DEWALT 20V MAX 6-1/2-Inch Circular Saw Kit (DCS391P1) User Manual

1. Introduction

This manual provides essential information for the safe operation, maintenance, and troubleshooting of your DEWALT 20V MAX 6-1/2-Inch Circular Saw Kit, model DCS391P1. Please read this manual thoroughly before using the tool to ensure proper function and safety.

Figure 1: DEWALT 20V MAX 6-1/2-Inch Circular Saw Kit (DCS391P1) including the saw, 5.0Ah battery, charger, and a carrying bag.

2. General Safety Instructions

Always follow basic safety precautions to reduce the risk of fire, electric shock, and personal injury. Keep this manual for future reference.

2.1 Work Area Safety

• Keep the 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.
• Keep children and bystanders away while operating a power tool.

2.2 Electrical Safety

• Power tool plugs must match the outlet. Never modify the plug in any way.
• Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges, and refrigerators.
• Do not expose power tools to rain or wet conditions.

2.3 Personal Safety

• Always wear eye protection. Use a dust mask, non-skid safety shoes, hard hat, or hearing protection when appropriate.
• Do not overreach. Keep proper footing and balance at all times.
• Dress properly. Do not wear loose clothing or jewelry. Keep hair and clothing away from moving parts.

3. Package Contents

Verify that all items listed below are included in your package. If any parts are missing or damaged, contact your retailer or DEWALT service center.

• DEWALT DCS391 6-1/2 in. Circular Saw
• DCB205 20V MAX* XR Premium Li-Ion Battery (5.0 Ah)
• Fast Charger
• 6-1/2 in. Carbide-tipped Blade
• Blade change wrench
• Instruction Manual
• Kit Box (or carrying bag)

Figure 2: The kit includes the DCS391 circular saw, a 6-1/2 inch carbide-tipped blade, and other accessories.

4. Product Components

Familiarize yourself with the various parts of your circular saw before operation.

Figure 3: Key components of the circular saw, highlighting the 0-50° bevel capacity, rubber overmold grip, and 6-1/2 inch blade.

• Blade Guard: Protects the user from the rotating blade.
• Blade: 6-1/2 inch carbide-tipped blade for cutting various materials.
• Motor: Powerful 5150 rpm motor for efficient cutting.
• Handle with Overmold Grip: Provides comfort and control during operation.
• Bevel Adjustment: Allows for angle cuts from 0 to 50 degrees.
• Depth Adjustment: Controls the cutting depth.
• Battery Port: For inserting the 20V MAX battery.
• Trigger Switch: Activates the saw.
• Lock-off Button: Prevents accidental starting.

5. Setup and Assembly

5.1 Battery Installation and Charging

1. Ensure the battery is fully charged before first use. Connect the charger to a power outlet and insert the battery.
2. To install the battery, align the battery pack with the tool's battery port and slide it in until it clicks securely into place.
3. To remove the battery, press the release button and pull the battery pack out.

5.2 Blade Installation

Always disconnect the battery before installing or changing the blade.

1. Place the saw on a flat surface with the blade guard open.
2. Press the spindle lock button to prevent the blade from rotating.
3. Using the provided blade wrench, loosen the blade bolt by turning it counter-clockwise.
4. Remove the outer washer and old blade.
5. Install the new 6-1/2 inch carbide-tipped blade, ensuring the teeth are pointing in the direction of rotation indicated on the saw.
6. Replace the outer washer and blade bolt. Tighten the blade bolt securely by turning it clockwise.
7. Release the spindle lock button.

Figure 4: Proper installation of the 6-1/2 inch carbide-tipped blade.

6. Operating Instructions

6.1 Adjusting Cutting Depth

Adjust the cutting depth so that the blade extends approximately 1/8 inch (3 mm) below the workpiece. This minimizes kickback and ensures cleaner cuts.

1. Loosen the depth adjustment lever.
2. Raise or lower the saw base to achieve the desired depth.
3. Tighten the depth adjustment lever securely.

6.2 Adjusting Bevel Angle

The saw allows for bevel cuts from 0 to 50 degrees.

1. Loosen the bevel adjustment lever.
2. Tilt the saw base to the desired angle, aligning the indicator with the scale.
3. Tighten the bevel adjustment lever securely.

Figure 5: The saw features a 0-50° bevel capacity for angled cuts.

6.3 Making a Cut

1. Ensure the workpiece is securely clamped.
2. Hold the saw firmly with both hands, maintaining a balanced stance.
3. Press the lock-off button, then squeeze the trigger switch to start the saw. Allow the blade to reach full speed before contacting the workpiece.
4. Guide the saw smoothly along the cutting line, applying steady, even pressure. Do not force the saw.
5. Once the cut is complete, release the trigger switch and allow the blade to stop completely before lifting the saw from the workpiece.

Figure 6: The 5,150 RPM motor provides ample power for cutting various materials.

7. Maintenance

Regular maintenance ensures optimal performance and extends the life of your tool. Always disconnect the battery before performing any maintenance.

7.1 Cleaning

• Keep the tool's ventilation openings clear to prevent overheating.
• Use a soft brush or compressed air to remove dust and debris from the motor housing and blade area.
• Do not use water or chemical cleaners.

7.2 Blade Care

• Inspect the blade regularly for sharpness and damage. A dull or damaged blade can cause kickback and poor cut quality.
• Replace worn or damaged blades promptly with appropriate 6-1/2 inch carbide-tipped blades.

8. Troubleshooting

This section addresses common issues you might encounter. For problems not listed here, contact DEWALT customer service.

9. Specifications

10. Warranty and Support

10.1 Warranty Information

This DEWALT product is covered by a 3-year limited manufacturer's warranty, 1 year of free service, and a 90-day money-back guarantee. For full warranty details, please refer to the warranty card included with your product or visit the official DEWALT website.

Figure 7: DEWALT's warranty policy for the tool.

10.2 Customer Support

For technical assistance, service, or replacement parts, please contact DEWALT customer service or visit their official website. You can find contact information on the DEWALT website or in your product documentation.

DEWALT Official Website: www.dewalt.com