Craftsman 509398 Owner'S Manual Download Page 1

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SAFETY:

READ ALL
INSTRUCTIONS
CAREFULLY

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owner’s

manual

Part No. SP6039

Printed in U.S.A.

10-INCH RADIAL SAW

GUARD KIT

• assembly
• operating
• repair parts

MODEL NO.

509398
509399

509398 FITS THE
FOLLOWING RADIAL
SAWS:

113.197120, 113.197190,
113.197160, 113.197240,
113.197110, 113.197111,
113.197150, 113.197151,
113.197210, 113.197211,
113.197250, 113.197251,
113.197180, 113.197181

509399 FITS THE
FOLLOWING RADIAL
SAWS:

113.197410, 113.197411,
113.197510, 113.197511,
113.197610, 113.197611,
113.197710,

Summary of Contents for 509398

Page 1: ... assembly operating repair parts MODEL NO 509398 509399 509398 FITS THE FOLLOWING RADIAL SAWS 113 197120 113 197190 113 197160 113 197240 113 197110 113 197111 113 197150 113 197151 113 197210 113 197211 113 197250 113 197251 113 197180 113 197181 509399 FITS THE FOLLOWING RADIAL SAWS 113 197410 113 197411 113 197510 113 197511 113 197610 113 197611 113 197710 ...

Page 2: ...ou no longer have your saw s owners manual call customer service at 1 800 325 1184 Have your saw s model num ber when you call 2 If you require this manual in Spanish or French call 1 800 511 2628 Si usted requiere que éste manual usuario en español o francés llame 1 800 511 2628 Pedir for mulario SP6039S 3 Si vous nécesstent ce mode d emploi en espagnol ou français téléphonez au 1 800 511 2628 De...

Page 3: ...ty informa tion is not followed someone will be seri ously injured or killed WARNING means if the safety informa tion is not followed someone could be seri ously injured or killed CAUTION means if the safety informa tion is not followed someone may be injured Read and follow all safety information and instructions Major Hazards Three major hazards are associated with using the radial arm saw for r...

Page 4: ...death Read and follow the information and instructions under ripping safety Wrong Way Feed Hazard Wrong way feed is ripping by feeding the workpiece into the outfeed side of the blade The rotational force of the blade can grab and pull the workpiece Before you can let go or pull back the force could pull your hand along with the work piece into the blade Fingers or hand could be cut off The propel...

Page 5: ...th the outfeed side of the blade during ripping and acts as a barrier to prevent wrong way feed 3 A squeeze trigger in the saw handle to fully raise the clear plastic guard at the start of a crosscut Note This is necessary because the guard will not automatically raise to clear the fence 4 A hold down to be lowered to just clear the top of the workpiece for ripping It acts as a barrier to the infe...

Page 6: ...ny protection during cross cutting if blade is pulled over your hand or your hand enters blade path from front or rear of blade Fingers or hand can be cut or cut off CAUTION Clear plastic portion of guard can get caught or jam in fence or table kerfs Read and follow the warning on the guard WARNING TO AVOID INJURY SHUT OFF POWER BEFORE CLEARING A JAMMED LOWER GUARD WARNING Clear plastic guard will...

Page 7: ...p from inhaling fine particles 4 Wear ear protectors plugs or muffs if you use saw daily 5 Keep good footing and balance do not over reach Work Area Safety Instructions 1 Keep children pets and visitors out of work area they could be hit by a thrown workpiece workpiece chips or pieces of blade 2 Turn saw off remove yellow key and unplug before leaving work area Do not leave until blade has stopped...

Page 8: ...lear table of all objects except workpiece to be cut and nec essary fixtures clamps or feather boards 7 If blade jams turn saw off immediately remove yellow key then free blade Do not try to free blade with saw on 8 Turn saw off if it vibrates too much or makes an odd sound Correct any problem before restarting saw 9 Do not layout assemble or setup work with saw on or while blade is spinning 10 Ke...

Page 9: ...ter Safety 3 Rip only workpieces longer than the diameter of the blade Do not rip workpieces that are shorter than the diameter of the blade being used 4 Workpieces that extend beyond the saw table can shift twist rise up from the table or fall as they are cut or afterwards Support workpiece with table extensions the same height as the saw table 5 To prevent tipping support outer ends of extension...

Page 10: ...afety label to alert you to wrong way feed On the infeed side of the guard is this safety label to remind you to lower the hold down to just clear the top of the workpiece for ripping On the side of the motor is this safety label to alert you to outfeed zone hazard Note where they are located on the saw Read and follow the safety information and instructions in these labels Refer to the manual for...

Page 11: ...ar safety goggles On the clear plastic guard is this OSHA required label On the bottom surface of the motor visible when the cutting tool is horizontal is this safety label alerting you to use a guard when edge molding and to position the cutting tool behind the fence see Accessories Section Safety ...

Page 12: ...40 1 C Spacer Table 40 1 D Front Table 40 1 E Table Support 2 F Handle Assembly 1 G Bag of Loose Parts 1 Containing H Adapter Motor Key 1 I Screw Pan Hd Ty T 6 32 x 1 2 1 J Screw Pan Hd Plastite 8 x 3 4 2 K Tee Nut 3 L Lever Bevel Lock 1 M Bag of Loose Parts 1 Containing N Guard Accessory 1 O Screw Plastite 8 x 1 2 1 P Washer 3 16 x 1 x 1 16 1 Q Instruction Form 1 List of loose parts with model 50...

Page 13: ... will be reused 2 Remove the 1 4 20 x 1 cup point screw from the T Nut located in the front table Retain this screw for future use 3 Remove all remaining nuts bolts and washers and lift off front table Discard the front table NOTE On models with 44 wide front tables Remove four screws from under side of table that secure table clamp channels to table Locate and save the five 5 rubber leveling grom...

Page 14: ... 3 Slide the arbor wrench handle between end of motor shaft and table support to act as a feeler gauge Carefully lower the motor with elevation crank until the end of shaft is just touching the arbor wrench The wrench should slide back and forth with only slight resistance Tighten screw A NOTE Do not change this elevation setting until both left and right hand table support channels have ben adjus...

Page 15: ...ble on the saw so that the mounting holes in the table line up with holes in the table supports and center chan nel of saw 5 Drop a flat washer into each counter bored hole 6 Start 1 3 4 long pan head screw through center hole and into U clip but do not fully tighten 7 Start cup point set screw through leveling hole and into tee nut but do not fully tighten 8 Put 1 long pan head screw in each of f...

Page 16: ... If there is more than 1 32 gap close gap by raising or lowering center of front table to raise center tighten cup point set screw against frame to lower center tighten center 1 3 4 long pan head screw 2 When gap is closed make sure cup point set screw touches frame look underneath table and center 1 3 4 long pan head screw is tightened NOTE Rip fence scale is no longer correct Measure distance be...

Page 17: ...stall them on the holes you just drilled 5 A 5 16 hole must be drilled in the left and right table rails Measure 3 from the front hole and drill a second hold This new hole will be used to mount the front table board 6 Identify top and bottom of table top has counterbored holes Place table bottom side up on solid surfaces Hammer three tee nuts into leveling holes These holes are not counterbored f...

Page 18: ... the level ing holes using a 1 8 inch hex L wrench Tighten the screws until they are flush with the table 11 From the underside of the table attach the table rails to the table board using the two holes nearest the end of each rail Leveling Front Table NOTE The goal of this adjustment is to make the front work table flat and parallel to the radial arm In order to do this you will choose four point...

Page 19: ... swing the arm to the right until the arbor shaft is over the right line at the front of the table 9 Mark the point on the line under the cen ter of the arbor shaft 10 Move the arm and motor until the arbor shaft is over the right line at the rear of the front table 11 Mark the point on the line under the cen ter of the arbor shaft 12 Repeat steps 7 11 on the left side 13 Label the points A B C an...

Page 20: ...wrench just fits between this point and the arbor shaft The wrench should slide back and forth with slight contact Use a 1 8 inch hex L wrench to tighten the leveling screws 20 Repeat steps 18 19 for the last two points Making Front Table Flat 1 Lay the edge of the rear table across the front edge of the front table There should be no gaps between the two 2 If you see a gap larger than 1 32 inch t...

Page 21: ...g a 2 Phillips screwdriver remove two pan head cross screws from motor side of handle assembly Discard handle and 2 screws 5 Using a 2 Phillips screwdriver remove two pan head cross recess plastite no 8 x 1 inch long screws from motor side of yoke assembly that hold the yoke cover in place NOTE Some models are clipped in place Use a flat blade screwdriver to push the clips through from the motor s...

Page 22: ...wedge from the bevel lock lever 9 Replace the bevel lock lever with new one supplied with kit Reinsert bevel wedge in new bevel lock lever Reinsert square nut between bevel lock lever and bevel lock wedge Reinsert the shaft support and rotate clockwise until end of shaft is flush with the rear of the bevel lock wedge NOTE Bevel lock lever must be replaced to prevent interference with guard assembl...

Page 23: ...install the 505 x 7 8 x 1 16 washer and 1 2 13 locknut Take care not to drop washer in opening of motor Tighten nut until the bevel lock lever will lock the motor in any position when in the lock position With the bevel lock lever in the unlocked position move the motor to any of the five index posi tions If motor does not index securely the adjust ment is too loose Caution On electronic models be...

Page 24: ...Install the adapter The two ends of the adapter fit into the center cooling slots of the motor then the adapter is rotated up into place 3 Install the replacement screw 6 x 1 2 with the old lockwasher into the top motor cover hole This locks the adapter in place Adapter Motor Cover Panel Top Motor Cover Screw Assembly ...

Page 25: ...method 5 When the carriage is moved slowly back and forth on the arm the marked tooth should just touch the square at all points If marked tooth moves into or away from square follow the adjustments as described in your saws original owners manual If you no longer have your saws owners manual call Customer Service at 1 800 325 1184 Have your saws model number ready when you call Shaft Wrench Sawbl...

Page 26: ... Always use the guard 1 Lock motor at 0 bevel blade vertical 2 Use one hand to lift clear plastic guard use other hand to grasp rear of guard below dust elbow Position guard so riving knife faces front of saw 3 Tilt front of guard down about 45 place over blade rotate guard to level position NOTE Make sure notch in guard fits onto tab on motor adapter This will prevent movement of guard about moto...

Page 27: ... position blade towards column motor towards front of arm 2 Lower arm until blade just clears table 3 Unlock rip lock while holding up lower plastic guard move yoke back until blade touches fence Lock rip lock 4 Loosen pawls riving knife knob Lower riv ing knife to the table and tighten knob The riving knife should rest flat against fence 5 If adjustment is needed a loosen riving knife bracket scr...

Page 28: ...off switch Remove after turning saw off Bevel Lock Lever Frees motor to rotate locks in any desired position pre set indexed positions 0 45 45 90 90 Move towards right to unlock towards left to lock Support motor before unlocking because it can swing down quickly Hold in unlocked position while mov ing motor Handwheel Raises lowers radial arm Turn clockwise to raise counterclock wise to lower To f...

Page 29: ...in in rip or out rip position Move blade carriage along arm to align line on indicator with desired number on scale Swivel Lock Frees blade carriage to rotate between rip and crosscut positions locks in position Pull to unlock push to lock Hold in unlocked position while mov ing blade carriage Table Clamp Thumbscrew Leg Set Model Frees table sections to allow fence changing Turn clockwise to tight...

Page 30: ...oveable raise over fence at start of crosscut See Saw Handle most workpieces will auto matically raise clear guard during rip ping See Guard Tab Hold Down Knob Frees hold down to move up and down locks hold down in place Turn counterclockwise to loosen clockwise to tighten Hold Down During ripping acts as partial bar rier to infeed side of blade keeps infeed side of workpiece from flut tering acts...

Page 31: ...ockwise to tighten Pawls During ripping slow or stop kick back by digging into workpiece when lowered during crosscutting provide partial barrier to leading edge of blade For ripping set pawl level on work piece surface For safety reasons set pawls before ripping See Ripping Set Up for details and illustrations Riving Knife Reduces kickback by keeping kerf open when lowered during cross cutting pr...

Page 32: ...e off table edge beyond 30 left miter position Use right miter position whenever possible Do not cut freehand You will not be able to control workpiece If blade jams turn off saw remove yellow key then free blade Rolling Carriage WARNING When saw is turned on blade can sud denly come forward To reduce risk of this happening Keep one hand on saw handle when turn ing saw on Adjust leveling feet to m...

Page 33: ...e lock and push blade to rearmost position behind fence lower blade to just clear table lower pawls or riving knife to clear fence by 1 4 raise clear plastic guard before changing bevel angle and when lowering beveled blade otherwise it may jam into table 3 Grasp saw handle then turn saw on Keep one hand on saw handle through step 6 4 Slowly lower blade until it touches table then lower one more f...

Page 34: ...lowering beveled blade otherwise it may jam into table 3 Position workpiece against fence and lower pawls or riving knife to clear fence or workpiece whichever is higher by 1 4 4 Grasp saw handle then turn saw on Keep one hand on saw handle through step 7 5 Hold workpiece down and against fence Keep hand at least 8 away from blade 6 Squeeze handle trigger to fully raise clear plastic guard so it w...

Page 35: ...2 lumber on the fence to define the cut length Keep hand holding down workpiece at least 8 from blade Carriage Stop Length Stop Crosscutting Hints 1 To extend life of table top make auxiliary table cover out of 1 4 plywood or fiberboard Clamp or nail to original table top section by section If you use nails nail in the four cor ners to make sure blade will not contact nails 2 Make several fences s...

Page 36: ...ands Use in rip when you set the blade 1 2 to 16 from the fence Out rip the blade is toward the table front and the motor is toward the column Use out rip only when you set the blade 16 or more from the fence Infeed and Outfeed Directions Infeed and outfeed refer to sides of the blade Infeed the side of the blade where the guard hold down is Always start a rip cut at the infeed side and push the w...

Page 37: ...liary fence when the blade is set 1 2 to 2 from the fence Use a push stick when the blade is set 2 or more from the fence Do not set the blade closer than 1 2 to the fence The radial saw is the wrong tool for such a narrow cut A band saw would be more appropriate for this type of cut Ripping Safety The hazards associated with ripping include outfeed zone hazard kickback and wrong way feed This sec...

Page 38: ...ete cut Do not reach around to pull it If blade jams turn saw off remove yellow key then free blade Kickback Kickback is the uncontrolled propelling of the workpiece back toward the user WARNING Kickback can happen when blade is pinched or bound by workpiece Pinching or binding can happen when pawls and riving knife are not used or not set correctly riving knife is not aligned with blade blade is ...

Page 39: ...herboard see Cutting Aides Keep hands away from outfeed side If blade jams turn saw off remove yellow key then free blade When cutting composition materials or other materials with one smooth and one rough side put rough side up so pawls will be more likely to grab Wrong Way Feed Wrong way feed is ripping by feeding the workpiece into the outfeed side of the blade WARNING Rotational force of blade...

Page 40: ...as a barrier to the hazardous outfeed side of the blade The riving knife rests on the table It keeps the workpiece kerf open This reduces the chances that the cut workpiece will spring closed and pinch the blade Pinching the blade is a cause of kickback The pawls rest level on the upper surface of the workpiece During cutting they allow the workpiece to pass freely from the infeed to the outfeed s...

Page 41: ...piece will be between blade and fence use out rip position for rips 16 or wider 3 Make kerf a turn saw on b lower blade about 1 16 into table c turn saw off and remove yellow key 4 Place workpiece parallel to and up against blade Note Workpiece will be between blade and table front 5 Lower hold down to workpiece then raise slightly so it just clears top surface of workpiece Lock in place 6 Lower r...

Page 42: ...l the edge that is not against the fence 1 When setting bevel angle raise radial arm to allow sufficient clearance for blade and guard to not jam in table 2 When blade is beveled manually raise clear plastic guard before lowering blade to table or kerf otherwise it may jam in the table 3 To set hold down place workpiece directly under guard nose rather than paral lel to blade 4 To set pawls place ...

Page 43: ...ed pressure to part of workpiece close to fence Keep hand at least 8 in front of hold down Note Most workpieces will automatically raise clear plastic guard as they pass from infeed to outfeed side Unusually tall and narrow workpieces may not raise clear guard When this happens push guard tab to raise guard then release tab when guard rests on top of workpiece surface CAUTION Pushing guard tab mea...

Page 44: ... fence Ripping Hints 1 To extend life of table top make auxiliary table cover out of 1 4 plywood or fiberboard Clamp or nail to original table top section by section If you use nails nail in the four com ers to make sure blade will not contact nails 2 Keep table clean of chips and sawdust 3 Use sharp blades 4 Use the right blade for each job 5 For workpiece with one smooth and one rough surface su...

Page 45: ...ibe one way you can proceed Making the base Start with a piece of 3 8 plywood at least 5 5 8 wide or wider and 12 long or longer Make two ripcuts Perform the first ripcut along the long side of the 3 8 plywood to create a 3 8 wide strip Next ripcut the 3 8 plywood to a width of 5 1 8 Crosscut the 3 8 plywood to 12 long Crosscut a 2 1 2 piece off of the 3 8 wide by 3 8 thick strip and save this sho...

Page 46: ...at least 5 1 2 wide and at least 30 long Cut the piece to 5 1 2 wide and 30 long Making the side pieces Using 3 4 plywood at least 30 long rip out one piece 2 1 4 wide and one piece 3 1 4 wide Separately crosscut both pieces to 30 long Putting it together Glue and then fasten with screws the side pieces to the base as shown Make sure the edge of the base and the face of the side piece are parallel...

Page 47: ...NING If you try to rip an irregular workpiece it could bind blade and cause kick back If the workpiece you want to rip does not have a straight edge attach a straight edged board to the workpiece a place irregular side of workpiece against fence b put straight edged board on top of work piece and against fence c tack straight edged board to work piece Note Straight edged board must not extend beyo...

Page 48: ...s Place spacers exactly as shown 3 Re install hex nut 4 Check that pawls work freely Lubricating Blade Guard Assembly If guard becomes difficult to raise 1 Clean sawdust from the slot and slider 2 Regrease with a small amount of light grease applied to the slot and slider Also add a thin coat of grease between the Trig ger and the Pull Link Grease Pull Link Here Slider Slot Maintenance ...

Page 49: ...818169 815757 820573 820566 820572 820568 818199 821560 STD60605 820985 805548 10 37384 820257 SP6311 SP6039 Screw Pan Hd Plastite 8 x 3 4 Handle Hoke Spring Trigger Washer 3 16 x 3 8 x 1 32 Screw Plastite 8 x 1 2 Bumper Table Rear 40 Table Rear 44 Table Spacer 40 Table Spacer 44 Table Front 40 Table Front 44 Table Support Adapter Motor Key Screw Pan Hd Ty T 6 32 x 1 2 Guard Accessory Washer 3 16 ...

Page 50: ...FTSMAN 10 RADIAL SAW GUARD KIT 509398 509399 Always order by Part Number Not by Key Number Figure 2 Repair Parts 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 ...

Page 51: ... x 5 16 Spacer 10 x 125 Washer Spring Knob 5 16 18 Washer 21 64 x 5 8 x 1 16 Spacer Knife Riving Nut Lock 1 4 20 Pawl AKB Bushing Screw Pan Hd 1 4 20 x 1 Holder AKB Key No Part No Description 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 824159 820519 STD551225 820530 808822 1 820632 3 STD533107 809019 4 820532 821310 821311 821312 821314 828139 60413 821449 824158 Screw Flat Hd Type TT 1 4 2...

Page 52: ...er service at 1 800 325 1184 Have your saw s model number when you call 2 If you require this manual in Spanish or French call 1 800 511 2628 Si usted requiere que éste manual usuario en español o francés llame 1 800 511 2628 Pedir formulario SP6039S 3 Si vous nécesstent ce mode d emploi en espagnol ou français téléphonez au 1 800 511 2628 Demander pour forme SP6039F 3 Part No SP6039 Form No SP603...

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