DeWalt DC390 Instruction Manual

D WALT Industrial Tool Co., 701 Joppa Road, Baltimore, MD 21286
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(JUL06) Form No. 644741-00
The following are trademarks for one or more D
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
CALL US TOLL FREE AT: 1-800-4-D
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General Safety Rules – For All Battery Operated Tools
WARNING! Read and understand all instructions. Failure to follow all
instructions listed below may result in electric shock, fire and/or serious
personal injury.
SAVE THESE INSTRUCTIONS
WORK AREA
• Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents.
• Do not operate power tools in explosive atmospheres, such as in the presence of
flammable liquids, gases, or dust. Power tools create sparks which may ignite the dust or
fumes.
• Keep bystanders, children, and visitors away while operating a power tool. Distractions
can cause you to lose control.
ELECTRICAL SAFETY
• Do not abuse the cord. Never use the cord to carry the tool. Keep cord away from heat,
oil, sharp edges or moving parts. Replace damaged cords immediately. Damaged
cords may create a fire.
• A battery operated tool with integral batteries or a separate battery pack must be
recharged only with the specified charger for the battery. A charger that may be suitable
for one type of battery may create a risk of fire when used with another battery.
• Use battery operated tool only with the specifically designed battery pack. Use of any
other batteries may create a risk of fire.
PERSONAL SAFETY
• Stay alert, watch what you are doing and use common sense when operating a power
tool. Do not use tool while tired or under the influence of drugs, alcohol, or medica-
tion. A moment of inattention while operating power tools may result in serious personal
injury,
• Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your
hair, clothing, and gloves away from moving parts. Loose clothing, jewelry, or long hair
can be caught in moving parts. Air vents often cover moving parts and should also be
avoided.
• Avoid accidental starting. Be sure switch is in the locked or off position before insert-
ing battery pack. Carrying tools with your finger on the switch or inserting the battery pack
into a tool with the switch on invites accidents.
• Remove adjusting keys or wrenches before turning the tool on. A wrench or key that is
left attached to a rotating part of the tool may result in personal injury.
• Do not overreach. Keep proper footing and balance at all times. Proper footing and bal-
ance enables better control of the tool in unexpected situations.
• Use safety equipment. Always wear eye protection. Dust mask, non-skid safety shoes,
hard hat, or hearing protection must be used for appropriate conditions.
TOOL USE AND CARE
• Use clamps or other practical way to secure and support the workpiece to a stable
platform. Holding the work by hand or against your body is unstable and may lead to a loss
of control.
• Do not force tool. Use the correct tool for your application. The correct tool will do the
job better and safer at the rate for which it is designed.
• Do not use tool if switch does not turn it on or off. Any tool that cannot be controlled with
the switch is dangerous and must be repaired.
• Disconnect battery pack from tool or place the switch in the locked or off position
before making any adjustments, changing accessories, or storing the tool. Such pre-
ventative safety measures reduce the risk of starting the tool accidentally.
• Store idle tools out of reach of children and other untrained persons. Tools are dan-
gerous in the hands of untrained users.
• 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 con-
nection from one terminal to another. Shorting the battery terminals together may cause
sparks, burns, or a fire.
• Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools,
with sharp cutting edges are less likely to bind and are easier to control.
• Check for misalignment or binding of moving parts, breakage of parts, and any other
condition that may affect the tool's operation. If damaged, have the tool serviced
before using. Many accidents are caused by poorly maintained tools.
• Use only accessories that are recommended by the manufacturer for your model.
Accessories that may be suitable for one tool, may become hazardous when used on
another tool.
SERVICE
• Tool service must be performed only by qualified repair personnel. Service or mainte-
nance performed by unqualified personnel could result in a risk of injury.
• When servicing a tool, use only identical replacement parts. Follow instructions in the
Maintenance section of this manual. Use of unauthorized parts or failure to follow
Maintenance Instructions may create a risk of electric shock or injury.

Additional Safety Rules for Circular Saws

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 cut-
ting 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 accura-
cy 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.
DC390 Copyright © 2005, 2006 D
WALT power tools: the yellow and black color
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WALT (1-800-433-9258)
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 elim-
inate 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: Wear appropriate hearing protection during use. Under some conditions and
duration of use, noise from this product may contribute to hearing loss.
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.
• The label on your tool may include the following symbols. The symbols and their definitions
WALT
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are as follows:
V ..................volts
Hz ................hertz
min ..............minutes
............direct current
................Class I Construction
WALT TOOL,
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....................(grounded)
..................Class II Construction
....................(double insulated)
BPM ............beats per minute
Important Safety Instructions for Battery Packs
Your tool uses either an 18 Volt D
packs, be sure to include catalog number and voltage: Extended Run-Time battery packs deliv-
er 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 charg-
er, 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 charg-
er, read the safety instructions below. Then follow charging procedures outlined.
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 bro-
ken 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 min-
utes and seek immediate medical attention. (Medical note: The liquid is 25-35% solution
of potassium hydroxide.)
• Do not carry extra battery packs in aprons, pockets, or tool boxes along with other
metal objects. Battery pack could be short circuited causing damage to the battery pack and
possibly causing severe burns or fire.
• Charge the battery packs only in D
• 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 ºC) (such as outside sheds or metal buildings in summer).
DANGER: Electrocution hazard. Never attempt to open the battery pack for any reason. If bat-
tery 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 whenever the
battery is out of the tool or charger. Remove cap before placing battery in
charger or tool.
WARNING: Fire hazard. 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. Transporting batteries can possibly cause fires
if the battery terminals inadvertently come in contact with conductive materials such as
keys, coins, hand tools and the like. The US Department of Transportation Hazardous
Material Regulations (HMR) actually prohibit transporting batteries in commerce or on airplanes
(i.e., packed in suitcases and carry-on luggage) UNLESS they are properly protected from short
circuits. So when transporting individual batteries, make sure that the battery terminals are pro-
tected and well insulated from materials that could contact them and cause a short circuit.
The RBRC™ Seal
The RBRC™ (Rechargeable Battery Recycling Corporation) Seal on the nickel
cadmium and nickel metal hydride batteries (or battery packs) indicate that the
costs to recycle these batteries (or battery packs) at the end of their useful life have
already been paid by D
cadmium and nickel metal hydride batteries in the trash or municipal solid waste
stream and the RBRC program provides an environmentally conscious alternative.
RBRC™ in cooperation with D
United States and Canada to facilitate the collection of spent nickel cadmium and nickel metal
hydride batteries. Help protect our environment and conserve natural resources by returning the
spent nickel cadmium and nickel metal hydride batteries to an authorized D
ter 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: Electrocution hazard. 120 volts are present at charging terminals. Do not probe with
conductive objects.
WARNING: Shock hazard. Do not allow any liquid to get inside charger.
CAUTION: Burn hazard. To reduce the risk of injury, charge only D
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 mate-
rials 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
able 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 dam-
age to electric plug and cord.
• Make sure that cord is located so that it will not be stepped on, tripped over, or other-
wise subjected to damage or stress.
• Do not use an extension cord unless it is absolutely necessary. Use of improper exten-
sion 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.
7.6 m 15.2 m
Wire Size AWG
18 18
• 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 charg-
er 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.
A ....................amperes
W ....................watts
..................alternating current
n o....................no load speed
....................earthing terminal
....................safety alert symbol
.../min ............revolutions or reciprocation
........................per minute
WALT battery pack. When ordering replacement battery
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READ ALL INSTRUCTIONS
WALT chargers.
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WALT. In some areas, it is illegal to place spent nickel
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WALT and other battery users, has established programs in the
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75 ft. 100 ft. 125 ft. 150 ft. 175 ft.
22.9 m 30.5 m 38.1 m 45.7 m 53.3 m
16 16 14 14
WALT service cen-
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WALT rechargeable
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WALT recharge-
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