J

K

L

DC390

I

H

G

18.0 Volt Cordless Circular Saw

A

B

F

E

3700 RPM

C

A. SWITCH LOCK-OFF BUTTON

B. TRIGGER SWITCH

C. BATTERY PACK

D. DEPTH ADJUSTMENT KNOB

E. SHOE

F. LOWER GUARD

RETRACTING LEVER

G. LOWER GUARD

H. BLADE CLAMPING SCREW

I. KERF INDICATOR

J. BEVEL ADJUSTMENT KNOB

(not shown)

K. BLADE LOCK BUTTON

(not shown)

L. AUXILARY HANDLE

D

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WALT 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 D

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WALT

The following are trademarks for one or more D

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WALT 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 D

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WALT 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 con-

nected 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 stor-

ing 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.

D 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 man- ner 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 D

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WALT tools are factory tested; if this tool does not operate, check the power supply. Your D

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WALT 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 D

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WALT 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 hid-

den 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 kick-

back 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 activi-

ties. 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

Hz................hertz

min..............minutes

..........direct current

..............Class II Construction

..............safety alert symbol

A ..............amperes

W ..............watts

..........alternating current no..............no load speed

............earthing terminal

.../min........revolutions per minute

Important Safety Instructions for Battery Packs

Your tool uses an 18 Volt D

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WALT 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 D

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WALT 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 D

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WALT. 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 D

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WALT 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 D

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WALT 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 D

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WALT 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 D

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WALT 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.

7.6 m 15.2 m 22.9 m 30.5 m 38.1 m 45.7 m

175 ft.

53.3 m

Wire Size AWG

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 ventila-

tion 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 Tune-

Up™ 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

Your tool uses a 18.0 Volt D

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WALT Charger. Your battery can be charged in D

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WALT 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.

FIG. 1

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 MAK-

ING 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.

L

FIG. 4

K

N

F

Work Piece Support

WARNING: It is important to support the work properly and to hold the saw firmly to prevent loss of control which could cause personal injury. Figure 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).

FIG. 8

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 FIG. 10

DO support board or panel

NEAR the cut.

DON’T support board or panel

AWAY from the cut.

O

G

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

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.

FIG. 5

K

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.

LOOSEN

(clockwise)

TIGHTEN

(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

If you need assistance regarding blades, please call 1800 654 155.

Cutting Depth Adjustment

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 observe how much tooth projects beyond the material.

D

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).

FIG. 7

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).

J

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.

SUPPORT

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.

2. Tilt the saw forward and rest front of the shoe on material to be cut.

FIG. 12

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

Cleaning

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.

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

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 D

E

WALT 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

D

E

WALT 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 D

E

WALT 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, D

E

WALT tools are covered by our:

FREE ONE YEAR SERVICE CONTRACT

D

E

WALT 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. D

E

WALT 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 D

E

WALT 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.

Battery

Cat. Number

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

D

E

WALT Battery and Charger Systems

Nominal

12

12

9.6

9.6

12

12

12

12

Voltage

24

24

24

18

18

14.4

14.4

9.6

9.6

7.2

7.2

18

14.4

2.4

1.25

1.2

2.0

1.7

1.3

1.25

1.3

Amp Hour

2.0

2.0

1.7

2.4

2.0

2.0

1.7

1.7

1.3

1.25

1.3

2.4

2.4

60

40

45

40

X

60

60

40

45

45

60

45

45

60

97014 98014 DW9106 DW9107 DW9108 DW9115

X X X X X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

45

45

X

X

45

45

X

X

45

45

X

X

45

45

60

60

45

45

X

X

15

15

60

45

45

60

60

40

45

45

60

45

45

60

60

40

45

45

60

30

30

45

45

X

30

30

60

30

30

45

45

X

30

30

15

15

15

15

15

15

15

15

60

40

45

40

X

60

60

40

45

40

X

60

45

X

30

X

X

60

45

X

30

X

60

60

15

15

15

15

X

15

240 Volts

45

X

30

30

60

30

30

45

DW9116

X

X

X

60

60

45

45

45

X

30

X

60

60

15

X

12

X

20

15

15

X

12

12

15

12

12

15

DW9117 DW9118

X X

X

X

X

X

20

20

15

15

X

X

90

90

90

X

60

60

60

60

60

90

90

X

60

X

X

60

12 Volts

45

X

30

X

60

60

45

X

30

30

60

30

30

45

DE9116 DE9118 DW911 DC011 DW0245 DE2046 DW9109

X X X X 60 60 X

X

X

X

X

X

X

X

X

60

60

60

60

X

X

60

60

45

45

X

X

90

90

60

60

45

45

60

60

45

45

X

X

X

X

X

X

X

X

60

60

45

45

60

60

60

90

90

X

60

60

60

30

30

45

45

X

30

30

60

30

30

45

45

X

30

30

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

45

X

30

30

60

30

30

45

90

X

60

X

X

60

45

X

30

X

60

60

45

X

30

X

60

60

X

X

X

X

X

X

X

X

X

X

X

X

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.