hi dego328, Yes what you have is a bad speed control.They will do all sorts of wonky things when the go bad.Hope that helps.
Tinker

Hi Dan, Sounds like a good one!
I can walk you through this fix.. First you must remove the speed knob part#67 by slipping a flat blade screw drive under the knob and prying up slow.
The knob should slip off its shaft.. next remove the 4 screws part#44
On the housing.
Your housing should lift up and off as you should have enough slack in the power wires to turn the housing over to get access to the locks holding the power switch.
Next remove the nut and washer holding the part #61 to the housing.

Thats it Dan, Happy to Help and Happy Scroll Sawing! Mark.

Yes-Clean contacts or replace switch

Say reg, are your replacement fuses a #3 AG fast acting 1 1/4 long x 1/4'' diameter fuse? That's what the type 2 dewalt scroll saw calls for!
I'm not sure on the type for the type 1 scroll saw.
But you might need check that you're using the right replacement fuses.
If for some reason your saw is drawing more then 3 amps it will blow the overload protection fuse.

Next you could check the brushes in the motor and see if you don't have one causing it to over load the motor. If it's blowing the fuse while running!
If it's blowing the fuse before the power is turned on you might have a power wire that's bare, causing it to short out. Or a loose connection causing it to pull more then 3 amps.

Hi David, Thanks for helping the Boy Scout's out! I enjoy helping them out also!

Let's see if I can help you get your saw going! Are you getting power up to the on/off switch with it plugged in? (when you tried the new fuse)

Start at the power cord with a multimeter. on page A you'll see part # 86 check to see if your getting power through the power cord here. if so move on to part #61
cb & pot. next check to see if your getting power to the fuse box. If it isn't the cb & pot could be bad. If you're getting power up to on/off switch with it plugged in then it could be the v/speed switch or a brush in motor or the motor. I hope this help's you get back to helping scouting! I enjoy making pinewood derby car's with the kid's in Cub Scouting myself lot's of fun! good luck with the fix!

Hi Paul, when you purchased your saw new, there was a tool Dewalt sends to remove the cover for the fuse. Try this fix first. Use a thin blade, flat screwdriver to open it. In the cover you will see two notches. Do not use the notch in very top, use the one that is out front. Find a flat blade screwdriver that will just fit the notch. Push it in, you should hear a snap sound. The fingers on the cover should let go and now all that is left to do is pull back on the screwdriver. Lets hope the cover will open for you! Happy Scroll Sawing!

I had the same problem. You just push in and up and the inside of the fuse assembly will just come out.

After lots of use the aluminum blade chuck seems to loosen up and the threads are not as fitting. The set screw may have backed out and leaving the blade not in full contact with the set screw. Or, the thumb screw gets polished smooth and needs to be filed to leave some gripping surface on the end of the contact surface.

Good luck. The blade chuck needs to be steel, to take the repeated torque to tighten the blade, and have larger screws making contact with the blade for more resistance. My saws can only saw for a few minutes and the blades are loose again.

I am having the same problem. It is sawing and makes like a rattling or grinding sound and then the blade starts to wobble and I have to stop and tighten it up again. I can't find anyone who can answer this either. If it is only a part I need I would get it and fix it myself but I don't know what is wrong.

Hi Gayla, this very thing happened to me also! You need to check the set screws in the blade holders to make sure they are flat. If they are rounded over some what the blade can slip in the chuck as the saw is running. To fix this problem you can try using sand paper or a file to make them flat. If you find yourself with the same problems after you try this fix, you need to replace the set screws and thumb screws. I hope this is the fix! Happy scroll sawing!

Hi Carol,

It sounds to me like your saw has more problems. First you also need to check your set screws in the blade chuck. Replace them if they are not flat. When new there is a small point on the tip. Through use the point wears off. If worn or rounded over the set screws are you problem. Replace them or make them flat using sandpaper or a file. Next, the rattling or grinding sound worries me. The rattling sound could be the rod draw in your saw rattling and the grinding sound could be you have some worn out sleeves. To see the parts I'm talking about, look on page B of the parts diagram just above. Look for part #24. To fix it you'll need open your saw up and turn the rod clockwise one to two turns to stop the ratting rod. Now for the grinding. It could be a number of things but you said your blade wobbles also. Look for parts #38 & #39 on page B. These could be what are making the grinding sounds.

You really need to take your saw in to a repair shop and have it looked at! This (would) be you're best bet! Happy to help! But let's get you back up and running! Happy Scroll Sawing Carol. Mark

Sometimes it can be the set screw and thumb screw. But not in every case.

In my experience, through use, and tightening the thumb screw too tight, you can strip the threads in the blade chuck part # 36. Also over time and use from tightening all the blades in the chuck you can spread the chuck open, causing the set screws not to line up right.

So if you find yourself trying to tighten the blade into the chuck and the blade keeps popping out, that may be the problem. You can try replacing all three of these parts and see if that helps.

Hi Yolanda,
Yes there is! Scroll up to the top of the page. Click on the arrow to the right to open it to page B. Is part #68 what your looking for? Part #286312-00, the Nozzle Air. You'll need the whole part. I don't know if anyone sells just the tip if this is the part you need for your fix. Glad to help! Happy Scroll sawing! Sometimes we just have to cut up.. to cut out and find that fix!

This is the 2nd time that the air hose broke where it mounts to the saw. Instead of purchasing another air hose every time it breaks and taking it to a Dewalt repair shop, is there a better method of attaching the air hose to the saw?

Hi Kent,

I would open the saw up and check the wiring for a loose connection. There is a circuit board inside as well that could be causing the problem. Make sure that the brushes slide easily in the brush holders. If not very lightly sand them with some fine sandpaper.

Good luck with your repair!

-Mark

if the brush is worn down to 3/8'', it must be replaced.
Use only identical DeWalt brushes as new brush assemblies are available. Always replace a used brush in the same orientation in the holder as it was prior to its removal. And keep them clean and sliding freely in their guides. As you must do maintenance to keep your saw running in top shape.

Canned air will help you clean out any carbon dust in the motor or guides.
Happy to help & Happy Scroll sawing

That's a beauty of a birdhouse, but don't it drive you crazy when you have to drill all of those little holes. It does me beautifull work. Keep on making dust.