Craftsman 21609 - 18 in. Scroll Saw Operator's manual

18 in. SCROLL SAW

VARIABLE SPEED

Model No.

315.216090

_ WARMNG: To reduce the risk of injury,

the user must read and understand the

operator's manual before using this product.

Customer HeUp Line: 1E800E932E3188

Sears, Roebuck and Co., 3333 Bevedy Rd., Hoffman Estates, IL 60179 USA

Visit the Craftsman web page: www.sears.com/craftsman

983000-769

08-05

Save this manual for future reference

US

[] Warranty ............................................................................................................................................................................ 2

[] Introduct(on ....................................................................................................................................................................... 2

[] Genera( Safety Rules ..................................................................................................................................................... 3=4

[] Specific Safety Rules ......................................................................................................................................................... 5

[] Symbols ......................................................................................................................................................................... 6=7

[] Eiectr(cal ............................................................................................................................................................................ 8

[] Glossary of Terms .............................................................................................................................................................. 9

[] Features ..................................................................................................................................................................... 10=11

[] Too(s Needed ................................................................................................................................................................. 12

[] Loose Parts .................................................................................................................................................................... 12

[] Assemb(y ................................................................................................................................................................... 13=15

[] Operat(on ................................................................................................................................................................... 15=19

[] Adjustments .................................................................................................................................................................... 20

[] Ma(ntenance .............................................................................................................................................................. 20=21

[] Troub)eshooting .............................................................................................................................................................. 22

[] Notes .............................................................................................................................................................................. 23

[] Exploded V(ew and Parts Ust .................................................................................................................................... 24=27

[] Parts Order(ng/Serv(ce ...................................................................................................................................... Back Page

ONE YEAR FULL WARRANTY ON CRAFTSMAN TOOL

(f this Craftsman tool falls due to a defect in material or workmanship within one year from the date of purchase, CON=
TACT TNE NEAREST SEARS PARTS & REPAIR CENTER at I=800=4=MY-NOME ® and Sears w(l( repair it, free of

charge. Th(s warranty app)(es only while th(s product (s (n the United States.

(f th(s tool is used for commerc(al or rental purposes, th(s warranty will apply for only n(nety days from the date of pup
chase.

This warranty gives you spec(fic legal rights, and you may also have other rights wh(ch vary from state to state.

Sears, Roebuck and Co., Dept. 817WA, Hoffrnan Estates, (L 60179

This too( has many features for making its use more pleasant and enjoyable. Safety, performance, and dependab((ity
have been given top prior(ty in the design of this product making it easy to maintain and operate.

_ WARMNG:Readandunderstandall instruc=

tions. Failure to follow a(! instruct(ons listed below

may result (n electric shock, fire, and/or serious
personal injury.

READ ALL INSTRUCTIONS

[] KNOW YOUR POWER TOOL. Read the operator's

manual carefu(iy. Learn the app(ications and (imitat(ons

as wel! as the specific potential hazards related to this
tool.

[] GUARD AGA)NST ELECTRICAL SHOCK BY PRE-

VENT(NG BODY CONTACT W(TH GROUNDED
SURFACES. For examp(e: pipes, radiators, ranges,

refrigerator enc(osures.

[] KEEP GUARDS )N PLACE and in good working order.

[] REMOVE ADJUST(NG KEYS AND WRENCHES. Form

the habit of checking to see that keys and adjusting
wrenches are removed from too( before turning it on.

[] KEEP WORK AREA CLEAN. C(uttered areas and

benches inv(te accidents. DO NOT (eave too)s or
p(eces of wood on the too( while it is in operation.

[] DO NOT USE (N DANGEROUS ENV(RONMENTS.

Do not use power tools in damp or wet (ocat(ons or

expose to ra(n. Keep the work area wel( ((t.

[] KEEP CHILDREN AND V(SITORS AWAY. A(( v(s(tors

should wear safety glasses and be kept a safe
distance from work area. Do not (et v(sitors contact

tool or extension cord wh(le operat(ng.

[] MAKE WORKSHOP CH(LDPROOF w(th pad(ocks,

master sw(tches, or by removing starter keys.

[] DON'T FORCE THE TOOL. it wi(! do the job better and

safer at the feed rate for which it was designed.

[] USE THE RIGHT TOOL. Do not force the too! or at-

tachment to do a job for wh(ch it was not designed.

[] USE THE PROPER EXTENS(ON CORD. Make sure

the extens(on cord (s in good condition. Use only a
cord heavy enough to carry the current the product will
draw. An undersized cord wi!l cause a drop in line vo(t-
age resu(ting in loss of power and overheating. A wire
gauge size (A.W.G.) of at least 16 is recommended for
an extens(on cord 25 feet or less (n length, if in doubt,

use the next heavier gauge. The smal(er the gauge
number, the heav(er the cord.

[] DRESS PROPERLY. Do not wear )oose cloth(ng, neck-

ties, or jewelry that can get caught and draw you into

moving parts. Rubber gloves and nonskid footwear

are recommended when working outdoors. Also wear

protective hair covering to contain long hair.

[] ALWAYS WEAR SAFETY GLASSES W(TH S)DE

SH(ELDS. Everyday eyeg(asses have on(y impact-

resistant lenses, they are NOT safety glasses.

[] SECURE WORK. Use c(amps or a v(se to hold work

when practica(, (t is safer than using your hand and
frees both hands to operate the tool.

[] DO NOT OVERREACH. Keep proper footing and

balance at all t(mes.

[] MAINTAIN TOOLS WITH CARE. Keep too(s sharp

and c(ean for better and safer performance. Follow

instructions for lubricating and changing accessories.

[] DISCONNECT TOOLS. When not (n use, before

servicing, or when changing attachments, blades, bits,
cutters, etc., a(! too(s shou(d be disconnected from

power source.

[] AVO)D ACC(DENTAL START(NG. Be sure sw(tch (s off

when plugging in any too!.

[] USE RECOMMENDED ACCESSORIES. Consult the

operator's manual for recommended accessories. The

use of improper accessor(es may result in injury.

[] NEVER STAND ON TOOL. Sedous injury could occur

if the tool is tipped.

[] CHECK DAMAGED PARTS. Before further use of

the tool, a guard or other part that is damaged should

be carefully checked to determine that it wil( operate
properly and perform its intended function. Check for

alignment of mov(ng parts, b(nding of moving parts,

breakage of parts, mounting and any other conditions

that may affect its operation. A guard or other part that

is damaged must be properly repaired or replaced by

an authorized service center to avoid risk of personal

injury.

[] USE THE RIGHT D(RECTION OF FEED. Feed work

into a blade, cutter, or sanding spindle against the
direction or rotation of the Made, cutter, or sanding
sp(ndie only.

[] NEVER LEAVE TOOL RUNNING UNATTENDED.

TURN THE POWER OFF. Don't leave tool unt(( (t
comes to a complete stop.

[] PROTECT YOUR LUNGS. Wear a face or dust mask if

the cutting operation is dusty.

[] PROTECT YOUR HEAR(NG. Wear hearing protect(on

during extended periods of operation.

[] DO NOT ABUSE CORD. Never carry tool by the cord

or yank it to disconnect from receptacle. Keep cord
from heat, oi(, and sharp edges.

[] USE OUTDOOR EXTENSION CORDS. When tool

is used outdoors, use only extension cords with
approved ground connection that are intended for use

outdoors and so marked.

[] KEEP BLADES CLEAN, SHARP, AND WITH

SUFF(C)ENT SET. Sharp blades min(m(ze sta((ing
and kickback.

[] BLADE COASTS AFTER BE)NG TURNED OFF.

[] NEVERUSEINANEXPLOSIVEATMOSPHERE.

Normalsparkingofthemotorcouldignitefumes.

[] INSPECTTOOLCORDSPERIODICALLY.Hfdamaged,

haverepairedbyaqualifiedservicetechnicianat

anauthorizedservicefacility.Theconductorwith

insulationhavinganoutersurfacethatisgreenwith

orwithoutyellowstripesistheequipment-ground-

ingconductor.Hfrepairor replacementof theelectric

cordorplugisnecessary,donotconnecttheequip-

ment-groundingconductorto a liveterminal.Repair
orreplacea damagedorworncordimmediately.Stay
constantlyawareofcordlocationandkeepit wellaway
fromthe rotatingblade.

[] INSPECTEXTENSIONCORDSPERIODICALLYand

replaceif damaged.

[] KEEPTOOLDRY,CLEAN,ANDFREEFROMOIL

ANDGREASE.Alwaysusea cleanclothwhenclean-

ing.Neverusebrakefluids,gasoline,petroleum-based

products,oranysolventsto cleantoo!.

[] STAYALERTANDEXERCISECONTROL.Watch

whatyouaredoingandusecommonsense.Donot
operatetoo!whenyouaretired.Donotrush.

[] DONOTUSETOOLJFSWITCHDOESNOTTURNJT

ONANDOFF.Havedefectiveswitchesreplacedbyan
authorizedservicecenter.

[] USEONLYCORRECTBLADES.Usethe rightblade

size,style,andcuttingspeedforthematerialandthe

typeofcut. Bladeteethshouldpointdowntowardthe
table.

[] BEFOREMAKINGA CUT,BESUREALLADJUST-

MENTSARESECURE.

[] BESUREBLADEPATHJSFREEOFNAILS.Inspect

forandremoveallnailsfromlumberbeforecutting.

[] NEVERTOUCHBLADEorothermovingpartsduring

use.

[] NEVER START A TOOL WHEN ANY ROTATING COM-

PONENT JS IN CONTACT WiTH THE WORKPIECE.

[] DO NOT OPERATE A TOOL WHILE UNDER THE

INFLUENCE OF DRUGS, ALCOHOL, OR ANY
MEDICATION.

[] WHEN SERWCING use only identical replacement

parts. Use of any other parts may create a hazard or
cause product damage.

[] USE ONLY RECOMMENDED ACCESSORIES listed

in this manual or addendums. Use of accessories

that are not listed may cause the risk of personal

injury. Instructions for safe use of accessories are
included with the accessory.

[] DOUBLE CHECK ALL SETUPS. Make sure blade is

tight and not making contact with saw or workpiece
before connecting to power supply.

[] FIRMLYCLAMPORBOLTthetoolto a workbenchor

tableat approximatelyhipheight.

[] KEEPHANDSAWAYFROMCUTTINGAREA.Donot

reachunderneathworkor in bladecuttingpathwith
yourhandsandfingersforanyreason.Alwaysturnthe

poweroff.

[] ALWAYSUSEA CLAMPto securethe workpiece

whenpossible.

[] ALWAYSSUPPORTLONGWORKPIEDESwhilecut-

tingto minimizeriskof bladepinchingandkickback.
Sawmayslip,walkor slidewhilecuttinglongorheavy

boards.

[] BESURETHEBLADECLEARSTHEWORKPIECE.

Neverstartthesawwiththebladetouchingthe
workpiece.Allowmotorto comeupto full speed

beforestartingcut.

[] DONOTFEEDTHEMATERIALTOOQUICKLY.Do

notforcetheworkpieceagainstthe blade.

[] NEVERreachbehind,under,or withinthreeinches

of thebladeanditscuttingpathwithyourhandsand
fingersforanyreason.

[] NEVERreachto pickupaworkpiece,apieceof scrap,

oranythingelsethatisinor nearthecuttingpathofthe

blade.

[] AVOIDAWKWARDOPERATIONSANDHAND

POSiTiONSwhereasuddenslipcouldcauseyour

handto moveintotheblade.ALWAYSmakesureyou

havegoodbalance.NEVERoperatethe sawonthe
floororina crouchedposition.

[] IFANYPARTOFTHISSAWIS MISSINGor should

break,bend,orfai!inanyway,orshouldanyelectrical
componentfailto performproperly,shutoffthepower
switch,removethe plugfromthepowersource,and

havedamaged,missing,orfailedpartsreplacedbefore

resumingoperation.

[] IFTHEPOWERSUPPLYCORDISDAMAGED,it

mustbereplacedonlybythemanufacturerorbyan
authorizedservicecenterto avoidrisk.

[] ALWAYSSTAYALERT!Donotallowfamiliarity(gained

fromfrequentuseofthesaw)to causeacarelessmis-
take.ALWAYSREMEMBERthata carelessfractionof

asecondis sufficientto inflictsevereinjury.

[] MAKESURETHEWORKAREAHASAMPLELIGHT-

INGto seetheworkandthat noobstructionswillinter-
ferewithsafeoperationBEFOREperforminganywork

usingthesaw.

[] ALWAYSTURNOFFTHESAWbeforedisconnecting

itto avoidaccidentalstartingwhenreconnectingto

powersupply.NEVERleavethesawunattendedwhile
connectedto a powersource.

[] TURNOFFTOOLandwaitforsawbladeto cometo

acompletestopbeforemovingworkpieceor changing
settings.

[] SAVETHESEINSTRUCTIONS.Referto them

frequentlyanduseto instructotherusers.Ifyouloan
someonethistool,loanthemtheseinstructionsalso.

WARNING:Somedustcreatedby powersanding,sawing,grinding,drilling,andotherconstructionactivities

containschemicalsknownto causecancer,birthdefectsor otherreproductiveharm.Someexamplesof these
chemicalsare:

leadfromlead-basedpaints,
crystallinesilicafrombricksandcementandothermasonryproducts,and
arsenicandchromiumfromchemically-treatedlumber.

Yourriskfromtheseexposuresvaries,dependingonhowoftenyoudothistypeofwork.Toreduceyourexposure

to thesechemicals:workinawellventilatedarea,andworkwithapprovedsafetyequipment,suchasthosedust

masksthatarespeciallydesignedto filteroutmicroscopicparticles.

Someofthefollowingsymbolsmaybeusedonthistool.Pleasestudythemandlearntheirmeaning.Proper
interpretationof thesesymbolswillallowyouto operatethetoolbetterandsafer.

SYMBOL DESJGNATION/!_XPLANATION

NAME

V Voltage

A Current

Hz Frequency(cyclespersecond)

W Power

min Time

'%, Type of current

m Type or a characteristic of current

no Rotational speed, at no goad

.../rain Revolutions, strokes, surface speed, orbits etc., per minute

Volts

Amperes

Hertz

Watt

Minutes

Alternating Current

Direct Current

No Load Speed

Class II Construction

Per Minute

Wet Conditions Alert

Double-insulated construction

Do not expose to rain or use in damp locations.

Read The Operator's Manual To reduce the risk of injury, user must read and understand

Eye Protection Always wear safety goggles or safety glasses with side

Safety Alert Precautions that involve your safety.

No Hands Symbol serious personal injury.

No Hands Symbol serious personal injury.

_,_ No Hands Symbol Failure to keep your hands away from the blade win result in

No Hands Symbol Failure to keep your hands away from the blade will result in

Hot Surface

®

operator's manual before using this product.

shields, or a full face shield when operating this product.

Failure to keep your hands away from the blade win result in

Failure to keep your hands away from the blade wil! result in

serious personal injury.

serious personal injury.

To reduce the risk of injury or damage, avoid contact with

any hot surface.

6

Thefollowingsignalwordsandmeaningsareintendedto explainthelevelsof riskassociatedwiththis
product.

SYMBOL SIGNAL M_=ANJNG

DANGER:

WARNING: result in death or serious injury.

CAUTION:

CAUTION: (Without Safety Alert Symbol) hdicates a situation that may result in

SERVICE

Servicing requires extreme care and knowledge and
should be performed only by a qualified service tech-
nician. For service we suggest you return the product to
your nearest AUTHORIZED SERVICE CENTER for repair.
When servicing, use only identical replacement parts.

_ WARNING:

The operation of any power tool can result in foreign objects being thrown into your eyes, which can
result in severe eye damage. Before beginning power tool operation, always wear safety goggles or
safety glasses with side shields and a ful! face shield when needed. We recommend Wide Vision Safety
Mask for use over eyeglasses or standard safety glasses with side shields. Always use eye protection
which is marked to comply with ANSHZ87.1.

hdicates an imminently hazardous situation, which, if not avoided, wil!

result in death or serious injury.

hdicates a potentially hazardous situation, which, if not avoided, could

hdicates a potentially hazardous situation, which, if not avoided, may

result in minor or moderate injury.

property damage.

_1_ WARNING: To avoid serious personal injury, do not

attempt to use this product until you read thoroughly
and understand completely the operator's manual.
Save this operator's manual and review frequently for

continuing safe operation and instructing others who

may use this product.

SAVE THESE INSTRUCTIONS

EXTENSION CORDS

Use only 3=wire extension cords that have 3=prong
grounding plugs and 3-pole receptacles that accept the
tool's plug. When using a power tool at a considerable
distance from the power source, use an extension cord
heavy enough to carry the current that the tool will draw.
An undersized extension cord wil! cause a drop in line
voltage, resulting in a loss of power and causing the motor
to overheat. Use the chart provided below to determine
the minimum wire size required in an extension cord. Only
round jacketed cords listed by Underwdter's Laboratories
(UL) should be used.

**Ampere rating (on tool data p_ate)

0-2.0 2.1-3.4 3.5-5.0 5.1-7.0 7.1-12.0 12.1-16.0

Cord Length Wire Size (A.W.G.)

25' 16 16 16 16 14 14

50' 16 16 16 14 14 12

100' 16 16 14 12 10 --

**Used on 12 gauge - 20 amp circuit
NOTE: AWG = American Wire Gauge

When working with the tool outdoors, use an extension
cord that is designed for outside use. This is indicated by

the letters "WA" on the cord's jacket.

Before using an extension cord, inspect it for loose or
exposed wires and cut or worn insulation.

_ WARNING: Keep the extension cord clear of the

working area. Position the cord so that it wil! not get
caught on lumber, tools or other obstructions while
you are working with a power tool. Failure to do so
can result in serious personal injury.

A

WARNING: Check extension cords before each

use. If damaged replace immediately. Never use tool
with a damaged cord since touching the damaged
area could cause electrical shock resulting in serious
injury.

ELECTRICAL CONNECTmON

This tool is powered by a precision built electric motor.
It should be connected to a power supply that is 120
volts, 60 Hz, AC only (normal household current}° Do
not operate this tool on direct current (DC). A substantial
voltage drop will cause a loss of power and the motor wilt
overheat. If the saw does not operate when plugged into
an outlet, double check the power supply.

SPEED AND WRING

The no=load speed of this too! is approximately 1,600
spm. This speed is not constant and decreases under
a load or with lower voltage. For voltage, the wiring in a
shop is as important as the motor's horsepower rating. A
line intended only for lights cannot properly carry a power
tool motor. Wire that is heavy enough for a short distance
win be too light for a greater distance. A line that can
support one power tool may not be able to support two
or three tools.

GROUNDING INSTRUCTIONS
In the event of a malfunction or breakdown, grounding
provides a path of least resistance for electric current to
reduce the risk of electric shock, This tool is equipped with
an electric cord having an equipment=grounding conduc=
tot and a grounding plug, The plug must be plugged into a
matching outlet that is properly installed and grounded in

accordance with all local codes and ordinances,

Do not modify the plug provided, If it will not fit the outlet,
have the proper outlet installed by a qualified electrician,
Improper connection of the equipment-grounding con-
ductor can result in a risk of electric shock, The conductor
with insulation having an outer surface that is green with or
without yellow stripes is the equipment-grounding
conductor, If repair or replacement of the electric cord or
plug is necessary, do not connect the equipment-
grounding conductor to a live terminal,

Check with a qualified electrician or service personnel if
the grounding instructions are not completely understood,
or if in doubt as to whether the tool is properly grounded,

Repair or replace a damaged or worn cord immediately,

This toot is intended for use on a circuit that has an outlet

like the one shown in figure 1, It also has a grounding pin
like the one shown,

FOOTSWtTCN

PLUG

SOROLLSAW

PLUG

®

120V GROUNDED OUTLET

Fig. 1

Anti-KickbackPawls(radial arm and table saws)

A device which, when properly installed and maintained,
is designed to stop the workpiece from being kicked back
toward the front of the saw during a ripping operation.
Arbor
The shaft on which a blade or cutting tool is mounted.

Bevel Cut
A cutting operation made with the blade at any angle

other than 90° to the table surface.

Chamfer

A cut removing a wedge from a block so the end (or part
of the end) is angled rather than at 90 °.

Compound Cut
A cross cut made with both a miter and a beve! angle.
Cross Cut

A cutting or shaping operation made across the grain or
the width of the workpiece.

Cutterhead (planers and jointer planers}
A rotating cutterhead with adjustable blades or knives.
The blades or knives remove matedal from the workpiece.

Bado Cut
A non-through cut which produces a square-sided notch
or trough in the workpiece (requires a special blade).

Featherboard
A device used to help control the workpiece by guiding it
securely against the table or fence during any ripping
operation.

FPM or SPM
Feet per minute (or strokes per minute), used in reference

to blade movement.

Freehand

Performing a cut without the workpiece being guided by a
fence, miter gauge, or other aids.

Gum

A sticky, sap-based residue from wood products.
Heel

Alignment of the blade to the fence.
Kerf
The material removed by the blade in a through cut or the
slot produced by the blade in a non-through or partial cut.

Kickback
A hazard that can occur when the blade binds or stalls,
throwing the workpiece back toward operator.

Leading End

The end of the workpiece pushed into the tool first.
Miter Cut

A cutting operation made with the workpiece at any angle
to the blade other than 90 °.

Non-Through Cuts
Any cutting operation where the blade does not extend
completely through the thickness of the workpiece.

Pilot Hole (drill presses}
A small hole drilled in a workpiece that serves as a guide
for ddlling large holes accurately.

Push Blocks (for jointer planers}

Device used to feed the workpiece over the jointer planer
cutterhead during any operation. This aid helps keep the
operator's hands well away from the cutterhead.

Push Blocks and Push Sticks (for table saws)

Devices used to feed the workpiece through the saw

blade during cutting operations. A push stick (not a push

block) should be used for narrow ripping operations.
These aids help keep the operator's hands well away from
the blade.

Resaw
A cutting operation to reduce the thickness of the work-

piece to make thinner pieces.

Resin
A sticky, sap=based substance that has hardened.

Revolutions Per Minute (RPM}
The number of turns completed by a spinning object in
one minute.

Ripping or Rip Cut
A cutting operation along the length of the workpiece.

Riving Knife/Spreader/Splitter (table saws}
A metal piece, slightly thinner than the blade, which helps

keep the kerf open and also helps to prevent kickback.

Saw Blade Path
The area over, under, behind, or in front of the blade. As

it applies to the workpiece, that area which win be or has

been cut by the blade.

Set
The distance that the tip of the saw blade tooth is bent (or
set) outward from the face of the blade.

Snipe (planers}

Depression made at either end of a workpiece by cutter

blades when the workpiece is not properly supported.

Through Sawing
Any cutting operation where the blade extends completely
through the thickness of the workpiece.

Threw-Back

The throwing back of a workpiece usuaIly caused by the
workpiece being dropped into the blade or being placed

inadvertently in contact with the blade.

Workpiece or Material
The item on which the operation is being done.
Worktable
Surface where the workpiece rests while performing a
cutting, drilling, planing, or sanding operation.

PRODUCTSPECIFICATIONS

Throat..............................................................................................................................................................................18in.

BladeSize......................................................................................................................................................5 in. plainorpin

NoLoadSpeed.............................................................................................................................................500- 1,600/rain.

hput ....................................................................................................................................120V,60Hz,AC©niy, 1.2 Amps

Net Weight ..................................................................................................................................................................... 28 bs.

LIGHT 8WITOH

BLADE OLA(V(P_ DRDP FOOT

80NEW8 LOOKKNOB

8AW

ONiOFFKNOB W(TH

VARIABLESPEED

TENS(ON KNOB

BLADE

BLADE

TENS(ONLEVER

TABLE

SAWDUST

EXHAUST

ARMATURE

AOCE88

BLOWER/LIGHT

/

SAWDUST

DROP

FOOT

8AW

BLADE

STORAGE DRAWER

BEVEL $OALE

LOOK KNOB

FOOTBWITON

10

F(g. 2

KNOWYOURSCROLLSAW

See Figures 2 - 3.

Before attempting to use this product, familiarize yourself
with all operating features and safety rules.

BEVEL SCALE

The bevel scale and indicator show the degree the saw
table is tilted.

_ WARMNG: For your own safety, always push

the knob OFF when machine is not in use. Also, in
the event of a power failure, push knob OFF. Lock
the scroll saw switch OFF with a padlock. This wi!!

prevent the machine from starting up again when the
power comes back on. Failure to heed this warning

can result in serious personal injury.

BLADE CLAMP SCREWS

Blade clamp screws are used when changing saw blades.

BLADE STORAGE DRAWER

Attached under the left side of the table is a blade storage
drawer. Htwill hold up to 20 blades.

BLADE TENSION KNOB

Loosen or tighten blade tension by turning the blade ten-
sion knob.

DROP FOOT AND DROP FOOT LOCK KNOB

This foot should be lowered until it just rests on top of the
workpiece to prevent the workpiece from lifting, yet not so
much that the workpiece drags. The vertical portion pro-
vides a blade guard to prevent accidental blade contact.

FOOT SWITCH

Use the foot switch to conveniently turn your scrotl saw
off and on.

LOCK POST

To prevent unauthorized use of the scroll saw, we suggest
that you disconnect it from the power supply and install
a padlock (not supplied) through the lock post beside the
knob, as illustrated, to lock the knob in the OFF position.
When the lock is properly installed and locked, the switch
is inoperable. Store the pad!ock key in another !ocation.

ON/OFF KNOB WiTH VARIABLE SPEED

Pull the knob out to turn ON the scroll saw and push the
knob in to turn OFF the scroll saw. Turn the knob to adjust
the speed from the high speed of approximately 1,600
SPM (strokes per minute) to the low speed of approxF
mately 500 SPM.

SAWDUST BLOWER / UGHY

With a convenient ON/OFF switch, the sawdust blower/
light keeps the line of cut on the workpiece clean and
lighted for more accurate scroll cuts. Place the switch in
the ON position, then depress the foot switch to activate
the blower and/or light. For best results, always direct air
flow at the blade and the workpiece.

SAWDUST EXHAUST

This feature wil! al!ow you to attach any 1-1/4 in. vacuum
hose for easy sawdust collection.

SAW TABLE WITH THROAT PLATE

Your scroll saw has an aluminum saw table with tilt control

for maximum accuracy. The throat plate inserted in the
saw table allows for blade clearance.

SWITCH

A power switch turns the sawdust blower/light on and off.

TABLE LOCK KNOB

Allows you to tilt the table and !ock it at any desired angle
from 5 ° left to 45 ° right.

PADLOCK

Fig. 3

11

Thefollowingtools(notincluded)areneededfor makingadjustments:

PHiLLiPSSCREWDRIVER

ADJUSTABLEWRENCH

FLATHEAD 8(?,F{EWDBIVER

Fig. 4

The following items are included with the tool:

[] Plain Blades (3)

[] Pin Blades (2)

[] Operator's Manual (Not Shown)

PiN BLADE

WARNING: The use of attachments or accessories not listed might be hazardous and could cause serious

personal injury.

PLAINBLADE

Fig. 5

12

UNPACKING
Thisproducthasbeenshippedcompletelyassembled.

[] Carefullyliftthesawfromthecartonandplaceit ona

levelworksurface.

[] hspectthetoolcarefullyto makesurenobreakageor

damageoccurredduringshipping.

[] Donotdiscardthepackingmatedaluntilyouhave

carefullyinspectedandsatisfactorilyoperatedthetool.

[] Thesawisfactorysetfor accuratecutting.After

assemblingit, checkforaccuracy.Hfshippinghas

influencedthesettings,referto specificprocedures

explainedinthismanual.

[] Hfanypartsaredamagedormissing,pleasecall

1-800-932-3188for assistance.

A

WARNING: Hfany parts are missing, do not operate
this tool until the missing parts are replaced. Failure
to do so could result in possible serious personal

injury.

WARNING: Do not attempt to modify this tool

or create accessories not recommended for use

with this toot. Any such alteration or modification is
misuse and could result in a hazardous condition

leading to possible serious personal injury.

WARNING: Do not connect to a power supply unti!

assembly is complete. Failure to comply could result
in accidental starting and possible serious personal
injury.

MOUNTING SCROLL SAW TO WORKBENCH

WARNING: To avoid serious personal injury from

unexpected tool movement, always securely mount
scroll saw to a workbench.

If the scroll saw is to be used in a permanent application,
we recommend that you secure it in a permanent loca-
tion such as a workbench. When mounting the saw to a
workbench, holes should be drilled through the supporting

surface of the workbench.

[] Each hole in the base of the saw should be bolted

securely using machine bolts, washers, and nuts (not
included). Bolts should be of sufficient length to ac=
commodate the saw base, washers, nuts, and the

thickness of the workbench.

[] Place scroll saw on workbench. Using the saw base as

a pattern, locate and mark the holes where the scroll
saw is to be mounted.

[] Dril! three holes through the workbench.

[] Place scroll saw on workbench aligning holes in the

saw base with the holes ddIled in the workbench.

[] Insert al! three bolts (not included) and tighten securely

with washers and nuts (not included).

NOTE: Al! bolts should be inserted from the top. Install
the washers and nuts from the underside of the bench.

The supporting surface where the scrol! saw is mounted
should be examined carefully after mounting to insure
that no movement during use can result. If any tipping or
walking is noted, secure workbench or supporting surface
before beginning cutting operations.

To Reduce Noise and Vibration:
You may wish to place a foam pad or piece of carpet
between the saw base and the workbench to help reduce

noise and vibration.

If a foam pad or piece of carpet is used, do not overtight=
en the mounting bolts. Leave some cushion between the
padding and the saw base to help absorb the noise and
vibration.

The size of the padding material should be approximately
24 in. x 12 in. x 1,/2 in.

CLAMPING SCROLL SAW TO WORKBENCH

See Figure 6.

If the scroll saw is to be used in a portable application, it is
recommended that you fasten it permanently to a mount-
ing board that can easily be clamped to a workbench or
other supporting surface. The mounting board should be
of sufficient size to avoid tipping of saw while in use. Any
good grade plywood or chipboard with a 3/4 in. thickness

is recommended.

[] Mount saw to board using holes in saw base as a tern=

plate for hole pattern. Locate and mark the holes where
scrol! saw is to be mounted.

[] Fol!ow last three steps in previous section called

Mounting Scroll Saw to Workbench.

\

8AWBABE

C-CLAMP MOUNTING

WORKBENCH

13

BOARD

Fig. 6

Hftagboltsarebeingused,makesuretheyarelong
enoughto gothroughholesinthesawbaseandthema-
terialto whichthesawis beingmounted.

Hfmachineboltsarebeingused,makesuretheyarelong
enoughto gothroughholesinthesawbase,thematerial
thesawisbeingmountedto, andthewashersandnuts.

NOTE:Htmaybenecessaryto countersinkwashersand
nutsonthebottomsideof mountingboard.

SQUARINGTHESAWTABLETOTHE BLADE

See Figures 7 - 8.

[] Loosen the drop foot lock knob and move drop foot

rod all the way up. Retighten drop foot lock knob.

[] Loosen the table lock knob to tilt the saw table until it

is approximately perpendicular or at a right angle to
the blade.

[] Place a small combination square on the saw table

next to the blade to check squareness.

[] Loosen the screw holding the scale indicator. Move

indicator to the 0 ° mark and securely tighten screw.

Remember, the bevel scale is a convenient guide but

DROPFOOT
LOCK KNOB

DROP

should not be relied upon for precision. Make practice
cuts on scrap material to determine if your angle set-
tings are correct.

[] Adjust the drop foot to desired position and securely

retighten the drop foot lock knob.

SETTING THE TABLE FOR HORJZONYAL OR

BEVEL CUTTING

See Figures 8 - 10.

A bevel scale is located under the saw table as a conve-

nient guide for setting the approximate saw table angle for
bevel cutting. When greater precision is required, make
practice cuts on scrap material and adjust the saw table
as necessary for your requirements.

NOTE: When cutting at angles, the drop foot should be
tilted so it is parallel to the saw table and rests flat against
the workpiece. To tilt the drop foot, !oosen phillips screw,
tilt drop foot to the proper angle, then retighten screw.

[] Loosen the table lock knob and push down on the right

side of the table, if the table stops at 0 °, the zero de-
gree stop is properly set. if the table stops somewhere
other than zero, adjust the zero degree stop.

To adjust:

[] To access the zero degree stop, loosen the table lock

knob, and tilt the table with the right side all the way
down. Just under the front of the saw table is the zero

degree stop.

[] Loosen the hex nut and rotate the hex bolt to raise

or lower the bolt as needed to adjust the zero degree
stop. Be sure to check to see that the table is square to
the blade.

DROP

FOOTROD

ZERO DEGREESTOP

D

BEVEL
SCALE

SCREW

Fig. 8

Fig. 7

14

HE×BOLT

ZERODEGREE

STOPASSEMBLY Fig.9

[] Now,byreturningthetableto thezeroposition,the

zerodegreestopprovidesa quickreferenceto the
presetposition.

Thezerostopassemblycanberotatedto theleftand

downoutoftheway,andthetablecanbeangledupto
12°to the left.

NOTE:Makesurethezerodegreestopisrotatedallthe
waydownorit willcontactthe bladestoragedraweras
youangletotheleft.

ZERO DEGREE

ASSEMBLY

Fig. 1 O

_ WARNING: Do not allow familiarity with tools to

make you careless. Remember that a careless frac-

tion of a second is sufficient to inflict severe injury.

_ WARNING: Always wear safety goggles or safety

glasses with side shields when operating tools.
Failure to do so could result in objects being thrown
into your eyes resulting in possible serious injury.

_ WARNING: Do not use any attachments or acces-

sories not recommended by the manufacturer of

this tool. The use of attachments or accessories not

recommended can result in serious personal injury.

_ WARNING: To prevent serious personal injury,

never leave the saw unattended until the blade has
come to a complete stop.

APPLICATIONS

You may use this tool for the following purposes:

[] Cutting wood, wood composition products, plastic,

and other fibrous material up to 2 in. thick

[] Cutting nonferrous metals such as aluminum, brass,

and copper

_k WARNING: Before starting any cutting operation,

clamp or bolt the saw to a workbench. Never oper-
ate the saw on the floor or in a crouched position.
Failure to heed this warning can result in serious
personal injury.

BASIC OPERATION OF THE SCROLL SAW

Before starting a cut, watch the saw run. If you experience
excessive vibration or unusual noise, stop immediately.
Turn the saw off, remove the switch key, and unplug saw.
Do not restart until locating and correcting the problem.

NOTE: After the saw is turned ON, a hesitation before
blade movement is normal.

CUTTING PROCEDURES

[] During each person's learning period on this saw, it is

expected that some blades will break unti! proper use
and adjustments are learned.

[] Plan how to hold the workpiece from start to finish.

[] Keep your hands away from the blade. Do not hand

hold pieces so small your fingers win go under the
blade guard.

[] Hold the workpiece firmly against the saw table.

[] Use gentle pressure and both hands when feeding the

work into the blade. Do not force the work.

[] Guide the workpiece into the blade slowly because the

teeth of the blade are very small and can only remove
material on the down stroke.

[] Avoid awkward operations and hand positions where

a sudden slip could cause serious injury from contact
with the blade. Never place hands in blade path.

[] To get accurate cuts, compensate for blade's tendency

to follow the wood grain as you are cutting wood.

[] Use extra supports (tables, saw horses, blocks, etc.)

when cutting large, small or awkward workpieces.

15

[] Neveruseanotherpersonasa substituteforatable

extensionor asadditionalsupportfora workpiecethat
islongerorwiderthanthebasicsawtable.

[] Whencuttingirregularlyshapedworkpieces,planyour

worksoit wil!notpinchtheblade.Workpiecesmust
nottwist,rockorslipwhilebeingcut.

AVOiDiNGiNJURY

[] Make sure saw is level and does not rock. Saw should

always be on a firm, level surface with plenty of room

for handling and properly supporting the workpiece.

[] Bolt saw to the support surface to prevent slipping,

walking or sliding during operations like cutting long,
heavy boards.

[] Turn saw off, remove switch key, and unplug cord from

the power source before moving the saw.

[] Do not remove jammed cutoff pieces until blade has

come to a fu!! and complete stop.

[] Choose the right size and style blade for the material

and type of cut you plan to do.

[] Use only recommended accessories.

[] With the exception of the workpiece and related sup-

port devises, clear everything off the saw table before

turning the saw on.

[] Properly support round materials such as dowel rods

or tubing because they have a tendency to ref! during
a cut causing the blade to "bite." To avoid this, always
use a "V" block or clamp workpiece to a miter gauge

[] Before removing loose pieces from the saw table, turn

saw off and wait for all moving parts to stop.

REMOWNG JAMMED MATERIAL

When backing out the workpiece, the blade may bind in
the kerf (cut). This is usually caused by sawdust clogging
the kerf or when the blade comes out of the blade hold-
ers. If this happens:

[] Wait until saw has come to a full and complete stop.

[] Place the switch in the OFF position.

[] Unplug the saw from the power source.

[] Remove the saw's blade and the workpiece. See

Removing the Saw Blade.

[] Wedge the kerf open with a flat screwdriver or wooden

wedge, then remove the blade from the workpiece.

WARMNG: To avoid serious personal injury, turn
saw off and wait for all moving parts to stop before

removing loose pieces from the table.

Teeth/ Width Thickness Speed or Strokes Material Cut

ranch Per Minute

10 500-1600 3/16 in. (4.8 mm) up to 2 in. (51 mm)

7 750-1250 3/32 in. (2.4 mm) to 1/2 in. (13 mm) thick

13 500-1000 3/32 in. (2.4 mm) to 1/8 in. (3 mm)

BLADE mNFORMATION [] When choosing a blade, carefully consider the following:

[] Scroll saw blades wear out and must be replaced • Very fine, narrow blades should be used to scref! cut

frequently for best cutting results. Scroll saw blades in thin material 1/4 in. (6 mm) thick or less.

generally stay sharp for 1/2 hour to 2 hours of cutting, _ Most blade packages state the size or thickness and
depending on type of material and speed of operation, type of material which that blade is intended to cut.

[] When cutting wood, best results are achieved when

cutting wood less than one inch thick.

[] When cutting wood thicker than one inch, the user as thinner blades.

must guide the workpiece very slowly into the blade
and take extra care not to bend or twist the blade while

cutting. _ Cutting material thicker than 3/4 in.

.! 10 in. .020 in. Popular size for cutting hard and soft woods

(2.8 mm) (0.5 mm) Plastics, paper, felt, bone, etc.

.067 in. .020 in. Extremely thin cuts on materials

(1.1 ram) (0.5 ram) Wood, plastics

.037 in. .015 in. For tight radius work in thin materials

(0.5 ram) (0.4 ram) Wood, veneer, bone, fiber, ivory, plastic, etc.

The package should also state the radius or size of
curve that can be cut with that blade size.

Wider blades cannot cut curves as tight or as small

[] Blades wear faster when:

Cutting plywood, hardwood, and other laminates.

Side pressure is applied to the blade.

16

CHOICEOF BLADEAND SPEED
Thescrollsawacceptsa widevarietyof bladewidthsand

thicknessesforcuttingwoodandotherfibrousmaterials.
Htuses5 in.longbladesof eitherthe pinendor plainend
style.Thebladewidthandthicknessandthenumberof
teethperinchto usearedeterminedbythetypeofmate-
rialandthesizeof theradiusbeingcut.

NOTE:Asa generalrule,alwaysselectnarrowbladesfor
intricatecurvecuttingandwidebladesfor straightand
largecurvecutting.

INSTALLmNGBLADES

See Figure 11.

Scroll saw blades wear out quickly and must be replaced
frequently for best cutting results. Expect to break some
blades while you learn to use and adjust the saw. Blades
generally stay sharp for 1/2 hour to 2 hours of cutting,
depending on the type of material and speed of operation.

PIN BLADES

Removing the Saw BJade:

[] Turn off the saw and unplug from power source.

_WAF{NING: Failure to turn the saw off and unplug

the saw from the power source could result in ac-

cidental starting causing possible serious injury.

TENSION

RELEASE

V-NOTCN

BLADE

8AW

BLADE KNOB

Fig. 11

[] Pull up on the tension release.

[] Turn blade tension knob clockwise to decrease (or

loosen) blade tension.

[] Pushing up from under the saw table, remove the

throat plate.

[] Loosen both the upper and lower blade clamp screws.

[] Pull up on the blade and push down on the saw arm

to disengage the upper pin in the V-notch of the upper
blade holder. Push the blade downward to disengage
the lower pin in the lower blade holder.

[] Remove the blade.

Replacing the Saw Blade:

[] Turn off the saw and unplug from power source.

[] Place the new blade through the opening in the saw

table with the teeth to the front of the saw and pointing
down toward the saw table. The pins on the blade go
under the blade holder in the lower blade holder.

[] Pull up on the blade and press the upper arm down to

position the upper end of the blade in the Vmotch in
the upper blade holder.

[] Securely tighten the upper and lower blade clamp

screws.

[] Push the tension release back down.

[] Turn the blade tension knob counterclockwise unti! the

blade has the desired amount of tension.

[] Replace the throat plate.

NOTE: If the blade touches the drop foot on either side
then the drop foot must be adjusted. See Adjusting Drop

Foot in the Adjustments section of this manual.

PLAIN BLADES

Removing the Saw Bmade:

[] Turn off the saw and unplug from power source.

[] Pull up on the tension release.
[] Turn blade tension knob counterclockwise to decrease

(or loosen) blade tension.

[] Pushing up from under the saw table, remove the

throat plate.

[] Loosen both the upper and !ower blade clamp screws.
[] Remove the blade.

Replacing the Saw Blade:

[] Turn off the saw and unplug from power source.

[] Place the new blade through the opening in the saw

table with the teeth to the front of the saw and pointing
down toward the saw table.

[] Position blade and tighten the lower blade clamp

screw securely.

17

[] Pulluponthe bladeandpresstheupperarmdownto

positiontheupperendof thebladeintheupperblade
holder.

[] Securelytightentheupperbladeclampscrew.
[] Pushthetensionreleasebackdown.
[] Turnthebladetensionknobclockwiseunti!theblade

hasthedesiredamountof tension.
[] Replacethethroatplate.
NOTE:ffthe bladetouchesthedropfootoneitherside

thenthedropfootmustbeadjusted.SeeAdjustingDrop
FootintheAdjustmentssectionofthismanual.

DROPFOOT

See Figure 12.

To prevent the workpiece from lifting, the drop foot should
be adjusted so it just rests on the top of the workpiece.
The drop foot should not be adjusted so that the
workpiece drags.

Always retighten the drop foot lock knob after each ad-
justment has been made.

[] Loosen the drop foot lock knob.

[] Lower or raise the drop foot to the desired position.

[] Retighten the drop foot lock knob.

The tall, front part of the drop foot acts as a blade guard
to prevent accidental contact with the blade.

TURNING THE SCROLL SAW ON AND OFF

See Figures 13 o 14.

[] Plug the foot switch into the power source.

[] Plug the scroll saw into the foot switch.

TO pOWEI_

soURCI_

[] Pull the ON/OFF knob out to the ON position. The

knob must remain in this position for the foot switch to

supply power to the saw.

[] Depress foot switch to turn saw ON.

NOTE: After saw is turned on, a hesitation before blade
movement is normal.

[] Release foot switch to turn saw OFF.

SWITCH

PULL/0H

PUSH/0FF

0H OFF

DROP FOOT

j LOOK KHOB DROP

OROP FOOT FOOT ROD

,_ WARNING: Do not use this foot switch with any tool

other than 21609 Scroll Saw. Failure to follow this

warning may result in serious injury.

VARIABLE SPEED

See Figure 14.

The ON/OFF knob also controls the variable speed of
the saw. By turning the knob, the vadable speed control

may be adjusted from the high speed of approximately
! ,600 SPM to the low speed of approximately 500 SPM.

Turn the ON/OFF knob clockwise to increase strokes per

minute and counterc!ockwise to reduce the strokes per
minute.

18

Thismotorhasanelectroniccontrolthatregulatesthe
speedandprovidesoverloadprotectionto themotor.If
themotorfailsto startafterabouttwo seconds,pushthe
knobOFFanddisconnectthesawfromthepowersource.
Referto thetroubleshootingchart.

NOTE:Ifthe internaloverloadprotectorhasbeentripped,
pushingtheON/OFFknobOFFwil!resetit.

SCROLLCUTTING
Forgeneralscrollcutting,followthepatternlinesby push-

ingandturningtheworkpieceat the sametime.Attempt=
ingtoturntheworkpiecewithoutalsopushingit could
causetheworkpieceto bindortwisttheblade.

mNTERIORSCROLLCUTTING

See Figure 15.

One convenient feature of a scroll saw is that it can be
used to make scroll cuts on the interior of a workpiece
without breaking or cutting through the edge or perimeter

of the board.

To make interior cuts in the workpiece:

[] Remove the scroll saw blade as explained in the In=

stalling Blades section previously in this manual.

[] Dd[[ a 1,/4 in. (6 mm) hole in the workpiece.

[] Place the workpiece on the saw table with the ddlled

hole over the access hole in the table.

[] Install the blade through the hole in the workpiece;

adjust the drop foot and blade tension.

[] When finished making the interior scroll cuts, simply

remove the blade from the blade holders as described

in the Installing Blades section, and remove the

workpiece from the saw table.

STACK CUTTING

See Figure 16.

After becoming well acquainted with the saw through
practice and experience, you may wish to try stack cut=
ting. Stack cutting may be used when several identical
shapes need to be cut. Several pieces of wood may be
stacked on top and secured to each other before cut=
ting. The wood pieces may be joined together by placing
double=sided tape between each piece or by wrapping
masking tape around the corners or ends of the stacked
wood. You must attach the stacked pieces of wood to
each other so they wil! move on the table as a single piece
of material.

_I1_ WARMNG: To avoid possible serious personal

injury, do not cut more than one loose piece of mate=
rial at a time.

Fig. 15

TAPE

Fig. 16

19

WARNING:Beforeperforminganyadjustment,

makesurethetool isunpluggedfromthepower
supplyandthe switchis intheOFF(O) position.

Failureto heedthiswarningcouldresultinserious
personalinjury.

ADJUSTINGDROPFOOT
[] Loosenthedropfootlockknob.

[] Centerthe dropfootaroundthesawbladetothede-

siredposition.
[] Tightenthedropfootlockknob.

ADJUSTINGBLADETENSION

See Figure 17.

Adjustments to blade tension can be made at any time.
Check the blade tension by the sound the blade makes
when plucked like a guitar string. This method can be
developed with practice and requires knowing the scroll

saw.

Pluck the back straight edge of blade while turning blade
tension knob. The sound should be a musical note. The

sound becomes less flat as tension increases, and de-
creases with too much tension.

To adjust the blade tension:

[] Turn off and unplug the saw from the power source.

Fig. 17

Turn the blade tension knob clockwise to decrease (or
loosen) the blade tension.

NOTE: Be careful not to make the blade too loose.

Too little tension may cause the blade to bend or break
before the teeth wear out.

Turn the blade tension knob counterclockwise to in-
crease (or tighten) blade tension.

NOTE: Be careful not to adjust the blade too tightly.
Too much tension may cause the blade to break as

soon as you start cutting.

,_ WARNING: When servicing, use only identical

replacement parts. Use of any other part may create
a hazard or cause product damage.

WARNmNG: Always wear safety goggles or safety

glasses with side shields during power tool operation
or when blowing dust. If operation is dusty, also wear
a dust mask.

GENERAL

Avoid using solvents when cleaning plastic parts. Most
plastics are susceptible to damage from various types of
commercial solvents and may be damaged by their use.
Use clean cloths to remove dirt, carbon dust, etc.

_ WARNING: Do not at any time let brake fluids,

gasoline, petroleum-based products, penetrating
oils, etc. come in contact with plastic parts. Chemi-
cals can damage, weaken or destroy plastic which
may result in serious personal injury.

It has been found that electric tools are subject to
accelerated wear and possible premature failure when
they are used on fiberglass boats, sports cars, wallboard,
spackling compounds, or piaster. The chips and gdndings
from these materials are highly abrasive to electric too!
parts such as bearings, brushes, commutators, etc.
Consequently, it is not recommended that this too! be
used for extended work on any fiberglass material, wall-
board, spackling compounds, or piaster. During any use
on these materials it is extremely important that the tool is
cleaned frequently by blowing with an air jet.

[] Keep the scroll saw clean.

[] After cleaning the table top initially, apply a thin coat

of automobile type (paste) wax to the table top so the
wood slides easily while cutting.

[] Do not allow pitch to accumulate on the saw table.

Clean with gum and pitch remover.

2O

ARM BEARINGS

See Figure 18.

Lubricate the arm bearings after the first 10 hours of use.
Oil after every 50 hours of use or whenever there is a
squeak coming from the bearings.

[] Carefully place the saw on its side as shown.

[] Remove the rubber cap from the upper and the lower

arm of the saw.

[] Squirt a few drops of SAE20 oi! around the shaft end

and arm bearings. Let oi! soak in overnight, remaining
in this position.

NOTE: Lubricate the bearings on the other side of the saw
in this same manner.

MOTOR BRUSHES

See Figure 19.

The saw has externally accessible motor brush assem-
blies that should be checked periodically for wear. When
either one of the two brushes becomes worn, replace
both brushes.

[] Unplug the saw from the power source.

[] Carefully place the saw on its side, exposing the under-

side of the saw housing.

[] Using a flat blade screwdriver, remove the bottom

brush assembly cap through the access hole in the
base and the top brush assembly cap from the top of
the motor.

[] Gently pry the brush assemblies out using a small

screwdriver, point of a nail, or paper clip.

[] If one motor brush is worn down shorter than 1/4 in.,

replace both motor brushes. Do not replace one side
without replacing the other.

NOTE: Ensure curvature of brush matches curvature
of motor, and that motor brush moves freely in brush
tube. Use the blunt end of something thin (eraser end
of pencil, etc.) to push the motor brush into the tube
until it stays.

[] Ensure the motor brush cap is oriented correctly

(straight), then tighten motor brush cap using a hand
powered screwdriver only. Do not overtighten.

21

[V_0TOR

BRUSH

o

_ gFWSH

CAP

Fig. 19

PROBLEM

Motor will not run.

CAUSE

Problem with ON/OFF switch, power
cord, foot switch, or outlet

SOLUTION

Have worn parts replaced before us-
ing scrol! saw again. Have the proper
outlet installed by a qualified electri-
cian.

Motor defective

Blades breaking.

Vibration (there is always some vibra-
tion when the saw is running).

Blade runout (blade not properly Realign blade.

aligned with arm motion).

Too much tension

Feeding too quickly

Wrong blade

Blade twisting in wood

Hmproper mounting of saw

Mounting surface

Loose table or table resting against
motor

Loose motor mounting

Blade holders out of line

Do not attempt any repair. Have
repaired by a qualified service techni-
cian.

Adjust tension.

Reduce feed rate.

Use narrow blades for cutting tMn
wood or tight corners and turns; use
wide blades for thicker wood or wide

turns.

Reduce side pressure on blade; check
blade tension.

Check mounting.

Check mounting in manual.

Tighten table lock knob.

Tighten mounting screws.

22

23

CRAFTSMAN 18 in. (457 ram} SCROLL SAW - MODEL NO, 216090

SEE F_GURE B FOR iNSERTiON

POINT INTO PART 38

49

47

A

FIGURE A

4O

41

12

58

14

42

" 29

/ 28 _ 30

21

41

32

15

18

16

39

KEY PART
NO. NUMBER

1 180A02030
2 101069006
3 180308000
4 180309000
5 979809001
6 101072009
7 180310000
8 A37130510060

9 979730001
10 Al1003050083
11 180312000
12 979804001
13 180313000
14 180303000
15 180102000
16 180105000
17 E07050613002
18 A10003060103
19 A18003050109

20 980123001
21 979786001
22 979785001
23 979784001
25 A10003050150
26 979772001
27 979820001
28 979821001
29 979822001
30 A38030612019
31 979824001
32 979825001
35 180111000
36 180113000

DESCRIPTION QTY.

Upper Clamp Assembly ................................. 1

Saw Blade ...................................................... 3

Throat Plate .................................................... 1

Table ............................................................... 1

Table Screw .................................................... 1

Saw Blade ...................................................... 2

Blade Drawer ................................................. 1

* Washer (M5) ................................................... 3

* Screw (M5 x 8) ............................................... 3

* Screw (M5 x 8) ............................................... 2

Lock Handle ................................................... 1

* Washer (M6) ................................................... 2

Scale .............................................................. 1

Scale Bracket ................................................. 1

Motor Cover ................................................... 1

Power Cord Assembly ................................... 1

Stain Relief ..................................................... 1

* Screw (M6 x 10) ............................................. 4

Clamp Screw .................................................. 2

Motor Assembly ............................................. 1

Brush Holder .................................................. 2

Brush Assembly ............................................. 2

Brush Cap ...................................................... 2

* Screw (M5 x 15) ............................................. 3

indicator ......................................................... 1

* Hex Bolt (M5 x 15) .......................................... 1

* Hex Nut (M5) .................................................. 1

Hex Bolt (Socket Hd. Special) ........................ 1

* Washer (M6) ................................................... 1

Stopper .......................................................... 1

Spring Pin (M5 x 10 mm) ................................ 1

Rubber Feet ................................................... 4

Base ............................................................... 1

KEY PART
NO. NUMBER

37 E07000846157
38 A10003050105
39 979769001
40 180257000
41 A03003050168
42 979766001
43 979767001
44 979775001
45 979762001
46 979758001
47 180237100
48 A36030508123
49 180238000

50 180242000
52 979776001
53 979759001
54 180250000
55 180241000
56 A63000000051
57 A10003040180
58 180106000

59 180110000
60 A30003004005
61 904222009
62 180108000
63 8180a00!10
64 180112000
65 180101000
66 180109000
67 8180A21000
68 180107000
69 180311000

70 180607000

DESCRiPTiON QTY.

Clamp (UC-15) ............................................... 3

* Screw (M5 x 10 Pan Hd.) ............................... 3

* Hex Bolt (M6 x 20) .......................................... 4

Data Plate ....................................................... 1

* Hex Bolt (M5 x 16).......................................... 3

* Screw (M4 x 30) ............................................. 2

Nozzle ............................................................ 1

Left Counterbalance ....................................... 1

Link ................................................................. 1

Bail Bearing (625ZZ) ....................................... 2

Right Counterbalance .................................... 1

* Washer (M5) ................................................... 1

Screw ............................................................. 1

Spacer ............................................................ 1

Set Screw (M6 x 6 mm) .................................. 2

* Screw (M4 x 8) ............................................... 1

* Fixed Plate ..................................................... 1

Spacer ............................................................ 1

* O-ring (P-5) .................................................... 1

* Screw (M4 x 18 mm) ...................................... 2

Table Spindle .................................................. 1

Table Pivot Stand ........................................... 1

* Hex Nut (M4) .................................................. 2

Label .............................................................. 1

Large Sponge ................................................. 2

Pc Board ........................................................ 1

Inslulation Film ............................................... 1

Lead Wire ....................................................... 1

Small Sponge ................................................. 1

Transformer Board Assembly ......................... 1

Medium Sponge ............................................. 1

BIade Drawn Bracket ..................................... 1

Foot Switch .................................................... 1

* STANDARD HARDWARE iTEM -- MAY BE PURCHASED LOCALLY

CRAFTSMAN 18 in. {457 mm} SCROLL SAW - MODEL NO. 216090 -_

45

49

44

49

46

47

\% 35 j

_36

5O

16 17

29

34

35

28

37

i

18

48

19

2O

26

L

14

38

FNGURE B

Ir

SEE FIGURE A

CRAFTSMAN 18 in, (457 rnrn) SCROLL SAW - MODEL NO. 216090

The modeI number will be found on a plate attached to the motor housing. Always mention the model number in all correspondence regarding your 1

Scroll Saw or when ordering repair parts.

SEE BACK PAGE FOR PARTS ORDERING iNSTRUCTiONS

PARTS UST FOR FmGURE B

KEY PART
NO, NUMBER DESCRIPTION QTY.

1 102032002
2 979745001
3 979747001
4 180243000
5 979749001
6 180a040!0
7 A42001030109
8 A4200!030140

9 180232000
10 108217000
!1 180253000
12 180210000
13 180204000
14 A4100!050!50
15 8000200011
16 180226000
17 180259000
18 180258000
19 180260000

20 180255000
21 166102100
22 180219000
23 180229000
24 180a02060
25 180261000
26 979829001
27 180256000
28 979765001

Tension Adjusting Knob ............................. 1

Support Plate ............................................. 1

Drop Foot ................................................... 1

Washer (M5) ............................................... 1

Hold Down Clamp ...................................... 1

Support Bar Assembly ............................... 1

Spring Pin (M3 x 10 mm) ........................... 1

Spring Pin (M3 x 14 mm) ........................... 1

Bellow ........................................................ 1

Blower ........................................................ 1

Blade Tension Lever ................................... 1

Washer ....................................................... 1

Bracket ....................................................... 1

Pin (M5 x 15 mm) ....................................... 2

Vr Switch .................................................... 1

Switch ........................................................ 1

Switch Label .............................................. 1

Warning Label ............................................ 1

On/Off Knob Label ..................................... 1

On/Off Knob ............................................... 1

Motor Pointer ............................................. 1

Switch Cover .............................................. 1

Led ............................................................. 1

Sawdust Blower/Light ................................ 1

Logo Plate .................................................. 2

Rubber Stopper ......................................... 4

Left Arm Cover ........................................... 1

Bearing Bushing ......................................... 4

KEY PART
NO, NUMBER DESCRIPTION QTY.

29 A41001052340
30 180215000
31 180205000
32 A35030616160
33 180254000
34 180201000
35 180223000
36 A42001050220
37 180a02040
38 180212000
39 180240000
40 180248000
41 180211000
42 180a02070
43 180252000
44 Al1003040255
45 180114000
46 Al1003040350
47 180251000
48 A95001050120
49 Al1003040400

50 180262000
51 A10003040107
52 180244000
53 180245000

983000769

04-!2-05

Spring Pin (M5 x 23.4 mm) ........................ 1

Spring ......................................................... 1

Adjustment Screw ...................................... 1

* Washer (M6) ............................................... 1

Tension Knob ............................................. 1

Upper Arm .................................................. 1

Bearing ....................................................... 2

Spring Pin (M5 x 22 mm) ........................... 2

Lower Clamp Assembly ............................. 1

Lower Arm .................................................. 1

Pin .............................................................. 1

Washer ....................................................... 4

Link ............................................................ 1

Lead Wire Assembly .................................. 1

Right Arm Cover ........................................ 1

* Screw (M4 x 25) ......................................... 3

Warning Label ............................................ 1

* Screw (M4 x 35) ......................................... 3

Drop Foot Lock Knob ................................ 1

Set Screw (M5 x 12 mm) ............................ 1

Screw, Ph. Hd. (M4 x 40 mm + S) .............. 4

Led Label ................................................... 1

Screw, Ph. Hd. (M4 x 10 mm) .................... 4

Spacer ........................................................ 1

Retaining Ring (K7) .................................... 1

Operator's Manual

* STANDARD HARDWARE iTEM -- MAY BE PURCHASED LOCALLY

Your Home

For repair-in your home-of all major brand appliances,

lawn and garden equipment, or heating and cooling systems,

no matter who made it, no matter who sold it!

For the replacement parts, accessories and

owner's manuals that you need to do-it-yourself.

For Sears professional installation of home appliances

and items like garage door openers and water heaters.

1-800-4-MY-HOME ® (1-800-469-4663)

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Call anytime, day or night (U. S.A. and Can ad a)

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HHHHHHHHH

www.sears.com www.sears.c_

OurHome

For repair of carry-in items like vacuums, lawn equipment,

and electronics, call or go on-line for the location of your nearest

Sears Parts & Repair Center.

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1-8oo-488-1222

ca,,anytime,nioht on, )

w_.sears.com

To purchase a protection agreement (U.S.A.)

or maintenance agreement (Canada)on a product serviced by Sears:

1-800-827-6655 (U.S.A.) 1-800-361-6665 (Canada'

Para pedir servicio de reparacien Au Canada pour service en fran(_aB: .................

a domicilio, y pard ordenar piezas: 1-800-LE-FOYER Mc

1-888-S U-HOGAR SM (1-800-533-6937)

(1-888-784-6427) www.sears.ca

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