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Tools and Blades

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Old 12-19-2009, 05:04 PM   #1
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Default DeWalt 788 Question

My DeWalt 788 is suddenly not wanting to hold the blade tension when I set it. Have looked through the owners manual and it doesn't have a trouble shooting section. Has anyone had experience with this problem? If so what is the fix if there is one short of taking the saw in for repair?
Thanks, Gary
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Old 12-19-2009, 06:00 PM   #2
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Is the tension lever moving back by it self, or is the lever staying put and the blade just losing tension.

If it's the second one, more than likely the blade is slipping in one of the blade holders. It can get a build up on the thumbscrew and set screw. some sand paper usually cleans it up. Or, you can dress the flat part of the thumbscrew on a grinder.

If it's the first problem with the tension lever, it could be the large allen bolt that is under the switch cover and goes through the tension lever. It may have loosened.

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Old 12-19-2009, 06:57 PM   #3
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Default Dewalt 788 Problem

Thanks for your response Ray, it's the second one. It just wants to pop loose from the setting. Is it an easy fix?
Gary
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Old 12-19-2009, 07:11 PM   #4
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Gary,
try this .
Quote:
f it's the second one, more than likely the blade is slipping in one of the blade holders. It can get a build up on the thumbscrew and set screw. some sand paper usually cleans it up. Or, you can dress the flat part of the thumbscrew on a grinder.
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Old 12-19-2009, 09:02 PM   #5
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It is the tension lever moving, not the blade slipping. I should have been more clear in my answer.
Gary
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Old 12-20-2009, 08:30 AM   #6
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It could be that the bolt has loosened then. Check bolt #52 on the diagram. It's right under the switch cover assembly. You also might want to check the four #78 screws.
http://www.ereplacementparts.com/ima...YPE_1_WW_2.gif

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Old 12-20-2009, 10:32 AM   #7
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I have the same problem but the blade is not moving at all in the holder, so it is not slipping, and the lever is not moving either. I contacted Dewalt and they asked me to describe any sound that occurs. I said it is not the knocking sound that I have heard about but more like a rattling or shaking loose sound and then the side of the blade starts to wobble like all the tension is gone before you tighten the handle. I told them this and they just told me the knocking sound is the only diagnostic sound they know of and to open it up and move the tension arm counter clockwise one or two turns. This is the fix I read of for the knocking sound which I do not have, so they weren't any help at all. I am still trying to figure out why this happens. The nearest repair shop is 4 hours away and in the winter not feasible. If I knew what part may need replacing I could order it and fix it myself. Any ideas would be greatly appreciated.
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Old 12-20-2009, 12:39 PM   #8
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Hmmm. If the blade is not slipping and the lever is not moving, I'm not sure what would cause the blade to start out tight and then loosen on it's own.

If you need to turn the lever up to 4 or 5 to get any tension on the blade, it's probably gotten sloppy.
Adjusting the tension rod will take up some slop and allow the blade to be tighter with less moving of the lever. It's a pretty simple adjustment.

1. Unplug the saw!
2. Remove the switch cover housing by removing the four screws marked #44 on the drawing in my previous post.
3. Remove the large allen bolt #52 and washer #87
4. lift and remove the tension lever #26
5. Remove the plate cover #80 by removing the four screws
6. Turn the tension rod #24 two turns clockwise.
7. Reassemble in reverse of above.

If it's REALLY sloppy, you might need another turn on the rod, but I would stick with two to start

Ray
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Old 12-20-2009, 12:59 PM   #9
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Gary, I have a 788 & it sounds like your tension is letting go even without the lever moving, so Ray is probably your solution to the problem. Good luck. -- Perk
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Old 12-20-2009, 05:13 PM   #10
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Thanks to all, I'll give the above solutions a try.
Gary
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