DEWALT DCS391 Cordless Circular Saw Instruction Manual

DEWALT DCS391 Cordless Circular Saw Instruction

Components

1. Trigger switch lock-off button
2. Trigger switch
3.  Battery pack
4.  Depth adjustment knob
5.  Shoe
6.  Lower blade guard retracting lever 7 Lower blade guard
7. Blade clamping screw
8.  Kerf indicator
9. Bevel adjustment knob
10. Blade lock button (not shown) 12 Auxiliary handle
11.  Battery release button
12. Blade wrench

WARNING: Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
WARNING: To reduce the risk of injury, read the instruction manual.

Intended Use

This heavy-duty circular saw is designed for professional wood cutting applications. Do not cut metal, plastic, concrete, masonry or fiber cement materials.
DO NOT use under wet conditions or in presence of flammable liquids or gases.
DO NOT let children come into contact with the tool. Supervision is required when inexperienced operators use this tool.

Definitions: Safety Alert Symbols and Words
This instruction manual uses the following safety alert symbols and words to alert you to hazardous situations and your risk of personal injury or property damage.

• DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
• WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

(Used without word) Indicates a safety related message. NOTICE: Indicates a practice not related to personal injury which, if not avoided, may result in property damage.

GENERAL POWER TOOL SAFETY WARNINGS

WARNING: Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.

SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
The term “power tool” in the warnings refers to your mains‑operated (corded) power tool or battery‑operated (cordless) power tool.

1. Work Area Safety
   

   • Keep work area clean and well lit. Cluttered or dark areas invite accidents.
   • Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
   • Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

 Electrical Safety

1. 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.
2. 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.
3. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
4. 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.
5. 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.
6. If operating a power tool in a damp location is unavoidable, use a ground fault circuit interrupter (GFCI) protected supply. Use of a GFCI reduces the risk of electric shock.

Personal Safety

1. Stay alert, watch what you are doing and use common sense when operating a power tool. Donor use a power tool while you are tired or under the  influence of drugs, alcohol or medication . Moment of inattention while operating power tools may result in serious personal injury.
2. Use personal protective equipment. Always wear eye protection. Protective equipment such as a dust mask, non‑skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.
3. Prevent unintentional starting. Ensure the switch is in the off‑position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.
4. 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.
5. Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
6. Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
7. If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust‑related hazards
8. Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.

 Power Tool Use and Care

1. 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.

2. 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.

3. Disconnect the plug from the power source and/ or remove the battery pack, if detachable, from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.

4. 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.

5. Maintain power tools and accessories. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.

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

7. Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.

8. Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

 Battery Tool Use and Care

1. 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.
2. Use power tools only with specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire.
3. 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.
4. 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.
5. Do not use a battery pack or tool that is damaged or modified. Damaged or modified batteries may exhibit unpredictable behavior resulting in fire, explosion or risk of injury.
6. Do not expose a battery pack or tool to fire or excessive temperature. Exposure to fire or temperature above 265 °F (130 °C) may cause explosion.
7. Follow all charging instructions and do not charge the battery pack or tool outside the temperature range specified in the instructions. Charging improperly or at temperatures outside the specified range may damage the battery and increase the risk of fire.

 Service

1. 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.
2. Never service damaged battery packs. Service of battery packs should only be performed by the manufacturer or authorized service providers.

Safety Instructions for All Saws

Cutting Procedures

1.   DANGER: Keep hands away from cutting area and the blade. Keep your second hand on auxiliary handle, or motor housing. If both hands are holding the saw, they cannot be cut by the blade.

2. Do not reach underneath the workpiece. The guard cannot protect you from the blade below the workpiece.

3. Adjust the cutting depth to the thickness of the workpiece. Less than a full tooth of the blade teeth should be visible below the workpiece.

4. Never hold the workpiece in your hands or across your leg while cutting. Secure the workpiece to a stable platform. It is important to support the work properly to minimize body exposure, blade binding, or loss of control.

5. Hold the power tool by insulated gripping surfaces, when performing an operation where the cutting tool may contact hidden wiring.
   Contact with a “live” wire will also make exposed metal parts of the power tool “live” and could give the operator an electric shock.

6. When ripping, always use a rip fence or straight edge guide. This improves the accuracy of cut and reduces the chance of blade binding.

7. Always use blades with correct size and shape (diamond versus round) of arbor holes. Blades that do not match the mounting hardware of the saw will run off‑center, causing loss of control.

8. Never use damaged or incorrect blade washers or bolt. The blade washers and bolt were specially designed for your saw, for optimum performance and safety of operation.

9. Further Safety Instructions for All Saws

Causes and Operator Prevention of Kickback:

• Kickback is a sudden reaction to a pinched, bound or misaligned saw blade, causing an uncontrolled saw to lift up and out of the workpiece toward the operator;
• When the blade is pinched or bound tightly by the kerf closing down, the blade stalls and the motor reaction drives the unit rapidly back toward the operator;
• If the blade becomes twisted or misaligned in the cut, the teeth at the back edge of the blade can dig into the top surface of the wood causing the blade to climb out of the kerf and jump back toward the

Kickback is the result of saw misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below:

1. Maintain a firm grip with both hands on the saw and position your arms to resist kickback forces. Position your body to either side of the blade, but not in line with the blade. Kickback could cause the saw to jump backwards, but kickback forces can be controlled by the operator, if proper precautions are taken.
2. 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.
3. When restarting a saw in the workpiece, center the saw blade in the kerf and check that saw teeth are not engaged into the material. If a saw blade binds, it may walk up or kickback from the workpiece as the saw is restarted.
4. Support large panels to minimize the risk of blade pinching and kickback. Large panels tend to sag under their own weight. Supports must be placed under the panel on both sides, near the line of cut and near the edge of the panel.
5. Do not use dull or damaged blades. Unsharpened or improperly set blades produce narrow kerf causing excessive friction, blade binding and kickback.
6. Blade depth and bevel adjusting locking levers must be tight and secure before making the cut. If blade adjustment shifts while cutting, it may cause binding and kick back.
7. Use extra caution when making a “plunge cut” into existing walls or other blind areas. The protruding blade may cut objects that can cause kickback.

Lower Guard Function Safety Instructions

1. Check the lower guard for proper closing before each use. Do not operate the saw if lower guard does not move freely and close instantly. Never clamp or tie the lower guard into the open position. If saw is accidentally dropped, lower guard may be bent. Raise the lower guard with the retracting handle and make sure it moves freely and does not touch the blade or any other part, in all angles and depths of cut.

2. Check the operation of the lower guard spring. If the guard and the spring are not operating properly, they must be serviced before use. Lower guard may operate sluggishly due to damaged parts, gummy deposits, or a build‑up of debris.

3. The lower guard may be retracted manually only for special cuts such as “plunge cuts” and “compound cuts.” Raise the lower guard by the retracting handle and as soon as blade enters the material, the lower guard must be
   released. For all other sawing, the lower guard should operate automatically.

4. Always observe that the lower guard is covering the blade before placing saw down on bench or floor. An unprotected, coasting blade will cause the saw to walk backwards, cutting whatever is in its path. Be aware of the time it takes for the blade to stop after switch is released.

Additional Specific Safety Instructions for Circular Saws

WARNING: Do not use abrasive wheels or blades.
WARNING: Do not use water feed attachments.

• Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body leaves it unstable and may lead to loss of
• Keep your body positioned to either side of the blade, but not in line with the saw KICKBACK could cause the saw to jump backwards (see Causes and Operator Prevention of Kickback and KICKBACK ).
• Air vents often cover moving parts and should be Loose clothes, jewelry or long hair can be caught in moving parts.
• Avoid cutting Inspect for and remove all nails from lumber before cutting.

Additional Safety Information

WARNING: Never modify the power tool or any part of it. Damage or personal injury could result.
WARNING:ALWAYS use safety glasses. Everyday eyeglasses are NOT safety glasses. Also use face or dust mask if cutting operation is dusty. ALWAYS WEAR CERTIFIED SAFETY EQUIPMENT:

• ANSI 1 eye protection (CAN/CSA Z94.3),
• ANSI 6 (S3.19) hearing protection,
• NIOSH/OSHA/MSHA respiratory

WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of California 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
  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.

• 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. Direct particles away from face and body.

• Use the appropriate dust extractor vacuum to remove the vast majority of static and airborne dust. Failure to remove static and airborne dust could contaminate the working environment or pose an increased health risk to the operator and those in close proximity.

• Use clamps or other practical ways to secure and support the workpiece to a stable Holding the work by hand or against your body is unstable and may lead to loss of control and injury.

• Air vents often cover moving parts and should be Loose clothes, jewelry or long hair can be caught in moving parts.

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 are as follows:

• V…………… volts
• Hz………….. hertz
• min…………. minutes
• DC or direct current …………………. Class I Construction (grounded)
• …/min…….. per minute
• BPM……….. beats per minute
• IPM………… impacts per minute
• RPM……….. revolutions per minute
• sfpm……….. surface feet per minute
• SPM……….. strokes per minute
• A…………… amperes
• W…………… watts
• AC or alternating current or AC/DC. alternating or direct current …………………. Class II Construction (double insulated)
• no………….. no load speed
• n……………. rated speed

BATTERIES AND CHARGERS

The battery pack is not fully charged out of the carton. Before using the battery pack and charger, read the safety instructions below and then follow charging procedures outlined. When ordering replacement battery packs, be sure to include the catalog number and voltage.

READ ALL INSTRUCTIONS

Important Safety Instructions for All Battery Packs

WARNING: Read all safety warnings, instructions, and cautionary markings for the battery pack, charger and product. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

• Do not charge or use the battery pack in explosive atmospheres, such as in the presence of flammable liquids, gases or Inserting or removing the battery pack from the charger may ignite the dust or fumes.
• NEVER force the battery pack into the charger. DO NOT modify the battery pack in any way to fit into a non‑compatible charger as battery pack may rupture causing serious personal injury. Consult the cha rt at the end of this manual for compatibility of batteries and chargers.
• Charge the battery packs only in DeWALT chargers.
• DO NOT splash or immerse in water or other
• DO NOT allow water or any liquid to enter battery
• Do not store or use the tool and battery pack in locations where the temperature may reach or exceed 104 °F (40 °C) (such as outside sheds or metal buildings in summer). For best life store battery packs in a cool, dry location.

NOTE: Do not store the battery packs in a tool with the trigger switch locked on. Never tape the trigger switch in the ON position.

• 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. Toxic fumes and materials are created when lithium‑ion battery packs are burned.
• Do not expose a battery pack or appliance to fire or excessive temperature. Exposure to fire or temperature above 265 °F (130 °C) may cause
• Follow all charging instructions and do not charge the battery pack or appliance outside of the temperature range specified in the Charging improperly or at temperatures outside of the specified range may damage the battery and increase the risk of fire.
• If battery contents come into contact with the skin, immediately wash area with mild soap and water. If battery liquid gets into the eye, rinse water over the open eye for 15 minutes or until irritation ceases. If medical attention is needed, the battery electrolyte is composed of a mixture of liquid organic carbonates and lithium salts.
• Contents of opened battery cells may cause respiratory irritation. Provide fresh air. If symptoms persist, seek medical attention.
•   Battery liquid may be flammable if exposed to spark or flame.
• Never attempt to open the battery pack for any reason. If the battery pack case is cracked or damaged, do not insert into the charger. Do not crush, drop or damage the battery pack. Do not use a battery pack or charger that has received a sharp blow, been dropped, run over or damaged in any way (e.g., pierced with a nail, hit with a hammer, stepped on). Damaged battery packs should be returned to the service center for recycling.

Storage Recommendations
The best storage place is one that is cool and dry, away from direct sunlight and excess heat or cold. Store the fully charged battery pack out of the charger.

Battery Pack Cleaning Instructions
Dirt and grease may be removed from the exterior of the battery pack using a cloth or soft non-metallic brush. Do not use water or any cleaning solutions. Fuel Gauge Battery Packs (Fig. B) Some battery packs include a fuel gauge. When the fuel gauge button is pressed and held, the LED lights will indicate the approximate level of charge remaining. This does not indicate tool functionality and is subject to variation based on product components, temperature, and end-user application.

Transportation
WARNING: Fire hazard. Do not store, carry, or transport the battery pack so that metal objects can contact exposed battery terminals. For example, do not place the battery pack in aprons, pockets, tool boxes, product kit boxes, drawers, etc., with loose nails, screws, keys, coins, hand tools, etc. When transporting individual battery packs, make sure that the battery terminals are protected and well insulated from materials that could contact them and cause a short circuit.
NOTE: Li‑ion battery packs should not be put in checked baggage on airplanes and must be properly protected from short circuits if they are in carry‑on baggage.

Shipping the DeWALT FLEXVOIT Battery Pack

The DeWALT FLEXVOLT  battery pack has a battery cap that should be used when shipping the battery pack.

Attach the cap to the battery pack to ready it for shipping. This converts the battery pack to three separate 20V batteries. The three batteries have the Watt hour rating labeled “Shipping” on the battery pack. If shipping without the cap or in a tool, the pack is one battery at the Watt hour rating labeled “Use”.
Example battery pack label:
USE: 120 Wh SHIPPING: 3 x 40 Wh
In this example, the battery pack is three batteries with 40 Watt hours each when using the cap. Otherwise, the battery pack is one battery with 120 Watt hours.
The RBRC ® Seal Please take your spent battery packs to an authorized DEWALT service center or to your local retailer for recycling. In some areas, it is illegal to place spent battery packs in the trash. You may also contact your local recycling center for information on where to drop off the spent battery pack. Do not place in curbside recycling. For more information visit www.call2recycle.org. or call the toll free number in the RBRC® Seal. RBRC® is a registered trademark of Call 2 Recycle, Inc.

Important Safety Instructions for All Battery Chargers

WARNING: Read all safety warnings, instructions, and cautionary markings for the battery pack, charger and product. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

• DO NOT attempt to charge the battery pack with any chargers other than a DEWALT charger. DEWALT chargers and battery packs are specifically designed to work together.
• These chargers are not intended for any uses other than charging DEWALT rechargeable battery packs. Charging other types of battery packs may cause them to overheat and burst, resulting in personal injury, property damage, fire, electric shock or electrocution.
• Do not expose the charger to rain or snow.
• Do not allow water or any liquid to enter charger.
• Pull by the plug rather than the cord when disconnecting the charger. This will reduce the risk of damage to the electric plug and cord.
• Make sure that the 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.
•  When operating a charger outdoors, always provide a dry location and use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
• An extension cord must have adequate wire size (AWG or American Wire Gauge) for safety. The smaller the gauge number of the wire, the heavier the cord and thus the greater its capacity. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. The following table shows the correct size to use depending on total length of all extension cords plugged together, and nameplate ampere rating. If in doubt, use the next heavier gauge.

Than

0| 6| 18| 16| 16| 14
6| 10| 18| 16| 14| 12
10| 12| 16| 16| 14| 12
12| 16| 14| 12| Not Recommended

• Do not place any object on top of the 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 The charger is ventilated through slots in the top and the bottom of the housing.
• Do not operate the charger with a damaged cord or Have them replaced immediately.
• Do not operate the charger if it has received a sharp blow, been dropped or otherwise damaged in any Take it to an authorized service center.
• Do not disassemble the 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
• The charger is designed to operate on standard 120V household electrical power. Do not attempt to use it on any other voltage. This does not apply to the vehicular
• Foreign materials of a conductive nature, such as, but not limited to, grinding dust, metal chips, steel wool, aluminum foil or any buildup of metallic particles should be kept away from the charger cavities and ventilation
• Always unplug the charger from the power supply when there is no battery pack in the cavity.

Charging a Battery (Fig. C)

1. Plug the charger into an appropriate

2. Insert and fully seat battery The red charging light will continuously blink while charging.

3. Charging is complete when the red charging light remains continuously Battery pack can be left in charger or removed. Some chargers require the battery pack release button to be pressed for removal.
   WARNING: Only charge batteries in air temperature over 40 ° F (4.5 ° C) and below 105 ° F (+40.5 ° C).

4. Charger will not charge a faulty battery pack, which may be indicated by the light staying Take charger and battery pack to an authorized service center if light stays OFF.

NOTE: Refer to label near charging light on charger for blink patterns. Older chargers may have additional information and/or may not have a yellow indicator light

Hot/Cold Pack Delay

When the charger detects a battery pack that is too hot or too cold, it automatically starts a Hot/Cold Pack Delay, suspending charging until the battery pack has reached an appropriate temperature. The charger then automatically switches to the pack charging mode. This feature ensures maximum battery pack life. A cold battery pack may charge at a slower rate than a warm battery pack. The hot/cold pack delay will be indicated by the red light continuing to blink but with the yellow light continuously ON. Once the battery pack has reached an appropriate temperature, the yellow light will turn OFF and the charger will resume the charging procedure.

DCB118 and DCB1112 Chargers
The DCB118 and DCB1112 chargers are equipped with an internal fan designed to cool the battery pack. The fan will turn on automatically when the battery pack needs to be cooled.

Electronic Protection System
Li-Ion tools are designed with an Electronic Protection System that will protect the battery pack against overloading, overheating or deep discharge. The tool will automatically turn off and the battery pack will need to be recharged.

Important Charging Notes

1. The charger and battery pack may become warm to the touch while 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.
2. If the battery pack does not charge properly:
3. Check operation of receptacle by plugging in a lamp or other appliance;
4. Check to see if receptacle is connected to a light switch which turns power off when you turn out the lights;
5. If charging problems persist, take the tool, battery pack and charger to your local service
6. You may charge a partially used pack whenever you desire with no adverse effect on the battery

Charger Cleaning Instructions
WARNING: Shock hazard. 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.

Wall Mounting

Some DeWALT chargers are designed to be wall mountable or to sit upright on a table or work surface. If wall mounting, locate the charger within reach of an electrical outlet, and away from a corner or other obstructions which may impede air flow. Use the back of the charger as a template for the location of the mounting screws on the wall. Mount the charger securely using drywall screws (purchased separately) at least 1” (25.4 mm) long, with a screw head diameter of 0.28–0.35” (7–9 mm), screwed into wood to an optimal depth leaving approximately 7/32” (5.5 mm) of the screw exposed. Align the slots on the back of the charger with the exposed screws and fully engage them in the slots.

SAVE THESE INSTRUCTIONS FOR FUTURE USE

OPERATION

WARNING: To reduce the risk of serious personal injury, turn unit off and remove the battery pack before making any adjustments or removing/ installing attachments or accessories . An accidental start‑up can cause injury.

Installing and Removing the Battery Pack (Fig. D)

NOTE: For best results, make sure your battery pack is fully charged. To install the battery pack 3 into the tool handle, align the battery pack with the rails inside the tool’s handle and slide it into the handle until the battery pack is firmly seated in the tool and ensure that it does not disengage. To remove the battery pack from the tool, press the release button 13 and firmly pull the battery pack out of the tool handle. Insert it into the charger as described in the charger section of this manual.

Proper Hand Position (Fig. L, Q)

WARNING : To reduce the risk of serious personal injury, ALWAYS use proper hand position as shown.
WARNING: To reduce the risk of serious personal injury, ALWAYS hold securely in anticipation of a sudden reaction. Proper hand position requires one hand on the main handle 20 and one hand on the auxiliary handle 12.

Trigger Switch (Fig. E)

WARNING: This tool has no provision to lock the trigger switch in the ON position and should never be locked ON by any other means. Release the trigger switch lock-off button 1 by pressing the button as shown. Pull the trigger switch 2 to turn the motor on. Releasing the trigger switch turns the motor off.

Changing Blades

To Install the Blade (Fig. A, F, G)

WARNING: Remove battery before service, adjustment, installing or removing accessories .

1. Place inner clamp washer 15 on saw spindle 17 with the large flat surface facing out toward the Retract the lower blade guard 7 and place blade 18 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 lower blade guard). Do not assume that the printing on the blade will always be facing you when properly installed. When retracting the lower blade guard to install the blade, check the condition and operation of the lower blade guard to assure that it is working properly. Make sure it moves freely and does not touch the blade or any other part, in all angles and depths of cut.
2. Place outer clamp washer 16 on saw spindle with the large flat surface against the blade with beveled side facing
3. Thread blade clamping screw 8 into saw spindle by hand (screw has left-hand threads and must be turned counterclockwise to tighten).
4. Depress the blade lock button 11 while turning the saw spindle with the blade wrench 14 until the blade lock engages and the blade stops
5. Tighten the blade clamping screw firmly with the blade

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. A, F, G)

WARNING: Remove battery before service, adjustment, installing or removing accessories.

1. To loosen the blade clamping screw 8 , depress the blade lock button 11 and turn the saw spindle with the blade wrench 14 until the blade lock engages and the blade stops 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 8 and outer clamp washer 16 Remove old blade.
3. Clean any sawdust that may have accumulated in the guard or clamp washer area and check the condition and operation of the lower blade guard as previously Do not lubricate this area.
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 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

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 blade 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 blade guard for proper closing before each use as outlined in Further safety instructions for All saws. If the lower blade guard is missing or not working properly, have the saw serviced before using. To assure product safety and reliability, repair, maintenance and adjustment should be performed by an authorized service center or other qualified service organization, always using identical replacement parts.

Checking the Lower Guard (Fig. A)

1. Turn tool off and disconnect from power
2. Rotate the lower blade guard retracting lever 6 from the fully closed position to the fully open
3. Release the lever and observe the guard 7 return to the fully closed

The tool should be serviced by a qualified service center if it:

• fails to return to the fully closed position,
• moves intermittently or slowly, or
• contacts the blade or any part of the tool in all angles and depth of cut.

Blades

CAUTION: Burn hazard. Do not touch the the blade immediately after use. Contact with the blade may result in personal injury.
WARNING: To minimize the risk of eye injury, always use eye protection. Carbide is a hard but brittle material. Foreign objects in the workpiece 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.
WARNING: Do not cut ferrous and or non‑ferrous metals (steel), masonry, glass, masonry‑type planking, cement board or tile with this saw. Do not use abrasive wheels or blades. 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 below to determine the correct size replacement blade for your model saw.

Blade                      Diameter               Teeth            Application

DW9155| 6–1/2″ (165 mm)| 18| General purpose cutting
DW9154| 6–1/2″ (165 mm)| 24| Smooth woodcutting
DW9153| 6–1/2″ (165 mm)| 90| Non-carbide, plywood/ vinyl siding cutting

If you need assistance regarding blades, please call 1–800–4-DeWALT (1–800–433–9258).

Kickback

Kickback is a sudden reaction to a pinched, bound or misaligned saw blade, causing an uncontrolled saw to lift up and out of the workpiece toward the operator. When the blade is pinched or bound tightly by the kerf closing down, the blade stalls and the motor reaction drives the unit rapidly back toward the operator. If the blade becomes twisted or misaligned in the cut, the teeth at the back edge of the blade  can dig into the top surface of the wood causing the blade to climb out of the kerf and jump back toward the operator. Kickback is more likely to occur when any of the following conditions exists.

I MPROPER WORK PIECE SUPPORT

1. Sagging or improper lifting of the cut off piece can cause pinching of the blade and lead to
2. Cutting through material supported at the outer ends only can cause As the material weakens it sags, closing down the kerf and pinching the blade.
3. Cutting off a cantilevered or overhanging piece of material from the bottom up in a vertical direction can cause The falling cut off piece can pinch the blade.
4. Cutting off long narrow strips (as in ripping) can cause The cut off strip can sag or twist closing the kerf and pinching the blade.
5. Snagging the lower guard on a surface below the material being cut momentarily reduces operator The saw can lift partially out of the cut increasing the chance of blade twist.

IMPROPER DEPTH OF CUT SETTING ON SAW

1. To make the most efficient cut, the blade should protrude only far enough to expose one-half of a This allows the shoe to support the blade and minimizes twisting and pinching in the material. See the section titled Cutting Depth Adjustment.

BLADES TWISTING (MISALINGMENT IN CUT)

1. Pushing harder to cut through a knot, a nail or a hard grain area can cause the blade to

2. Trying to turn the saw in the cut (trying to get back on the marked line) can cause blade

3. Overreaching or operating the saw with poor body control (out of balance), can result in twisting the blade.

4. 1. Changing hand grip or body position while cutting can result in blade

5. Backing up the saw to clear blade can lead to

MATERIALS THAT REQUIRE EXTRA ATTENTION

1. Wet lumber
2. Green lumber (material freshly cut or not kiln dried)
3. Pressure treated lumber (material treated with preservatives or anti-rot chemicals)

USE OF DULL OR DIRTY BLADES

1. Dull blades cause increased loading of the saw. To compensate, an operator will usually push harder which further loads the unit and promotes twisting of the blade in the Worn blades may also have insufficient body clearance which increases the chance of binding and increased loading.

LIFTING THE SAW WHEN MAKING A BEVEL CUT

1. Bevel cuts require special operator attention to proper cutting techniques – especially guidance of the saw. Both blade angle to the shoe and greater blade surface in the material increase the chance for binding and misalignment (twist) to occur.

RESTARTING A CUT WITH THE LADE TEETH JAMMED AGAINST THE MATERIAL

1. The saw should be brought up to full operating speed before starting a cut or restarting a cut after the unit has been stopped with the blade in the Failure to do so can cause stalling and kickback. Any other conditions which could result in pinching, binding, twisting, or misalignment of the blade could cause kickback. Refer to the sections Further Safety Instructions for All Saws and Blades for procedures and techniques that will minimize the occurrence of kickback.

Cutting Depth Adjustment (Fig. H, I)

1. Hold the saw firmly and loosen (clockwise) the depth adjustment knob 4 and move shoe to obtain the desired depth of 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- half 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 I. 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.

Bevel Angle Adjustment (Fig. I)

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 consisting of a calibrated quadrant and a bevel adjustment knob 10.

To Set the Saw for a Bevel Cut

1. Loosen (counterclockwise) the bevel adjustment knob 10 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 (Fig. J)

If Additional Adjustment is Needed:

1. Adjust the saw to 0 °
2. Retract the lower blade Place the saw on blade side.
3. Loosen bevel adjustment knob 10. Place a square against the blade and shoe to adjust the 90 °
4. Turn the calibration screw 19 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

Kerf Indicator (Fig. K)

The front of the saw shoe has a kerf indicator 9 for vertical and bevel cutting. This indicator enables you to guide the saw along cutting lines penciled on the material being cut. The kerf indicator lines up with the left (inner) 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.

Workpiece Support (Fig. L–O, Q)

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 L, Q 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 L 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. N). DON’T support board or panel away from the cut (Fig. O). 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.

Cutting (Fig. L, M)

Place the wider portion of the saw shoe on that part of the workpiece which is solidly supported, not on the section that will fall off when the cut is made. As an example, Figure L illustrates the RIGHT way to cut off the end of a board. Always clamp work. Don’t try to hold short pieces by hand! (Figure M) 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 trigger 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. 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 SWITCH 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 switch and allow the blade to stop before lifting the saw from the work. As you lift the saw, the spring- tensioned lower blade 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 lower blade guard  manually (as is necessary for starting pocket cuts), always use the retracting lever.
WARNING: When cutting thin strips, be careful to ensure that small cutoff pieces don’t hang up on the inside of the lower blade guard.

Ripping (Fig. P)

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 DeWALT rip fence is recommended.

Pocket Cutting (Fig. Q)

WARNING: Never tie the lower blade guard in a raised position. Never move the saw backwards when pocket cutting. This may cause the saw 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

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

3. Using the lower blade guard retracting lever, retract the lower blade guard to an upward Lower the rear of the shoe until the blade teeth almost touch the cutting line.

4. Release the lower blade guard (its contact with the work will keep it in position to open freely as you start the cut). Remove your hand from the lower blade guard retracting lever and firmly grip the auxiliary handle 12 , as shown in Figure Q. 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

6. Start the motor and gradually lower the saw until its shoe rests flat on the material to be Advance saw along the cutting line until cut is completed.

7. Release the trigger switch and allow the blade to stop completely before withdrawing the blade from the

8. When starting each new cut, repeat the above

MAINTENANCE

WARNING: To reduce the risk of serious personal injury, turn unit off and remove the battery pack before making any adjustments or removing/ installing attachments or accessories. An accidental start‑up can cause injury.
Your DeWALT power tool has been designed to operate over a long period of time with a minimum of maintenance. Continuous satisfactory operation depends upon proper tool care and regular cleaning.

Cleaning

WARNING: Blow dirt and dust out of all air vents with clean, dry air at least once a week. To minimize the risk of eye injury, always wear ANSI Z87.1 approved eye protection when performing this procedure.
WARNING: Never use solvents or other harsh chemicals for cleaning the non‑metallic parts of the tool. These chemicals may weaken the plastic materials used in these parts. Use a cloth dampened only with water and mild soap. Never let any liquid get inside the tool; never immerse any part of the tool into a liquid.

Accessories

WARNING: Since accessories, other than those offered by DeWALT, have not been tested with this product, use of such accessories with this tool could be hazardous. To reduce the risk of injury, only DeWALT recommended accessories should be used with this product. Recommended accessories for use with your tool are available at extra cost from your local dealer or authorized service center. If you need assistance in locating any accessory, please contact DeWALT
call 1-800-4-DeWALT ( 1‑800‑433‑9258 )
or visit our website: www.dewa lt.com.

Repairs

The charger and battery pack are not serviceable. There are no serviceable parts inside the charger or battery pack.

WARNING: To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including brush inspection and replacement, when applicable) should be performed by a DeWALT factory service center or a DeWALT authorized service center. Always use identical replacement parts.

Register Online

Thank you for your purchase. Register your product now for:

• Warranty service: Registering your product will help you obtain more efficient warranty service in case there is a problem with your
• Confirmation OF Ownership: In case of an insurance loss, such as fire, flood or theft, your registration of ownership will serve as your proof of
• FOR YOUR safety: Registering your product will allow us to contact you in the unlikely event a safety notification is required under the Federal Consumer Safety
• Register online at dewalt.com

Three Year Limited Warranty

For warranty terms, go to https://www.dewalt.com/Legal/Warranty/3-Year- Limited-Warranty.
To request a written copy of the warranty terms, contact: Customer Service at DeWALT Industrial Tool Co., 701 East Joppa Road, Towson,
MD 21286 or call 1-800-4-DeWALT (1-800-433-9258).

References

• DEWALT® Power Tools Official Site | Guaranteed Tough®
• DeWalt Tool & Product Warranty Information | DeWalt
• Call2Recycle | Leading the Charge For Battery Recycling
• DEWALT® Power Tools Official Site | Guaranteed Tough®
• Manual-Hub.com – Free PDF manuals!

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>