with beveled side facing out.
Work Piece Support
WARNING: It is important to support the work properly and to
FIG. 8
hold the saw firmly to prevent loss of control which could cause
personal injury. Figure 8 illustrates proper hand support of the saw.
Maintain a firm grip with both hands on the saw and position your
body and arm to allow you to resist kickback if it occurs. ALWAYS
TURN OFF TOOL AND REMOVE BATTERY BEFORE MAKING ANY
ADJUSTMENTS!
Figure 8 shows proper sawing position. Note that hands are kept
away from cutting area. To avoid kickback, DO support board or
panel NEAR the cut (Fig. 9). DON’T support board or panel away
from the cut (Fig. 10).
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 cut it.
FIG. 9
L
FIG. 4
FIG. 10
DO support board or panel
NEAR the cut.
K
DON’T support board or panel
AWAY from the cut.
N
F
SUPPORT
Cutting
G
O
H
4. Thread blade clamping screw (H) into saw spindle by hand (screw has left-hand threads and must be turned counterclockwise to tighten).
5. Depress the blade lock (K) while turning the saw spindle with the blade wrench until the blade lock engages and the
blade stops rotating (Fig. 5).
6. 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. 5
K
1. To loosen the blade clamping screw (H), depress the blade lock (K) and
turn the saw spindle with the blade wrench until the blade lock engages
and the blade stops rotating. With the blade lock engaged, turn the blade
clamping screw clockwise with the blade wrench (screw has left-hand
threads and must be turned clockwise to loosen).
2. Remove the blade clamping screw (H) and outer clamp washer (O) only.
Remove old blade.
3. Clean any sawdust that may have accumulated in the guard or clamp
LOOSEN
washer area and check the condition and operation of the lower blade
TIGHTEN
(clockwise)
guard as previously outlined. Do not lubricate this area.
(counterclockwise)
4. Select the proper blade for the application (see 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 2 through 6 under To Install the Blade, making sure that the blade will rotate in the proper direction.
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.
Blades
WARNING: To minimize the risk of eye injury, always use eye protection. Carbide is a hard but brittle material. Foreign
objects in the work piece such as wire or nails can cause tips to crack or break. Only operate saw when proper saw blade
guard is in place. Mount blade securely in proper rotation before using, and always use a clean, sharp blade.
CAUTION: Do not cut ferrous metals (steel), masonry, glass or tile with this saw.
A dull blade will cause slow, inefficient cutting overload on the saw motor, excessive splintering, and could increase the
possibility of kickback. Please refer to the table on next page to determine the correct size replacement blade for your
model saw.
Model
DC390
Blade
DW9155
DW9154
DW9153
Diameter
165mm (6-1/2")
165mm (6-1/2")
165mm (6-1/2")
Teeth
18
24
90
Application
General Purpose Cutting
Smooth Wood Cutting
Non-carbide, Plywood/Vinyl Siding Cutting
Place the wider portion of the saw shoe 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 8 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.
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
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. 11)
Ripping is the process of cutting wider boards into narrower strips –
cutting grain lengthwise. Hand guiding is more difficult for this type of
sawing and the use of a rip fence is recommended.
FIG. 11
INSTALL RIP
FENCE
IN THIS
DIRECTION
POCKET CUTTING (FIG. 12)
CAUTION: Turn off tool and remove battery pack from saw before
changing accessories or making any adjustments.
CAUTION: Never tie the blade guard in a raised position. Never move
the saw backwards when pocket cutting. This may cause the unit to
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 shoe so the blade cuts at desired depth.
FIG. 12
2. Tilt the saw forward and rest front of the shoe on material to be cut.
3. Using the retracting lever, retract lower blade guard to an upward
position. Lower rear of shoe until blade teeth almost touch cutting
line.
4. Release the blade guard (its contact with the work will keep it in position to open freely as you start the cut). Remove hand from guard
lever and firmly grip auxilary handle, as shown in Figure 12. Position
your body and arm to allow you to resist kickback if it occurs.
5. Make sure blade is not in contact with cutting surface before starting
saw.
6. Start the motor and gradually lower the saw until its shoe 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.
MAINTENANCE
If you need assistance regarding blades, please call 1800 654 155.
Cleaning
Cutting Depth Adjustment
Use only mild soap and a damp cloth to clean the tool. Many household cleaners contain chemicals which could seriously
damage plastic. Also, do not use gasoline, turpentine, lacquer or paint thinner, dry cleaning fluids or similar products.
Never let any liquid get inside the tool; never immerse any part of the tool into a liquid.
CAUTION: Turn off tool and remove battery pack from saw before changing accessories or making any adjustments.
1. Hold the saw firmly and loosen (clockwise) the depth adjustment knob (D) and
FIG. 6
move shoe to obtain the desired depth of cut (Fig. 6).
2. Make sure the depth adjustment knob has been retightened (counterclockwise)
before operating saw.
For the most efficient cutting action, set the depth adjustment so that one tooth of the
blade will project below the material to be cut. This distance is from the tip of the tooth
to the bottom of the gullet in front of it. This keeps blade friction at a minimum,
removes sawdust from the cut, results in cooler, faster sawing and reduces the chance
of kickback. A method for checking for correct cutting depth is shown in Figure 7. Lay
a piece of the material you plan to cut along the side of the blade, as shown, and
D
observe how much tooth projects beyond the material.
NOTE: When using carbide-tipped blades, make an exception to the above rule and allow only one-half of a tooth to project below the material to be cut.
Bevel Angle Adjustment
CAUTION: Turn off tool and remove battery pack from saw before changing
accessories or making any adjustments.
The full range of the bevel adjustment is from 0˚ to 50˚. The quadrant is graduated
in increments of 1˚. On the front of the saw is a bevel angle adjustment mechanism (Fig. 7) consisting of a calibrated quadrant and a knob (J).
CHARGER CLEANING INSTRUCTIONS
WARNING: Disconnect the charger from the AC outlet before cleaning. Dirt and grease may be removed from the exterior of the charger using a cloth or soft non-metallic brush. Do not use water or any cleaning solutions.
Lubrication
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 certified 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.
Accessories
FIG. 7
J
TO SET THE SAW FOR A BEVEL CUT
1. Loosen (counterclockwise) the bevel adjustment knob (J) and tilt shoe to
the desired angle by aligning the pointer with the desired angle mark.
2. Retighten knob firmly (clockwise).
Shoe Adjustment for 90˚ Cuts
CAUTION: Turn off tool and remove battery pack from saw before changing accessories or making any adjustments.
IF ADDITIONAL ADJUSTMENT IS NEEDED
1. Adjust the saw to 0˚ bevel.
2. Retract blade guard. Place the saw on blade side.
3. Loosen bevel adjustment knob. Place a square against the blade and shoe to adjust the 90˚ setting.
4. Move the adjustment screw so that the shoe will stop at the proper angle.
5. Confirm the accuracy of the setting by checking the squareness of an actual cut on a scrap piece of material.
Kerf Indicator
The front of the saw shoe 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 (outer) side of the saw blade,
which makes the slot or “kerf” cut by the moving blade fall to the right of the indicator. Guide along the penciled cutting
line so that the kerf falls into the waste or surplus material.
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.
CAUTION: The use of any non-recommended accessory may be hazardous.
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 1800 654 155.
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 1800-654-155 for
a free replacement.
DEWALT Battery and Charger Systems
Battery
Output
Nominal
Chargers/Charge Time
240 Volts
12 Volts
Cat. Number
Voltage
Amp Hour
97014
98014
DW9106
DW9107
DW9108
DW9115
DW9116
DW9117
DW9118
DE9116
DE9118
DW911
DC011
DW0245
DE2046
DW9109
DW0242
DE0240-XJ
DW0240
DW9096
DE9095-XJ
DE9091-XJ
DW9091
DC9071
DE9074-XJ
DW9072
DE9071-XJ
DW9071
DW9050
DW9063
DW9062
DW9061
DW9048
DW9057
DW9046
DC9096
DC9091
24
24
24
18
18
14.4
14.4
12
12
12
12
12
12
9.6
9.6
9.6
9.6
7.2
7.2
18
14.4
2.0
2.0
1.7
2.4
2.0
2.0
1.7
2.4
1.25
1.2
2.0
1.7
1.3
1.25
1.3
1.7
1.3
1.25
1.3
2.4
2.4
X
X
X
X
X
45
45
60
45
45
60
60
40
45
45
60
40
45
40
X
60
X
X
X
X
X
45
45
60
45
45
60
60
40
45
45
60
40
45
40
X
60
X
X
X
X
X
45
45
60
45
45
60
60
40
45
45
60
40
45
40
X
60
X
X
X
X
X
45
45
60
30
30
45
45
X
30
30
45
X
30
X
X
60
X
X
X
60
60
45
45
60
30
30
45
45
X
30
30
45
X
30
X
60
60
X
X
X
X
X
15
15
15
15
15
15
15
15
15
15
15
15
15
15
X
15
X
X
X
60
60
45
45
60
30
30
45
45
X
30
30
45
X
30
X
60
60
X
X
X
20
20
15
15
15
12
12
15
15
X
12
12
15
X
12
X
20
15
X
X
X
X
X
90
90
60
60
60
90
90
X
60
60
90
X
60
X
X
60
X
X
X
60
60
45
45
60
30
30
45
45
X
30
30
45
X
30
X
60
60
X
X
X
X
X
90
90
60
60
60
90
90
X
60
60
90
X
60
X
X
60
X
X
X
60
60
45
45
60
30
30
45
45
X
30
30
45
X
30
X
60
60
X
X
X
60
60
45
45
60
30
30
45
45
X
30
30
45
X
30
X
60
60
60
60
60
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
60
60
60
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
60
60
45
45
60
30
30
45
45
X
30
30
45
X
30
X
60
60
X Indicates that the battery pack is not compatible with that specific charger.
All charge times are approximate. Actual charge time may vary.
Read the instruction manual for more specific information.
The battery voltage is nominal, it can measure above or below depending on the state of charge.