Craftsman 509398 manual

FOR Y OUR SAFETY : READ ALL INST RUCTIONS CAREF ULL Y Save This Manual For Future Reference o wner’ s manual P ar t No. SP6039 Printed in U .S .A. 10-INCH RADIAL SA W GU ARD KIT • assembly • operating • repair part s MODEL NO . 509398 509399 509398 FITS THE FOLLO WING RADIAL SA WS: 113. 1971 20, 11 3.1 97 190, 113. 1971 60, 11 3.1 97 240, 1[...]

2 Section Title P age Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Saf ety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ass embly . . . . . . . . . . . . . . . . . . . . . [...]

3 This manual has saf ety inf or mation and instructions to help users el iminate or reduce the risk of accidents a nd injuries, including: 1. Se v er e cuts , and loss of finger s or other body par ts due to contact with the bl ade. 2. Eye i mpact injuries a nd bli ndness, fr om being hit by a thr o wn workpiece, wo rkpiece chips or pieces of b la[...]

4 Kickbac k Hazar d Kick back is the un controlled propell i ng of t he workpiece bac k tow ard the user during rip- ping. The cause of kic kback is the bi ndi ng or pinching of the b lade in the workpiece . Se v- eral conditi ons can cause the blade to bind or pinch. When a w orkpiece kic ks back, it could hit hard enoug h to cause int er nal orga[...]

5 Guard Function and Features The guard i s a v er y important saf et y f eatu re , designed to reduce the risk of injury associ- ated with bla de contact. Insta ll the guar d correctl y . Follo w the specifi c instructions in the ripping and cr osscutting sections to set and use the guard corr ectly f or each type of cut. Guard F eatures Inc lude:[...]

6 6. Set of pa wls to be lo wered to the work- piece surf ace f or ripping. They allo w the workpiece t o pass freely from inf eed t o out- f eed side , b ut help s top the ki ckbac k motion from outf eed to inf eed side b y grab bing into the workpiec e surf ace. Pa w l s m ust be r eset each time a diff erent thic kness workpi ece is cut. 7. A gu[...]

7 Safety In st ruct ions Read and f ollow al l saf ety instructions . P ers onal Saf ety Instructions 1. W ear saf ety gog gles labeled ANSI Z87.1 (or in Canada CSA Z94.3-99) on the pac k- age. It means the goggles mee t i mpact stan- dards s et b y the American Nat ional Standards Insti tute . Regul ar e y eglasses are not saf ety goggles . 2. W e[...]

8 Saw S afety Instructions 1. Use guard, pa wls and riving kni f e accord- ing to i nstructions. K eep them in w orking order . 2. Routinely chec k saw f or br oken or dam- aged par ts. Repair or r eplace damaged par ts bef ore usi ng sa w . Chec k ne w or repaired p ar ts f or alignment, b inding, and correct i nstallati on. 3. Unplug sa w bef ore[...]

9 Blade S afety Inst ructions 1. Use only b lades marked f or at l east 3450 rp m . 2. Use only 10" or smaller diameter b lades . 3. Use b lades f or thei r recommended c ut- ting procedures . 4. K eep b lade sharp and clean. 5. Do not o ve r ti ghten b lade nut because b lade collar coul d warp . 6. Do not turn sa w on and off in r apid seque[...]

10 On-Product S afety Labels There are s ev er al saf et y labels on the sa w . The y aler t the user to hazards e xpl ained in the man ual and remind the user ho w to av oid the hazard. At the outfeed side, to th e right of the guard near the sa w handle is this sa f ety label to aler t you to wr ong wa y feed: On the inf eed side of the guard is [...]

11 Near the saw handle is this saf e ty l abel to aler t you to thr o wn objects and to remind you to we ar saf ety goggles: On the c lear plasti c guar d is this OSHA required l abel: On the bot tom surface of the motor , visib le when the cutting tool is horiz ontal, is this saf ety label alerting you to use a guard when edge molding, and to posi[...]

12 Identify Parts The f ollow ing parts are included: Note: Before begi nning assembl y , c heck that all parts are in cluded. If you are mi ssing any pa rt, do not assem ble guard. Contact your Em erson T ool Co. Service Cente r at 1-800-325-1 184 to get the missi ng part. Someti mes small part s can get lost in pack aging materia l. Do not throw [...]

13 W ARN ING Plugging in sa w during assembl y could result in el ectrical shoc k, or severe cut s fr om contact wit h spinni ng blade. Do not plug in saw at an y time during assembly . Plug in saw onl y when it is to be used. Remo ve Sawb lade and Guard 1. Tighten carriage loc k knob . 2. Loosen guard clamp scre w , remo ve guard. 3. Motor sh aft [...]

14 Attaching T able Supports 1. Attach a t able supp or t to each si de of the sa w using t he four he x head bolt s and flat washe rs. Put the bolts thro ugh the center of the enlarged holes i n the table supports so that the suppor ts ma y slide up or down as needed. Put a loc kw asher and he x nut on each bolt and hand tighte n. NO TE : The goal[...]

15 Installing Fr ont T able 1. Set out: - front t able - tee nut - 1/4 " U-clip - 1/4" diam. x 7/8" long cup point set scre w - four 1/4" diam. x 1" long pan head scre ws - 1/4" dia. x 1-3/4" long pan head screw - fiv e 17/64" I.D . x 5/8" O .D . flat washers - f our 1/4" lockw ashers - f our 1/4&qu[...]

16 Make Front T able Flat 1. Place rear tab le on its edge, across cen- ter of fr ont tabl e . Chec k f or gap betw een sur- fa c e s. If there i s l ess than 1/32" gap, t ighten cup point set sc rew unt il it touches frame (look under neath tab le) , then ti ght en center (1- 3/4" long pan head screw . If there is more tha n 1/32" g[...]

17 Installing T able Boar ds (44" Wide Models) Installing Fr ont T able 1. P os ition the front tab le and inser t the front tw o scre ws. The rear scre w holes in the tab le do not line up o n any holes in the saw base . 2. Using the rear scre w holes as a drill guide, dr ill a 5/ 16" hol e in the saw base for each of the two rear scr e [...]

18 Assembly 7. Stand the front tab le on one edge. Put a mounting scr ew wi th a w a sher throu gh each of the mounting holes . Then put a rubber grommet on the bottom of each mounting scre w . 8. Place the front table on the sa w so that the mounting sc rews l ine up with the U-clips . The front tab le should e xtend about one inch bey ond the tri[...]

19 3. Unloc k the be v el loc k to release the motor . Hold onto the motor as you do thi s . CA UTION: The motor is he avy and can swing do wn quickl y . Y ou can be cut or injur ed if the arbor shaft hits you. Hold the motor when you unl ock the bevel loc k. 4. T urn the motor until the arbor shaft is pointing str aight down t o ward the tab le . [...]

20 16. Mo ve the arbor sh aft o ver t he lo west point. 17. Plac e the handle end of the arbor wrench o ver this point and lo wer the ar m until the arbor shaft is just touching the wrench. The wrench should sl ide back and f or th with slight contact . 18. Mo ve the arbor sh aft o ver an other point . Do not change the ele v ation of the ar m. 19.[...]

21 1. Pull motor/car riage to end of ar m and loc k the rip lock . Rotate motor to out -rip posi- tion. 2. On the rear of the motor is located t he motor suppo r t ca p. Remo ve this cap . A small scre wdriver will assist y ou in remov al of t his cap . (This cap is not on all models) 3. Using a 3/4" soc k et , shor t e xtension and ratch et r[...]

22 7. The f ollo win g items can n ow be remo v ed from the front of the y oke as an assembly: a. Shaft suppor t b . Shaft washer c. W asher .505 x 7/8 x 1/16 d. Bev el lo ck le v er e. Square n ut 1/2 x 13 f . Be v el spring wedge g. Bev el loc k knob h. Screw , pan head plastite no . 8 x 3/8" long 8. Remov e the be vel spring wedge from this[...]

23 13. Usi ng the two #8 x 3/4 pa n head scre ws provi ded, at tach t he ne w handl e in the same wa y as the old one was remov ed. 14. Ins pect motor su ppor t cone on y ok e, and cone on motor f or lubrication on contacti ng surf aces . These surf ac es should be gener - ously lubricated. If necessary lubricate with lithium whit e g rease (not su[...]

24 Installing Guar d Adapter 1. Remov e the t op motor co v er scre w and loc kwasher . K eep t he washer . Discard the old sc rew . 2. Install t he adapter . The two e nds of the adapter fit into the center cooli ng slots of the motor , then the adapter is rotated up into pl ace. 3. Install t he replacement sc rew (#6 x 1/2") with the old loc[...]

25 Installing Blade/Squaring Cr osscut Tr a v e l NO TE: This adj ustment helps ens ure the b lade accurat ely tra v els square to the rip f ence. 1. Inde x ar m at 0° miter and loc k. 2. Install sa wb lade as s hown. Motor shaft has left handed threa ds - turn nut cou nter- cloc kwise to tighten. CA UTION: Do no t overtight en arbor nut. Use arbo[...]

26 Install Fenc e , Rear T ables, and T able Clamps 1. Inser t fence , th en spacer tab le , then rear tab le. 2. Tilt clamp f orw ard and snap into place in opening at rear of tab le suppor t. 3. Repeat steps for other tab le clamp . 4. Tighten thumbscre ws to clamp tabl e sec- tions i n place . (Steps 2, 3 and 4 only apply to models with 40"[...]

27 Guard Installation Steps/Align Ri ving Knife to Blade The goal of this adjust ment is to p osition the riving knif e di rectly in line with the b lade. Riving knif e alignment is an impor tant saf e ty f act or . The riving knif e rides i n t he k erf of the cut workpiece during ripping to keep t he tw o sides of the workpiece from pinching on t[...]

28 On-Off Switch Be vel Loc k Lever Y ellow K ey Miter Lock Handwh eel Control Functi on Operation/ Comment s Miter Lock F rees ra dial ar m to move; locks in an y desi red position; pre-set inde x ed positi ons at 0°, 45°L, 45°R Pull o ut and to ward s right to unloc k, push to loc k. Hold in unloc ked posi tion while mov- ing ar m On-Off Switc[...]

29 * NO TE: Af ter instal ling ne w guard and ne w tab le board s rip f ence scale is no longer correct. Mea- sure distance betwee n fe nce and blade when sa w is in rip position. T able Cl amp Thumbscre w Swivel L ock Rip Scale & Rip Indicato rs Rip Loc k Saw Handle Control Function Oper ationlComments Rip Lock F rees carriage to mov e along r[...]

30 Guard Hold Down Knob Hold Down Pa w l s Riving Knife Riving Knif e Bracket Paw l s/ R i v in g Knife Knob Guar d Clamp Screw Dust Elbow Control Function Oper ation/Comments Guard Clamp Scre w Secures guard t o motor ; frees guard f or remov al T urn countercloc kwise to loosen, clockw ise to ti ghte n Guard Protects aga inst contact wi th upper [...]

31 Paw l s Riving Knif e P awls/Riv ing Knife Knob Guard T ab Control Function Oper ation/Comments Guard T ab Pro vides manual wa y to r ais e clear plastic guar d during r ipping when workpiece f ails to rai se it Push and hold until w orkpiece clears guard, t hen release P awls/ Riving Kni f e Knob F rees pa wls and riving knif e to independentl [...]

32 Crosscutting Defi ned Crosscutti ng is cutting a wo r kpiece to leng th. The workpiece is held firmly against the f ence, and the blade is pull ed thro ugh the workpiece to mak e the cut. Straigh t, bev el, miter , and compound cuts can be made . Crosscut ting Safety The hazards as sociated with crosscuttin g include: e xposed blade teeth, rolli[...]

33 Crosscutting Crosscut Kerf s A ker f or shall ow cut i s needed in the tab le and f ence to ser v e as a path for the b lade and to ensure that the b lade cut s all the w a y through the w orkpiece. A kerf i s needed f or each diff erent cutting path. T o mak e an appro x imately 1/16" deep k erf: 1. Prepare tab le: - put f en ce in fr ont [...]

34 Cr osscutting Making Crosscut s F ollow these s teps to mak e crosscu ts. 1. Prepare tab le: - put f en ce in fr ont position - tight en tabl e clamps 2. Prepare b lade: - lo ck mot or in cr osscut posi tion - loc k radial arm at desired miter angle - lo ck motor at desired b ev el angl e* - unloc k carriage lock and push b lade to rearmost posi[...]

35 Crosscutting Repetitive Cr osscutting Repetitiv e crosscut ting is the repeated and continuo us cutting of many pi eces of lumber to the same length. Ca rriage and leng th stops can help mak e this type of crosscutti ng more eff icient. A carriage stop defines t he dist ance neede d to pull the b lade through to complete each cut. This will pre [...]

36 Ripping Ripping Defined Ripping is changing the width of a workpiece b y cutting along its length. The workpiece i s f ed into the b lade, which rot at es in a fix ed position, par allel to the f ence and a set dis- tance from the f ence. A solid f ence (no ker fs) ser ves as a guide f or the w orkpiece. Place the f ence in the front positi on f[...]

37 Ripping W orkpiece Pos itioning Alwa ys set up so that the wider part of the w o rkpi ece is between the blade and fence. This giv es y ou gr eater clear ance f or push stic ks, and allo ws better st ability f or f eeding the workpiece. Push Stic ks and Push Blocks Use push stic ks and push bl oc ks instead of the hands to push the workpiece thr[...]

38 Outfe ed Zone Hazar d D ANGER Rotational f orce of b lade can pull hands and finger s back into blade. T ouching, h olding, or pulli ng on out- feed side of work piece while b lade is still spinni ng will result in fingers, hand or arm being cut off. T o reduce risk of out feed haz ard: [ Set pa wls and riving knif e; th ey act as par- tial barr[...]

39 T o reduce risk of kic kbac k: [ Set pa wls and riving knif e accor ding to rip- ping set-up pr ocedure. Correctl y set riving knif e is more lik ely t o pre v ent workpie ce from binding or pinchi ng blade; correctly set p awls are more l ikely to grab into wor k- piece to stop or s low kic kbac k if one hap- pens. [ Chec k that riving knif e i[...]

40 Hold Down Function The hold do wn m ust be set correctly during ripping to act as barrier against the inf eed side of the b lade, to help keep the workpiece flat on the tab le, and to def lec t workpiece chips. It m ust be l ower ed to just clear the workpiece . The hold do wn m u st be re-set each time a diff erent thi c kness workpiece is cut.[...]

41 Ripping Ripping Set-up Procedure F ollo w these steps befo re r ipping. These s teps must b e repeated eac h time a diff erent t hic kness w orkpi ece is ripped. A kerf m ust be made f or each differe nt width cut. Also see the speci al not es for be vel set-up t hat fol low t his section. 1. Prepare tab le: - inser t solid (no k erfs) f ence ( [...]

42 7. Remov e w ork piece from tab le . 8. Ready push stic k or push bloc k. 9. Set up tab l e ex tensi on(s) and suppor t their out er ends. Do not use another per- son to support w orkpieces because t his can cause kic kback and it exposes helper to pote ntial hazar ds at ou tfeed side. Special Notes f or Bevel Set-Up CA UTION Bevel ri pping crea[...]

43 2. Inser t yell ow k ey and turn saw on. 3. Stand at inf eed side and out of line of workpiece , in case of kic kbac k. Start and finish cut from i nfeed side. 4. Put w or kpiece on tab le, in front of hold down, an d tight against f ence . T o hol d work- piece in position, put left hand on tabl e, at least 8" in fro n t of hol d down, and[...]

44 Ripping Dado Blades, Molding Heads See Accessories f or inf ormation on saf et y , installati on and use of dado blade s and molding heads . Edging Edging is the use of a dado b lade or molding head in the horizont al position. It is an adva nced technique that re quires a molding head guard and a special fe nce. See Acces- sories f or inf ormat[...]

45 Bef ore cutt ing an y wood on your sa w , study all of the Crosscut t ing and Ripping Instruc- tions f ound on pages 45 through 57. As y ou learn new r adial arm saw w oodworking t ech- niques, you’ ll see that man y types of cuts need diff erent support and feeding de vic es , kno wn as jigs or f ixtures . The y can help you mak e cuts more a[...]

46 Making the Handle: • Mi ter crosscut a piece of 3 /4" thic k ply- wood to the shape and siz e shown. The mitered corners can be an y size that looks lik e the dr awi ng (about 1-1/2" b y 1-1 /2"). Putting it together: • Usi ng good quality wood working glue , glue the 2-1/2" st r ip sa v ed earlier to the base as shown. I[...]

47 Cutting Ai des Clamp the f eathe rboard t o th e front tab le, so that the angled edge of the f eatherboard is against the w orkpiece on the i nfe ed side of the b l ade. Do not cl amp the featherboar d agains t the cut of f part (out-feed si de) of the w orkpi ece . If clamped to the outf eed side, the featherboar d can squeeze the kerf c losed[...]

48 Replacing P a wls Mak e sure th e teeth of the pa wls are alw a ys shar p . If the y become dull the pa wls must be replaced: 1. Use 7/16" wrench to remo ve he x n ut. Remov e old p awls . 2. Install ne w pa wls . Place spacer s e xactly as shown. 3. Re-instal l he x nu t. 4. Check that pa wls w ork freely . Lubricating Blade Guar d Assembl[...]

49 P ARTS LIST CRAFTSMAN 10" RADIAL SA W GU ARD KIT #50 93 98 & #50 9399 Alwa ys order b y Part Number - Not by K ey Number FIGURE 1 Repa ir P ar ts * Standard Hardware I tem - Ma y be purchased locally . ▲ 509398 Only Key No. P ar t No. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 — 808380-5 820520 820534 820533 STD551008 [...]

50 P ARTS LIST CRAFTSMAN 10" RADIAL SA W GU ARD KIT #5093 98 & #509 399 Alwa ys order b y Part Number - Not by K ey Number Figure 2 Repair P arts 1 2 3 4 5 6 7 8 9 10 11 13 12 14 15 16 17 3 3 14 13 18 19 20 21 22 23 24 25 26 27 28 29 8 9 30 32 31 31 33[...]

51 P ARTS LIST CRAFTSMAN 10" RADIAL SA W GU ARD KIT #50 93 98 & #50 9399 Alwa ys order b y Part Number - Not by K ey Number FIGU RE 2 – GU ARD * Stand ard Hardwa re Item - Ma y Be Purchased Loc ally Key No Part N o. Des crip tio n 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 821217 821313 STD55102 5 815865 STD60110 5 802392-47 808447-6 827919 [...]

© 2000 Em erson Ele ctric Co. 10-INCH RADIAL SA W GU ARD KIT For Customer Ser vice Questions or Replacement Parts Call 1-800-325-1184 NO TE: 1. This man ual is intended to be used along with you r original s aw man ual. If y ou no l onger ha ve your saw’ s o wners manual, call customer ser vice at 1 -800-325-1184. Ha v e y our sa w’ s model n [...]