DeWalt DC380, DC385 User Manual

DC380
DC385

Figure 1

Figure 2

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a

e

f

i

h

c

d

d

i

f

g

1

Figure 3

Figure 4

j

c

Figure 5

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HEAVY-DUTY CORDLESS RECIPROCATING SAW
DC380, DC385

Congratulations!

You have chosen a DEWALT tool. Years of
experience, thorough product development and
innovation make DEWALT one of the most reliable
partners for professional power tool users.

Technical data

DC380 DC385

Voltage V
Max. power output W 340 390
No-load speed min-1 0-2,900 0-3,000
Stroke length mm 25.4 28.6
Weight (without

battery pack) kg 2.1 2.7

Battery pack DE9096 DE9503

Battery type NiCd NiMH
Voltage V
Capacity Ah 2.4 2.6
Weight kg 1.0 1.0

Charger DE9116 DE9130

Mains voltage VAC 230 230
Battery type NiCd/NiMH NiCd/NiMH
Approx. charging time min 60/70 30/40
Weight kg 0.4 0.52

Fuses

Europe 230 V tools
10 Amperes, mains

U.K. & Ireland 230 V tools
13 Amperes, in plugs

DC

18 18

DC

18 18

Defi nitions: Safety Guidelines

The definitions below describe the level of severity
for each signal word. Please read the manual and
pay attention to these symbols.

DANGER: Indicates an imminently

WARNING: Indicates a potentially

hazardous situation which, if not
avoided, will result in death or
serious injury.

hazardous situation which, if not
avoided, could result in death or
serious injury.

CAUTION: Indicates a potentially

CAUTION: Used without the safety alert

hazardous situation which, if not
avoided, may result in minor or
moderate injury.

symbol indicates a potentially hazardous
situation which, if not avoided, may
result in property damage.

Denotes risk of electric shock.

EC-Declaration of conformity

DC380, DC385

DEWALT declares that these tools and chargers
have been designed in compliance with:
98/37/EC,89/336/EEC, 73/23/EEC, EN 55014-2,
EN 55014-1, EN 60335, EN 60745, EN 61000-3-2
& EN 61000-3-3.

For more information, please contact DEWALT at the
address below, or refer to the back of the manual.

DC380 DC385

Sound pressure (LpA) dB(A 89 87
Acoustic power (LWA) dB(A) 100 98
Weighted RMS acceleration value m/s2 12 19.9

Sound pressure uncertainty (KpA) dB(A) 2.8 3
Acoustic power uncertainty (KWA) dB(A) 2.8 3

Director Engineering and Product Development
Horst Grossmann

DEWALT, Richard-Klinger-Strase 11D-65510,
Idstein, Germany

11/2006

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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 SAFETY

a) Keep work area clean and well lit.

Cluttered or dark areas invite accidents.

b) Do not operate power tools in explosive

atmospheres, such as in the presence of
flammable liquids, gases or dust. Power

tools create sparks which may ignite the dust
or fumes.

c) Keep children and bystanders away

while operating a power tool. Distractions

can cause you to lose control.

2) ELECTRICAL SAFETY

a) Power tool plugs must match the outlet.

Never modify the plug in any way. Do
not use any adapter plugs with earthed
(grounded) power tools. Unmodified plugs

and matching outlets will reduce risk of
electric shock.

b) Avoid body contact with earthed or

grounded surfaces such as pipes,
radiators, ranges and refrigerators. There

is an increased risk of electric shock if your
body is earthed or grounded.

c) Do not expose power tools to rain or wet

conditions. Water entering a power tool will

increase the risk of electric shock.

d) Do not abuse the cord. Never use the

cord for carrying, pulling or unplugging
the power tool. Keep cord away from
heat, oil, sharp edges or moving parts.

Damaged or entangled cords increase the
risk of electric shock.

e) When operating a power tool outdoors,

use an extension cord suitable for
outdoor use. Use of a cord suitable for

outdoor use reduces the risk of electric
shock.

3) PERSONAL SAFETY

a) Stay alert, watch what you are doing

and use common sense when operating
a power tool. Do not use a power tool
while you are tired or under the influence

of drugs, alcohol or medication. A

moment of inattention while operating power
tools may result in serious personal injury.

b) Use safety equipment. Always wear eye

protection. Safety equipment such as

dust mask, non-skid safety shoes, hard hat,
or hearing protection used for appropriate
conditions will reduce personal injuries.

c) Avoid accidental starting. Ensure the

switch is in the off-position before
plugging in. Carrying power tools with

your finger on the switch or plugging in
power tools that have the switch on invites
accidents.

d) Remove any adjusting key or wrench

before turning the power tool on. A

wrench or a key left attached to a rotating
part of the power tool may result in personal
injury.

e) Do not overreach. Keep proper

footing and balance at all times. This

enables better control of the power tool in
unexpected situations.

f) Dress properly. Do not wear loose

clothing or jewellery. Keep your hair,
clothing and gloves away from moving
parts. Loose clothes, jewellery or long hair

can be caught in moving parts.

g) If devices are provided for the

connection of dust extraction and
collection facilities, ensure these are
connected and properly used. Use of

these devices can reduce dust-related
hazards.

4) POWER TOOL USE AND CARE

a) Do not force the power tool. Use the

correct power tool for your application.

The correct power tool will do the job
better and safer at the rate for which it
was designed.

b) Do not use the power tool if the switch

does not turn it on and off. Any power

tool that cannot be controlled with the switch
is dangerous and must be repaired.

c) Disconnect the plug from the power

source before making any adjustments,
changing accessories, or storing power
tools. Such preventive safety measures

reduce the risk of starting the power tool
accidentally.

d) Store idle power tools out of the reach

of children and do not allow persons
unfamiliar with the power tool or these
instructions to operate the power tool.

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Power tools are dangerous in the hands of
untrained users.

e) Maintain power tools. Check for

misalignment or binding of moving
parts, breakage of parts and any other
condition that may affect the power
tools operation. If damaged, have the
power tool repaired before use. Many

accidents are caused by poorly maintained
power tools.

f) Keep cutting tools sharp and clean.

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

g) Use the power tool, accessories and

tool bits etc., in accordance with
these instructions and in the manner
intended for the particular type of
power tool, taking into account the
working conditions and the work to
be performed. Use of the power tool for

operations different from those intended
could result in a hazardous situation.

5) BATTERY TOOL USE AND CARE

a) Ensure the switch is in the off position

before inserting battery pack. Inserting the

battery pack into power tools that have the
switch on invites accidents.

b) Recharge only with the charger specified

by the manufacturer. A charger that is

suitable for one type of battery pack may
create a risk of fire when used with another
battery pack.

c) Use power tools only with specifically

designated battery packs. Use of any

other battery packs may create a risk of
injury and fire.

d) When battery pack is not in use, keep it

away from other metal objects like paper
clips, coins, keys, nails, screws, or other
small metal objects that can make a
connection from one terminal to another.

Shorting the battery terminals together may
cause burns or a fire.

e) Under abusive conditions, liquid may be

ejected from the battery, avoid contact.
If contact accidentally occurs, flush with
water. If liquid contacts eyes, additionally
seek medical help. Liquid ejected from the

battery may cause irritation or burns.

6) SERVICE

a) Have your power tool serviced by

a qualified repair person using only
identical replacement parts. This will

ensure that the safety of the power tool is
maintained.

Additional Safety Instructions for
Battery Packs

WARNING: Fire hazard! Avoid metal

short circuiting the contacts of a
detached battery pack. Do not store
or carry the battery pack without the
battery cap placed over the contacts.

• The battery fluid, a 25-30% solution of
potassium hydroxide, can be harmful. In case
of skin contact, flush immediately with water.
Neutralize with a mild acid such as lemon
juice or vinegar. In case of eye contact, rinse
abundantly with clean water for at least 10
minutes. Consult a physician.

• Never attempt to open a battery pack for
any reason.

Additional Safety Instructions for
Battery Packs and Chargers

• Make sure that the battery pack is dry and
clean before inserting it into the charger.

• Use only chargers labelled “NiMH” or “NiMH +
NiCd” to charge DEWALT NiMH battery packs.

• Never carry the charger by its cord. Never pull
the cord to disconnect from the socket. Keep
the cord away from heat, oil and sharp edges.

• Do not expose the charger to damp or wet
conditions.

• Do not attempt to charge wet battery packs.

• Never attempt to open a battery pack for any
reason.

• Always follow the instructions in the back of this
manual for battery pack disposal.

• When not in use, chargers and battery packs
must be stored in a dry place and locked up
securely, out of reach of children.

LABELS ON CHARGER AND BATTERY PACK

In addition to the pictographs used in this manual,
the labels on the charger and the battery pack show
the following pictographs:

Battery charging

Battery charged

Battery defective

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Hot/cold pack delay

Do not probe with conductive objects.

Do not charge damaged battery packs

Read instruction manual

before use.

Use only with DEWALT battery packs,

others may burst, causing personal injury
and damage.

Do not expose to water.

Have defective cords replaced

immediately.

Charge only between 4 °C and 40 °C.

Discard the battery pack with due care for

the environment.

Do not incinerate the battery pack NiMH/

NiCd+.

Charges NiMH and NiCd

battery packs.

See technical data for charging time.

Additional Safety Instructions for
Reciprocating Saws

• Hold tool by insulated gripping surfaces
when performing an operation where the
cutting tool may contact hidden wiring or
its own cord. Contact with a "live" wire will also

make exposed metal parts of the tool "live" and
shock the operator.

• NEVER switch on the tool when the saw blade
is jammed in the workpiece or in contact with
the material.

• Keep hands away from moving parts. Never
place your hands near the cutting area.

• Use extra caution when cutting overhead

and pay particular attention to overhead

wires which may be hidden from view.

Anticipate the path of falling branches and
debris ahead of time.

• Do not operate this tool for long periods of
time. Vibration caused by the operating action
of this tool may cause permanent injury to
fingers, hands, and arms. Use gloves to provide
extra cushion, take frequent rest periods, and
limit daily time of use.

SWITCHING ON AND OFF

• After switching off, never attempt to stop the
saw blade with your fingers.

• Never put the saw down on a table or work
bench unless switched off. The saw blade will
keep running briefly after the tool has been
switched off.

WHEN SAWING

• When using saw blades specially designed for
cutting wood remove all nails and metal objects
from the workpiece before starting work.

• Wherever possible, use clamps and vices to
fasten the workpiece securely.

• Do not attempt to saw extremely small
workpieces.

• Do not bend too far forward. Make sure
that you always stand firmly, particularly on
scaffolding and ladders.

• Always hold the saw with both hands.

• For cutting curves and pockets, use an adapted
saw blade.

CHECKING AND CHANGING THE SAW BLADE

• Only use saw blades conforming to the
specifications contained in these operating
instructions.

• Only sharp saw blades in perfect working
condition should be used; cracked or bent saw
blades should be discarded and replaced at
once.

• Ensure that the saw blade is securely fixed.

Do not use the tool on a ladder.

Package Contents

The DC380 package contains:

1 Cordless reciprocating saw
1 Saw blade
2 Battery packs, NiCd (DC380KA)
2 Battery packs, NiMH (DC380KB)

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1 Charger (DC380KA/DC380KB)
1 Kitbox (DC380KA/DC380KB)
1 Instruction manual
1 Exploded drawing

The DC385 package contains:

2 Battery packs, NiCd (DC385KA)
2 Battery packs, NiMH (DC385KB)
1 Charger (DC385KA/DC385KB)
1 Kitbox (DC385KA/DC385KB
1 Instruction manual
1 Exploded drawing

NOTE: Battery packs and chargers are not included
with N-models.

• Check for damage to the tool, parts or
accessories which may have occurred during
transport.

• Take the time to thoroughly read and
understand this manual prior to operation.

Description (fi g. 1)

WARNING: Never modify the power

tool or any part of it. Damage or
personal injury could result.

INTENDED USE

Your DC380, DC385 cordless reciprocating saws
have been designed for professional sawing of
wood, metal and tubes. The compact design
permits cutting extremely close to the edge of
difficult areas. DO NOT use under humid conditions
or in presence of flammable liquids or gases.

The DC380, DC385 cordless reciprocating saws are
professional power tools. DO NOT let children come
into contact with the tool. Supervision is required for
those under 16 years of age.

a. Variable speed switch
b. Lock-off button
c. Blade clamp lever
d. Saw shoe
e. Battery pack
f. Battery release buttons
g. Charger
h. Charging indicator (red)

Charger

The DE9116/DE9130 chargers accept DEWALT
NiCd and NiMH battery packs ranging from

7.2 to 18 V.

Electrical Safety

The electric motor has been designed for one
voltage only. Always check that the battery pack
voltage corresponds to the voltage on the rating
plate. Also make sure that the voltage of your
charger corresponds to that of your mains.

Your DEWALT charger is double insulated

in accordance with EN 60335.

Mains Plug Replacement
(U.K. & Ireland only)

DANGER:

• Should your mains plug need replacing and you
are competent to do this, proceed as instructed
below. If you are in doubt, contact an authorized
DEWALT repair agent or a qualified electrician.

• Disconnect the plug from the supply.

• Cut off the plug and dispose of it safely; a plug
with bared copper conductors is dangerous if
engaged in a live socket outlet.

• Only fit 13 Amperes BS1363A approved plugs
fitted with the correctly rated fuse (1).

• The cable wire colours, or a letter, will be
marked at the connection points of most good
quality plugs. Attach the wires to their respective
points in the plug (see below). Brown is for Live
(L) (2) and Blue is for Neutral (N) (4).

• Before replacing the top cover of the mains plug
ensure that the cable restraint (3) is holding the
outer sheath of the cable firmly and that the two
leads are correctly fixed at the terminals crews.

1

4

3

WARNING: NEVER use a light socket.
NEVER connect the live (L) or

neutral (N) wires to the earth
pin marked E or

2

.

Using an Extension Cable

An extension cord should not be used unless
absolutely necessary. Use an approved extension
cable suitable for the power input of your charger
(see technical data). The minimum conductor size is
1 mm2; the maximum length is 30 m.

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Assembly and Adjustment

WARNING: Use only DEWALT battery

WARNING: Prior to assembly and

adjustment, always remove the battery
pack. Always switch off the tool before
inserting or removing the battery pack.

packs and chargers.

Battery Pack (fi g.1)

DC380, DC385 BATTERY TYPE

The DC380 and DC385 operate on 18 volt battery
packs.

Charging the Battery Pack (fi g. 2)

When charging the battery pack (d) for the first time,
or after prolonged storage, it will only accept an
80% charge. After several charge and discharge
cycles, the battery pack will attain full capacity.
Always check the mains prior to charging the battery
pack. If the mains is functioning but the battery pack
does not charge, take your charger to an authorised
DEWALT repair agent. Whilst charging, the charger
and the battery pack may become warm to touch.
This is a normal condition and does not indicate a
problem.

WARNING: Do not charge the battery

To charge the battery pack (e), insert it into the
charger (o) as shown and plug in the charger. Be
sure that the battery pack is fully seated in the
charger. The red charging indicator (h) will blink.
After approx. 1 hour/30 minutes (depending on
charger), it will stop blinking and remain on. The
battery pack is now fully charged. The battery pack
can be removed at any time or left in the connected
charger for a longer period of time (with a maximum
of 14 days).

pack at ambient temperatures < 4 °C
or > 40 °C. Recommended charging
temperature: approx. 24 °C.

Inserting and Removing the
Battery Pack from the Tool

1. Insert the battery pack (e) into the grip until it
clicks in place.

2. To remove the battery pack, press the two
battery release buttons (f simultaneously and
pull the pack out of the grip.

Battery Cap (fi g. 2)

A protective battery cap (i) is supplied to cover the
contacts of a detached battery pack. Without the

protective cap in place, loose metal objects could
short circuit the contacts, causing a fire hazard and
damaging the battery pack.

1. Take off the protective battery cap (i) before
placing the battery pack (e) in the charger
or tool.

2. Place the protective cap over the contacts
immediately after removing the battery pack
from the charger or tool.

WARNING: Make sure the protective

battery cap is in place before storing or
carrying a detached battery pack.

Automatic Refresh

The automatic refresh mode will equalize or balance
the individual cells in the battery pack at its peak
capacity. Battery packs should be refreshed
overnight after every 10th charge/discharge cycle
or whenever the pack no longer delivers the same
amount of work.

To refresh your battery pack, place it in the charger
as usual. The red light will blink continuously
indicating that the charge cycle has started.

When the 1-hour/30-minute charge cycle (depending
on charger) has completed, the light will stay on
continuously and will no longer blink. The battery
pack is fully charged and can be used at this time.

If the battery pack is left in the charger after the initial
1-hour/30-minute charge (depending on charger),
the charger will automatically initiate the refresh
mode. This mode will continue up to
8 hours, but the battery pack can be removed at
any time during the refresh mode.

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
has reached an appropriate temperature. The
charger then automatically switches to the pack
charging mode. This feature ensures maximum
battery life. The red indicator blinks long, then short
while in the Hot/Cold Pack Delay mode.

ASSEMBLY
Replacing the Saw Blade (fi g. 3, 4)

1. Move the blade clamp lever (c) up to release the
blade clamping mechanism.

2. Insert the saw blade into the holder (j) until it
engages. The blade can be installed with the

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teeth pointing down, up, left or right, as shown
in figure 4.

3. Move the blade clamp lever (c) down to lock the
blade clamping mechanism.

4. To remove the saw blade, proceed in reverse
order.

SAW BLADES
material recommended saw blade

ferrous metal fine-toothed
non ferrous metal coarse-toothed
wood coarse-toothed
plastic fine-toothed
masonry carbide-tipped

A wide variety of dedicated saw blades is available
as an option.

CAUTION: To reduce the risk of

damage to the workpiece, always select
your saw blade with great care.

Setting the Adjustable Saw Shoe
(fi g. 5)

The saw shoe can be adjusted to limit the depth of
cut and prolong the life of your saw blade.

1. Push and hold the shoe release button (k).

2. Slide the saw shoe (d) into one of the three
settings.

3. Release the shoe release button.

Instructions for Use

WARNING:

• Always observe the safety instructions and
applicable regulations.

• Ensure the material to be sawn is secured in
place.

• Apply only a gentle pressure to the tool and
do not exert side pressure on the saw blade.
If possible, work with the saw shoe pressed
against the workpiece. This prevents damage
to the blade and stops the tool from jerking and
vibrating.

• Avoid overloading.

• Let the blade run freely for a few seconds
before starting the cut.

WARNING: ALWAYS use NIOSH/

OSHA/MSHA-approved respiratory
protection. Prolonged contact with dust
may be hazardous to your health.

Prior to operation, make sure your battery pack is
(fully) charged.

OPERATION

WARNING: Turn unit off and disconnect

battery pack before installing and
removing accessories, before adjusting
or when making repairs. Lock the trigger
switch when the tool is not in use and
when storing the tool.

WARNING: Always wear proper

personal hearing protection that
conforms to ANSI S12.6 (S3.19)
during use. Under some conditions

and duration of use, noise from this
product may contribute to hearing loss.

Switching On and Off (fi g. 1)

For safety reasons the variable speed switch (a) is
equipped with a lock-off button (b).

1. Press the lock-off button (b) to unlock the tool.

2. To run the tool, press the variable speed switch
(a). The pressure exerted on the variable speed
switch determines the tool speed.

3. To stop the tool, release the switch.

CAUTION: Do not switch the tool ON

or OFF when the saw blade touches the
workpiece or other materials.

Cutting Wood

• Clamp the workpiece securely and remove all
nails and metal objects.

• Holding the tool with both hands, work with the
saw shoe pressed against the workpiece.

Plunge Cutting in Wood

1. Rest the saw shoe on the workpiece in such
a position that the blade forms an appropriate
angle for the plunge cut.

2. Switch the tool on and slowly feed in the blade.
Make sure that the saw shoe remains in contact
with the workpiece at all times.

Pocket Cuts

1. Measure and mark the required pocket cut.

2. Using a narrow saw blade rest the bottom of
the saw shoe on the workpiece and make sure
that the blade is positioned on the cutting line.

28

If necessary, e.g. in confined spaces, use the

outer edge of the saw shoe as your guideline.

3. Switch on the tool and feed the blade into the
material at full speed, holding the tool firmly
against the workpiece.

Dust Extraction

When the tool is used indoor for extended periods
of time, use a suitable dust extractor designed in
compliance with the applicable Directives regarding
dust emission.

Cutting Metal

• When cutting thin metal always stabilize the
workpiece with wood on both sides.
This guarantees clean cuts and prevents
damaging of the material.

• For long, straight cuts draw a line on the
workpiece.

• Apply a thin film of lubricant along the cutting
line, switch on the tool and follow the cutting
line.

Cutting Plastics

Always work at reduced speed. Carry out a test cut
to check whether the material is sensitive to heat.

ENGLISH

Cleaning

• Unplug the charger before cleaning the housing
with a soft cloth.

• Remove the battery pack before cleaning your
power tool.

• Keep the ventilation slots clear and regularly
clean the housing with a soft cloth.

Optional 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.

Consult your dealer for further information on the
appropriate accessories.

Protecting the Environment

Separate collection. This product must

not be disposed of with normal
household waste.

Cutting Masonry

WARNING: When sawing asbestos

cement hazardous dust may be
produced. Follow the statutory
guidelines and observe the
recommendations issued by the
asbestos cement manufacturers.

MAINTENANCE

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.

Lubrication

This tool requires no lubrication.

Should you find one day that your DEWALT product
needs replacement, or if it is of no further use to you,
do not dispose of it with household waste. Make this
product available for separate collection.

Separate collection of used products

and packaging allows materials to be
recycled and used again. Re-use of
recycled materials helps prevent
environmental pollution and reduces
the demand for raw materials.

Local regulations may provide for separate collection
of electrical products from the household, at
municipal waste sites or by the retailer when you
purchase a new product.

EWALT provides a facility for the collection and

D
recycling of D
reached the end of their working life. To take
advantage of this service please return your product
to any authorised repair agent who will collect them
on our behalf.

EWALT products once they have

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