DeWalt DW1251 Operating instructions

POWERSHOP RADIAL ARM SAW
W1251 DW1501DW1503
ADJUSTMENT & OPERATING
INSTRUCTIONS
PART No.: 822503 (2/85)

THE CONTROLS
1. MITRESCALE
18. MITRECLAMP
19. MIRE LATCH
17. YOKE
16. TABLECLAMP —i
15. FENCE
2. ARM END-CAP
3.ARM
4. RIP-LOCATING
SLIDE BAR
5. WORKTABLE
8. ROLLER HEAD/
YOKE ASSEMBLY
14. BEVEL LATCH -
13. BEVEL SCALE -
12. BEVEL CLAMP
6. ELEVATING
HANDLE
7. RIPLOCK
10. YOKECLAMP
9. COLUMN
11. COLUMN
BASE

INTRODUCTION '
Your DeWaltRadial ArmSawisa precisionwoodworking machine and beforeleaving the factory the machine wassetand
adjusted to operateaccurately. Inevitably, however,duringtransportation and handling,some of thesesettings will have been
disturbed andit will be necessary foryouto check and readjust the machinebefore youare able to obtain the precise
woodworking results for whichthisRadial ArmSawwas designed.
This isnota difficult process butwe recommend you to followtheseinstructionscarefully and in fhe sequencegivenbefore you
attempt to startworkingwithyourmachine.
In addition tothe setting-upinstructions, the followingpagesalsoinclude a short guide tothe safeoperation of thisversatile
machine.Again, follow theseinstructionscarefully,until you havelearnt the fundamentals.After that, your own ingenuity and
imaginationwilldetermine how muchversatility youcan extractfromyourDeWaltPowershop.
DeWaltproducts are covered bya manufacturer'sguarantee. If, during the guaranteeperiod of6 monthsfrompurchasedate, a
DeWalt productbecomesdefective dueto faultymaterials or workmanship.Black & Decker guarantee to repair it free-of-
charge,providedthat:
1. The product hasnot beenmisused.
2. Repairs have not beenattempted by personsotherthan ourown Service Staff orthe staff of authorisedrepairers.
3. Proof of purchasedate is produced.
For the address of yournearestDeWaltService & RepairCentre,telephoneBlack & Decker on Slough(0753)74277.
CONTENTS
THE CONTROLS
INTRODUCTION
SAFETY — IMPORTANTDO'S AND DON'TS
5.
6.
7.
8.
Page No.
. ...2
3
4
. ...5
6
1. UNPACKING & ASSEMBLY:
2. ADJUSTINGTABLE TOP PARALLELWITH ARM
3. ASSEMBLY OF WORKTABLEONTOSUPPORT
BRACKETS
4. CHECKS & ADJUSTMENTS TO ENSUREACCURACY
4.1 Checking the CrosscutTravel is 90C
to the Fence 8
4.2 Checking theSaw Blade is Parallel tothe
Arm Tracks 9
4.3 Checking the Blade is Perpendicular to Table 10
4.4 Adjusting Roller HeadBearing toArm Tracks 10
4.5 AdjustingBase to Column 11
THE SAWBLADE GUARD ...12
5.1 Mounting the BladeGuard 12
5.2 Adjusting the BladeGuard 12
5.3 Removing the BladeGuard
5.4 Removing the Sawblade
MAKING A TRIAL CUT
6.1 Wiring uptothe Mains ...
6.2 Making theCut
SCALEADJUSTMENTS
7.1 Rtp Scale
7.2 BevelScale
7.3 MitreScale
CLAMP HANDLE ADJUSTMENTS
12
12
13
13
14
14
14
15
9. HINTS ON GENERALCARE OF YOURPOWERSHOP1 5
Page No.
10.THE VARIOUSOPERATING ADJUSTMENTS OF BASIC
MACHINE
101 Arm Rotation 16
11
10.2 BladeHeight
10.3 YokeAssemblyRotation
10.4 Blade Tilting
MAKING THE BASIC CUTS
16
16
16
16 11.1 CrossCut
11.2 Mitre Cut17
11.3 Bevel Cut17
11.4 Ripping 17
11.5 BevelRipping...' 18
11.6 CompoundMitre 18
11.7 Coving/Hollowing 18
11.8 Dishing 18
11.9 Circle Cutting ' 19
12. OPERATION OFTHE MACHINE WITH OPTIONAL
ATTACHMENTS AND ACCESSORIES
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
12.9
12.10
12.11
Shaping/Moulding 19
Rebating 20
Ploughing/Grooving 21
DiscSanding 21
DrumSanding 22
Sabre Sawing ' 22
Routing
Drilling/Boring
SpecialMitreFences
AutomaticSafetyReturn
Legstands ......
LIST OF ATTACHMENTS & ACCESSORIES
23
24
24
24
24
26

SAFETY - IMPORTANTDO'S AND DON'TS
For your own safety and efficient useof yourDeWaltPowershop.followtheseinstructionscarefully.
DO
Ensure that the machine is properlyconnected to 1.
the mains viaa 13 amp fusedplug(240v) or
permanentlywired in (415v).
Be surethat the earthwire is firmly connected to2.
the earthterminal inthe plug.
Alwaysdisconnectyourmachinefrom the power 3.
supplybeforechanging any attachments or
accessories.
DO NOT
Neverconnect the machine uptoany voltage
other than thatstated onthe motorratingplate.
Neverswitch onthe machinewithout the correct
guardsbeingproperlymounted.
Neverswitch onthe machine unless all clamping
handles are tightened.
4. Ensure all guards are correctlypositioned andall
clamping handles are tightenedbeforestarting
' the machine.
5. Alwayswearclose-fittingclothingwithout
looseends.Removeloose-fittingornaments
and ties, and ensurelonghair is secured or
closely covered.
6. Wearprotective eye shields.
7. Makesure the sides ofthe blade andthe arbor
collars or flanges are clean and that the recessed
sides ofthe collars are against the blade.
8. Makesure the arbor nutis securelytightened
usingboth the alien keyand spannerprovided.
4. Donot allowspectators(especiallychildren)
within the vicinity ofthe machine while
working with it.
5. Donot leave the machinepluggedinto the
mainswhileunattended.
6. Never use bladeslarger in diameterthanthat
supplied as standardequipment(250mm).
7. Never rip without the rivingknife and
anti-kickback fingerscorrectlyadjusted.
Neverfeed in materialfrom the wrongsidewhen
ripping - follow the instructionlabel onthetopof
the arm.
9. Beforeswitching onto make a cut,make
surethat the fence isinthe correct
position. The bladeshould not contact the
material until you pull-the saw carriage
forward.
9. Neverattempt tooilor grease thearm tracks or
motor.
10. Keep saw bladessharp and properlyset.
10. Neverwedgeanythingagainst the motor fanto
hold the motorshaft still.
11. Whenrippingalways usethe rivingknife and
anti-kickback fingers in their correctpositions.
12. Keep the bearingtracks inthearmandthe
bearings onthe rollerheadassemblyclean and
dryand freefromgrease.
13. Periodically check the machine'sadjustments to
ensureaccuratewoodworking and readjust in
the recommendedsequence if necessary.
11. Neverfeed the materialinto the bladefasterthan
it will cutit comfortably.
12. Donot lift the Powershop byits
worktable.
14. Keepyour sawina dry place.

1. UNPACKING & ASSEMBLY (Numbers in brackets refer to Controls Illustrations on page 2).
1. Open thetopofthe carton.
2. Remove allthe loosely-packedtableparts and other
easily accessiblecomponents.
3. Tipthe cartoncarefullyuntil the column-end ofthe
carton is resting onthe floor.
4.You will nowbe able to slide the machine outofthe
cartonsingle-handed and then tilt the machine
forward until itis restingwith its baseframe onthe
floor.
5. Ifyouare going to mount the Powershop ontoan
existing bench, you willfind it easier todo thisnow.
If youare going to mount the Powershop ontoits
optional legstand, we suggst yousetupthe legstand
now and secure the machine toit beforeproceeding
(See para. 12.11).
6. Havingidentified the elevatinghandle(6),secure itto
thetopofthe columnwith the cross-headscrew
supplied.
7. By turning the elevatinghandle,raise thearmofthe
machine so that the cartoncontaining the
motor/yokeassembly canbe removed.
8. Remove thetwo alienscrewsfrom thearm end-cap
(2) and take thecap off.
9. Take the completemotor/yokeassembly outofits
carton and carefullyinsert the threebearings (2on
the left, 1 onthe right) ofthe rollerheadinto the
tracks inside the arm. In doing so takecare that the
rip lock (7)is released and lined up correctly with its
slide strip onthe lowerright-handside ofthe arm.
10. Checkthat the movement ofthe rollerhead inthearm
tracks is smooth by pushing it backwards and
forwards along the arm. Check alsothat therip lock
will release and lock the rollerhead in position as
required.
If either of thesechecksindicatesincorrectmounting,
remove the rollerheadfrom thearm tracks and repeat
procedure 9 again.
11. Replace thearm end-cap (2)and secure it firmly with
thetwo alienscrews.
12. Fixthe cablesupportspring onthe arm:
DW1251 Insert endof springintosmallhole half way
along thetopofthe arm.
DW1 5101 /3 Fixtheendofthe spring tothe mounting
point onthe right-handside ofthearmby
inserting the screwprovidedthrough the
end-loop ofthe spring.
The cable is thenroutedalong thearmand
down the back ofthe column.

7
2. ADJUSTINGTABLE TOP PARALLELWITH ARM
To obtainaccuratewoodworkingresults, itis essentialthat
the table is completelyparallelwith the arm. The following
instructionsexplain howtodo this:-
1. Prepare the baseframe forthe tableboards by
setting the2 angled support brackets (A-Fig. 1) on
eachside ofthe frame so that the securingbolts (B)
and(C)areatthe mid-point inthe slottedholes. At
this stage the boltsshouldonly be finger tight.
NOTE: Some models feature location pins which pre-
set the position of the brackets on the main frame.
On these models the bolts can already be tightened,
but you should still make the following checks. If they
indicate the location pins are wrongly positioned: tap
the pins out with a hammer and adjust via the slotted
holes in the support brackets.
Fig. 1
Usethetipofthe motorspindle toactasa gauge to
checkthat the2 supportbrackets areonthe sameplane,
as follows:
(i)
(iv)
(v)
(vii)
Rotate the elevatinghandle and raise thearm
enough to allow the motor to turn 90° into the vertical
position.
Releasebevellatch and bevellock and turn the
motor body until itis vertical.When it reaches the
verticalpositionpresshome the bevellatch so that
the motor is lockedintoposition.
Release thearm clamp lever andtherip lock and
bring the motor toits fully forwardposition onthe
arm.
Rotate thearmto bring the motor shaft toa position
directlyover the left tablo supportbracket.
Carefully lower the motor, by turning the elevating
handle, until thetipofthe motorarborjusttouches
the supportbracket as shown.(Fig. 2)
Tighten thenut (C), rotate thearmtoits45° position
left and move the yokeassemblybackalong thearm
until the shaft is againover the supportbracket (Fig.
3).Ifthe motorarbordoes not justtouch the support
bracketherealso,gently tapthe bracket upor down
as required and thentighten nut(B) (Fig. 1). Having
tightenedboth (B)and (C). check once morethat the
motor arborjusttouches the uppersurface ofthe
left-handsupportbracketover its entirelength. Ifit
does not, loosen the nuts and repeat the above
procedure.
Now move thearmtothe right ofthe machine and
repeatthis procedure to correctly secure the right-
handsupportbracket.
Carry outa finalcheck,running thetipofthe motor
arbor along thetopof bothbrackets and makesure
that all nuts are completelysecure.
Now adjust the centraltablesupportstrip inthe same
way so that itis perfectlylevelwith thetwo side
support brackets.(Fig. 4).
N.B. Itis important notto change the height ofthe
arm duringthisadjustment procedure.
After completing the aboveadjustment,return the
motor tothe horizontalposition.
Fig. 2
Fig. 4

3. ASSEMBLY OF WORKTABLE ONTO SUPPORT BRACKETS
Note: The worktablecomprises 5 elements(Fig. 5):
a largefixed portion (F) whichattaches to the front of the
base frame, a woodenfence (M) againstwhich the
materialbeingworked is held and threemovablestrips
of tablewhich are used to adjust the position ofthe
fence relative tothesaw blade to ensure the different
types/depth ofcutcanbe carried out withsafety.
(i) Secure the frontboard (F)tothe support brackets
using the slotheadedbolts (G)andthe relative
washers and nutsmakingsurethat the holes inthe
middle ofthe boardlocateover the centralsupport
flange inthe baseframe.
Note: The additionalholes onthe left handside ofthe
table arefor mounting the tablesideextension.
(ii) Mount the sawblade(see Fig.6) makingsure the
lower teethpointtowards the back ofthe machine.
Tighten the blade onthe shaft using the larger ofthe
alienkeysprovided to hold the shaftsteady while
tightening the arbor nut anti-clockwise(left-hand
thread) with the largeopen-endedspanner.
(Note that the brassarbor nuthasan innercircularring
rather thanbeinghexagonalacross its full width - thenut
shouldalways be mountedwiththisinnerringfacing the
motor).
(iii) Youcannow checkthat the frontboard is flat and
parallel tothearm across its entire width. Todo this,
lower the blade so that the bottomtoothjusttouches
the front board onthe front left handside.Then,with
the mitrelatch and clampreleased,swing thearmso
that the bladeskims thetopofthe boardacross its
width. Ifthetipofthe blade, does not just touch the
board alltheway across,thenwith a screwdriver
adjust the frontadjustingscrew inthe middle ofthe
board upor downuntilthat isthe case.Thenmove
the sawbladebackalong thearmand adjust the rear
adjusting screw inthe sameway.
(iv) Mount the bladeguard as follows:-
1. Release the bevellatch (14) and bevelclamp(12)
and tilt the motor and bladeabout 30°tothe left.
2. Loosen the lockingscrew (P) (Fig. 7)and turn the
retaining bracket (N) anti-clockwiseuntil the right
hook ofthe rear blackguard (F)canbe lifted free of
the supportlug.
3. Slide the blackguardroundclockwiseuntil it reaches
the dottedlineposition in the illustration.
4. Now lower the guardover the sawblademakingsure
that the hingedplasticsectiondoes not foul against
the motorshaft and that the lowermetaledge onthe
other side ofthe guardengagessatisfactorilywith the
lugs onthe motorhousing - thiswillensurealsothat
the hole onthe upperguardbracketlocatesover the
retentionbolt ontopofthe motor.
Place the washer onthe bolt and secure the wing nut
to hold the guard firmly.
NOTE:Whenever you remove the guard, resecure the
wing nut and its washer to the retaining bolt on
top of the motor housing so that no parts can
be lost.
ALWAYS REPLACE THE GUARDBEFORE
SWITCHING ON YOURMACHINE AND
REMEMBER THATEVEN A STATIONARY
SAWBLADE IS SHARP SO TAKECARE NOT
TO CATCHYOURSELF ONTHE TEETH.
6. Slide the black guard (F) backroundanti-clockwise
and hook the right-hand endofit onto the support
lug, then securebracket (N) over the same lugby
tightening screw(P).
Fig. 5
-
f
'
i «t
I
Fig. 6
Fig. 7

(v) Position the reartableboards andthe fence(Fig. 8)
according tothe material thickness andthe type of
cuttobe carried out.
Note: Never lift your Powershop by gripping
worktable or you risk twisting it and therefore
having to repeat the support bracket
adjustment procedure.
Mounting the Left-Hand Table Extension
SuppliedwithyourPowershop isa left-hand table
extension to enableleft-handmitres tobe carried out
satisfactorily.
The extension piece hasthe samedepth asthe main fixed
table andit attaches tothe mainmachine as follows:
(i) Two metalsupportstrips are each first secured tothe
lower left-handsurface ofthe mainworktable.
(ii) The extensiontable cannowbe fixed tothe support
strips viathe slottedholesusing the bolts/self-
tappingscrewsprovided.
FENCELOCATIONS
The following illustrations show
where the fence must beto perform
each type ofcut according to
thickness/width of material.
Fig. 8
4. CHECKS AND ADJUSTMENTS TO ENSUREACCURACY
4.1 Checking the
Crosscut Travel is
90°tothe Fence
NOTE: In carrying out these checks and adjustments
you may find it more convenient to remove the
sawblade guard but remember that even a
stationary sawblade is sharp so take care not
to catch yourself on the teeth.
With the mitrelatch (19) engaged,lock the clamphandle
(18) so that the sawblade is positioned fora straight 0°
cross- cut.Release therip lock (7)and push thesaw
carriageback so that the sawblade is just in front ofthe
fence.Then, by turning the elevatinghandle,lower thearm
so that the sawbladealmosttouches the surface ofthe
table in front ofthe woodenfence.
Youarenowina position to checkthat the bladewill cuta
line at90°tothe fence.Proceed as follows:-
(i) Place a rectangularpiece of board in front ofthe
fence alongside the blade andlaya square flat on
topofitas shown in Fig. 9 with one side flat against
the fence andthe otheralongside the blade,
(ii) With the lowerleft-handpart ofthe bladeguard
raised (oryoumay find it easier to remove the guard
completely)pull thesaw carriageforwardawayfrom
the fence and checkthat the tooth onthe blade
protrudingfurthest tothe left (it will be either onthe
leading or trailingedge ofthe blade)staysparallel to
the square asyou pull thesaw bladepast the square.
If itisnot runningsquare, thearmisnotat90°tothe
fence.
Note: At thisstage, donot worry ifthe face ofthe
bladeitself isnot parallelwith the square.
This will be adjustednext. Wearenow
merelycheckingthat the line ofthe blade
across the table isat90°tothe fence.
Fig. 9

Fig. 10
To Adjust the Crosscut Travel
(i) With the mitrelatchengaged inthe0° position.
slacken the mitreclamp.
(ii) Loosen the locknuts on each side ofthe arm. as
shown in Fig. 10.
(ill) Release the mitrelatch and depending on which way
the arm needs to move to give the true 90° crosscut
required,loosen and tighten the adjusting flanges on
either side ofthearm (Fig. 11) ifthe front ofthearm
needs togotothe left, loosen the adusting flange on
the right ofthearmand tighten the flange onthe left.
If the opposite isthe case, andthearm needs to
move tothe right,loosen the adjusting flange onthe
left and tighten the flange onthe right. Adjust the
flanges a little ata time and re-engage the mitre
latch and clamp and check the crosscuttravel ofthe
blade relative tothe fence with a square. Donot
overtighten the adjustingflanges orthe mitre latch
will betoo stiff to operate easily.
(iv) Once satisfied that the crosscuttravel is accurate,
retighten the locknuts on eachside ofthearm(asin
Fig. 10).
(v) Adjust the pointer onthe mitrescale so that it
registers 0°in this position.
Fig. 11
4.2.Checking the
Saw Blade is Parallel
to theArm Tracks.
Thischeck isto ensurethat, inthe straight 90° cross- cut
position, the blade runstrueacross the table and does not
run "dogfashion"(Fig. 12). Ifthe blade is incorrectly
adjusted in thisway. it willproduce a cut widerthan the
setofthe blade(distanceacross the tips ofthe teeth). It
would alsotend to causescorchmarks onthe timber
being cut.
To Check
(i) Place a square against the fence asin Fig. 9 and,
with the sawbladejust in front ofthe fence inthe90°
crosscut position (lock itin thatposition with therip
lock) checkthat the left handface ofthe blade is
parallel tothe square. Ifitisnot parallel, adjustment
is necessary.
To Adjust
The illustration (Fig. 13) shows the components ofthe
yoke assembly. The precisealignment of rollerhead (8)
withyoke (17) is made possible by collar (I) which is fixed
to the yoke bythe lockingnuts(J).
(i) Firstly, graspyoke in bothhands and check itfor
movement left or right, if there is movementtighten
nut (H) whichincreases the frictionbetween therip
locatingslide bar(K)and nylon block (L).
(ii) Then, ifthe blade is still not parallel tothe square.
release the yoke clamp (10) and loosen the locknuts
(J) (Fig. 13/13a) and turn yokeslightly to left or right
until the blade isin factparallel tothe square and
therefore alsoparallel tothearm tracks.Then tighten
all nuts.
(iii) Havingadjusted the bladeparallel tothearm tracks
in this way, release therip lock and pull thesaw
carriage forward. Raise thesaw bladejustabove the
surface ofthe table by turning the elevatinghandle.
(iv) Now release therip locating slide barandthe yoke
clamp and thenrotate the yoke 90°so that the blade
is facing the fence and lock it into that position with
the slide barandthe yokeclamp.Thenpush thesaw
carriage backwardsuntil the blade is restingagainst
the fence.
If the blade is completelyflat,across its faceagainst
the fence, this will confirm that thesaw will perform
accurate parallel rip cutting.
Fig. 12
Fig. 13
Fig. 133

If byany chance the blade does notlie flatagainst
the fencethenreturn ittothe0° cross-cutposition
and repeat the aboveadjustmentprocedure(making
bladeparallel toarm tracks).
4.3 Checking the
Blade is Perpendicular
to Table
Fig. 14
4.4 Adjusting
Roller Head Bearings
toArm Tracks.
(iv)
For accuratewoodworking, itis alsonecessarythat the
sawbladecuts a precise 90° vertical line when intended to
doso.
To Check
With thearminthe cross-cutposition andall
latches/Clamphandlesengaged,place a steelsquarewith
one edge onthe worktableparallel tothe fence(Fig. 14)
andthe otheredgeagainst the left face ofthe sawblade
(makesure the squarepassesbetween the teeth ofthe
blade and restsagainst the innerface). Ifthe blade isnot
thencompletelyflatagainst the square, it follows that itis
also notat rightangles(90°) tothe worktable.
To Adjust
(i) Removebevelpointerdisc (A)by removing thetwo
screws (B)in Fig. 15 and re-engage the bevel latch.
Loosen thetwo outside alien screws (Fig. 16).
Tilt the motor left or right until the blade is flat against
the square.
Firmly retighten the alien screw(s) L.
NOTE:It may be necessary to loosen the centre alien
screw (M) slightly before the motor will tilt. If
you do so, be sure to secure it again firmly
before replacing the bevel pointer disc.
(v) Replace the bevelpointerdisc.
In mostcases the aboveadjustmentswill beall that are
necessary to enableaccurate sawing with your DeWalt
Radial Arm Saw.
However, in time itis possiblethatplaymightdevelop in
the adjustment ofthe roller head bearings tothearm
tracks which will causeinaccuracy.
The rollerhead is suspended by threespecialbearings
(Fig. 17). Twoof these are mounted on straightbearing
shafts (Q)andthe third is mounted onan eccentricshaft
(R).
If there is lateralmovementbetween the bearings andthe
arm tracks,(and you will be able to feel it,if there is)
proceed as follows:
(i) Pull the yokeassemblyforward totheendofthearm
tracks and lock itin positionwith therip lock.
(ii)Remove therip scale pointer onthe right ofthe yoke
assembly by withdrawing thetwo Phillipsscrews.
With therip scalepointerremoved, you haveaccess
with an alien keytothe locking screw as shown.(Fig.
18). Havingslackenedthisscrew,alsoloosen the
13mm lock nut(J) immediatelybeneath it. (Fig.19).
Then release therip lock and with an alien keyvia
the accesshole inthe underside ofthe yoke(Fig. 20)
rotate the eccentricbearing (R) slightlyuntil itis
sufficiently in contactwith thearm track to ensure
that all3 bearingsrotate asthe yokeassembly is
movedbackwards and forwardsalong the arm. Ifyou
find it difficult to feelwhen the adjustment is correct,
you may find it easier ifyou remove theArm end-cap
so that youcanseethe3 bearingsrotating inthe
tracks. Oncesatisfiedthat the adjustment is correct,
retighten the 13mm lock nutand then the horizontal
alienscrew and replace the ripscalepointer.
NOTE: Thetopand bottomedges ofall three
bearings should bein contact with thearm tracks
over their entirelength andthe roller headassembly
shouldmovefreely but withoutside-play.
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
10