Craftsman 509399, 509398 User Manual
Save This Manual
For Future Reference
owner’s
manual
MODEL NO.
509398
509399
509398 FITS THE
FOLLOWING RADIAL
SA WS:
113.197120, 113.19719 0,
113.197160, 113.19724 0,
113.197110, 113.19711 1,
113.197150, 113.19715 1,
113.197210, 113.19721 1,
113.197250, 113.19725 1,
113.197180, 113.19718 1
509399 FITS THE
FOLLOWING RADIAL
SA WS:
113.197410, 113.19741 1,
113.197510, 113.19751 1,
113.197610, 113.19761 1,
113.197710,
FOR YOUR
SAFETY:
READ ALL
INSTRUCTIONS
CAREFULLY
10-INCH RADIAL SAW
GUARD KIT
• assembly
• operating
• repair parts
Part No. SP6039 Printed in U.S.A.
Table of Contents
Section Title Page
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Crosscutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Ripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Cutting Aides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
NOTE:
1. This manual is intended to be used along with your original saw manual. If you no longer have
your saw’s owners manual, call customer 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
2
.
Safety
This manual has safety information and
instructions to help users eliminate or
reduce the risk of accidents and injuries,
including:
1. Sever e cuts, and loss of fingers or other
body parts due to contact with the blade.
2. Eye impact injuries and blindness, from
being hit by a thrown workpiece, wo rkpiece
chips or pieces of blade.
3. Bodily impact injuries, broken bones and
internal organ damage from being hit by a
thrown workpiece.
4. Shock or electrocution.
5. Burns.
Major Hazards
Three major hazards are associated with
using the radial arm saw for ripping. They
are outfeed zone hazard, kickback and
wrong way feed.
This section only briefly explains these hazards. Read the ripping and crosscutting
safety sections for more detailed explanations of these and other hazards.
Outfeed Zone Hazard
Safety Symbol and Signal Words
An exclamation mark inside a triangle is the
safety alert symbol.
It is used to draw attention to safety information in the manual and on the saw. It is
followed by a signal word, DA NGER ,
WARNING or CAUTION, which tells the
level of risk:
DANGER
tion is not followed someone will be seriously injured or killed.
WARNI NG
tion is not followed someone could be seriously injured or killed.
CAUTION
tion is not follo w ed someone ma y be injur ed.
Read and follow all safety information
and instructions.
: means if the safety informa-
: means if the safety informa-
: means if the safety informa-
If you reach around the blade to the outfeed
side when ripping, and try to hold down or
pull the workpiece through to complete a cut,
the rotational f orce of the blade will pull your
hand back into the blade.
Fingers will be cut off.
Read and follow the information and
instructions under ripping safety.
3
Safety
Kickback Hazar d
Kickback is the un controlled propell ing of the
workpiece back tow ard the user during ripping.
The cause of kickback is the binding or
pinching of the blade in the workpiece. Several conditions can cause the blade to bind
or pinch.
When a workpiece kicks back, it could hit
hard enough to cause internal organ injury,
broken bones, or 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 pul l back, the force
could pull your hand along with the workpiece into the blade. Fingers or hand could
be cut off.
The propelled workpiece could hit a
bystander, causing severe impact injury or
death.
Read and follow the information and
instructions under ripping safety.
4
Guard Function and Features
The guard is a v ery important safet y feature,
designed to reduce the risk of injury associated with blade contact. Install the guard
correctly. Follow the specific instructions
in the ripping and crosscutting sections
to set and use the guard correctly f or
each type of cut.
Guard Features Include:
1. A non-moveable metal upper portion,
(Upper Guard) which is fastened to the
motor by the guard clamp screw, and which
fully covers the upper half of the blade.
2. A moveable clear plastic portion, (Plas-
tic Lower Guard) which partially covers the
lower half of the blade. It protects against
contact with the side of the blade during
crosscutting when blade is in its rearmost
position and the guard is resting on the
table, so the leading and trailing teeth of the
blade are not e xposed. It also protects
against contact with the outfeed side of the
blade during ripping, and acts as a barrier to
prevent wrong way feed.
Safety
Handle/Squeeze
Trigger
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 w orkpiece f or ripping. It a cts as
a barrier to the infeed side of the blade,
keeps the workpiece from fl uttering, and acts
as a sawdust deflector. It is locked/unlocked
by the hold down knob.
5. A riving knife to be lo wered to the table
for ripping. It k eeps the w orkpiece k erf open,
thereby reducing b lade pin ching and the risk
of kickback . It also acts as a barrier to the
hazardous outfeed side and prevents wrong
way feed. It is locked/ unlocked b y the riving
knife/pawls knob. When lo wered for crosscutting, it acts as a barrier to the leading
edge of the blade.
Upper Guard
Hold Down
Knob
Hold Down
Plastic Lower
Guard
Workpie ce
Pawls, Riving
Knife Knob
Riving
Knife
Pawls
5
Safety
6. Set of pawls to be lowered to the workpiece surface for ripping. They allow the
workpiece to pass freely from infeed to outfeed side, but help stop the kickback motion
from outfeed to infeed side by grabbing into
the workpiece surface. Pawls must be reset
each time a different thickness workpiece is
cut.
7. A guard tab to manually raise the plastic
guard at the start of ripping unusual workpieces whose size/shape do not cause the
guard to raise automatically.
Guard Tab
Hazards Associated wit h Clear Portion of Guard
The follo wing safet y information applies to al l
blades and accessories.
WARNING
Clear plastic portion of guard will not
provide any protection during crosscutting 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.
Clear plastic guard will increase risk of certain hazards:
• During rip and bevel cuts, narrow cut
off pieces can be pinched between
guard and blade. Cut-off pieces can
kickback.
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
• Cut-off pieces can jam between
guard and blade. Turn saw off and wait
for blade to stop before freeing
jammed guard or blade.
• In bevel position blade teeth are fully
exposed. Fingers or hand can be cut
off.
6
• Workpiece or cut-off pieces can be
violently thrown by blade. Wear safety
goggles. Stand out of workpiece path.
Safety Instructions
Read and follow all safety instructions.
Personal Safety Instructions
1. Wear safety goggles labeled ANSI Z87.1
(or in Canada CSA Z94.3-99) on the package. It means the goggles meet impact standards set by the American National
Standards Institute. Regul ar eyeglasses are
not safety goggles.
2. Wear close fitting clothes, short sleeved
shirts, and non-slip shoes. Tie up long hair.
Do not wear glov es , ties , je w elry, loose clothing, or long slee ves . These can g et caught in
the spinning blade and pull body parts into
the blade.
3. Wear dust mask to keep fr om inhal ing
fine particles.
4. Wear ear prote ctors, plugs or muffs i f you
use saw daily.
Safety
Safety Goggles
Dust Mask
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 unti l blade has stopped spinning.
3. Make work area child-proof: remove yellow key to prevent accidental start-up; store
key out of sight and re ach; lock work area.
4. Keep floors clean and free of sawdust,
wax and other slippery materials.
5. Keep work area well lighted and uncluttered.
6. Use saw only in dry area. Do not use in
wet or damp areas.
Ear Protectors
7
Safety
Saw Safety Instructions
1. Use guard, pawls and riving knife acco rding to instructions. Keep them in working
order.
2. Routinely check saw for broken or damaged parts. Repair or replace damaged
parts before using saw. Check new or
repaired parts for alignment, binding, and
correct installation.
3. Unplug saw before doing maintenance,
making adjustments, correcting alignment,
or changing blades.
4. Do not force saw. Use saw, blades and
accessories only as intended.
5. Have yellow key out and saw switched
off before plugging in power cord.
Workpiece Safety Instructions
6. Before turning on saw, clear table of all
objects except workpiece to be cut and necessary fixtures, clamps, or feather-boards.
7. If blade jams, turn saw off immediately,
remove yellow ke y, then free blade. Do not
try to free blade with saw on.
8. Turn saw off if it vibrates too muc h 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. Keep saw table clean.
11. Store items awa y fr om sa w. Do not climb
on saw or stand on saw table to reach items
because saw can tip over.
1. Cut only wood, woodlike or plastic materials.
Do not cut metal.
2. Cut only one workpiece at a time. Stacking or placing workpieces edge to edge can
cause user to lose control of workpiece.
8
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 sa w
table can shift, twist, rise up from the tab le,
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
extensions with sturdy legs or an outrigger.
6. Do not use another person to help support workpieces or to aid by pushing or pulling on workpieces, because these actions
can cause kickback. Use table extensions.
Safety
Dia.
7. Use clamps or vice to hold workpiece. It’s
safer than using your hands.
Blade Safety Instr u ctions
1. Use only blades marked for at least 3450
rpm.
2. Use only 10" or smaller diameter blades.
3. Use blades for their recommended cutting procedures.
4. Keep blade sharp and clean.
5. Do not overtighten blade nut because
blade collar could warp.
6. Do not turn saw on and off in rapid
sequence because blade can loosen.
7. Blade should stop within 15 seconds after
saw is switched off . If blade tak es longer , the
saw needs repair. Contact Authorized Service Center.
9
Safety
On-Product Safety Labels
There are several safety labels on the saw.
They alert the user to hazards explained in
the manual and remind the user how to
avoid the hazard.
At the outfeed side, to the right of the
guard near the saw handle is this safety
label to alert you to wrong way feed:
Note where they are located on the saw.
Read and follow the safety information
and instructions in these labels. Refer to
the manual for detailed e xplanations and
instructions.
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:
10
Near the saw handle is this safety label to
alert you to thrown objects and to remind
you to wear safety goggles:
On the clear plastic guard is this OSHA
required label:
Safety
On the bottom surface of the motor , visib le
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)
11
Assembly
Identify Parts
The following parts are included:
Note: Before beginning assembly, check that all parts are included. If you are missing any part, do not assemble guard.
Contact your Emerson Tool Co. Service Center at 1-800-325-1184 to get the missing part. Sometimes small parts can
get lost in packaging material. Do not th row away any packag ing until guard i s put together . Check packaging for miss ing
parts before contacting Emerson Tool Co. A complete parts list (Repair Parts) is at the end of the ma nual. Use the list to
identify the number of the missing part.
List of loose parts with model 509398
A. Guard Assembly ...... .. ............. .. ... ....... 1
B. Rear Table 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..............................
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 509399
A. Guard Assembly ...... .. ............. .. ... ....... 1
B. Rear Table 44"..................................... 1
C. Spacer Table 44" ................................. 1
D. Front Table 44"..................................... 1
E. Table Support ........ .. .. ............. .. ... ....... 2
F. Handle Assembly........................ ......... 1
G.Bag of Loose Parts..............................
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.Te e N ut.................. ............. .. .. .......... 3
L. Lever Bevel Lock............................ 1
M.Bag of Loose Parts.............................. 1
Containing:
N. Guard Acc e s s o ry ............... .. ... ....... 1
O. Screw Plastite #8 x 1/2.................. 1
P. Washer 3/16 x 1 x 1/16.................. 1
Q. Instruction Form............................. 1
B
C
D
1
A
G
I
J
O
K
L
E
F
H
1
P
Q
M
N
12
Assembly
WARNING
Plugging in saw during assembly
could result in electrical shock, or
severe cuts from contact with spi nning
blade.
Do not plug in saw at any time during
assembly.
Plug in saw only when it is to be used.
Remove Sawblade and Guard
1. Tighten carriage lock knob.
2. Loosen guard clamp screw, remove
guard.
3. Motor shaft has left hand threads. Hold
shaft wrench and rotate arbor wrench down
(clockwise).
4. Remove shaft n ut, outer collar, sawblade,
and inner collar. Dispose of guard but retain
shaft nut, outer collar sa wblade and inner
collar.
Remove Original Table Boards, and
Mounting Supports
W ARNING
This retro fit guard kit required additional clearance behind fence. New
table boards are being supplied for
this reason.
Set Screw
NOT E
: All original hardware ( except f or T-Nut)
will be required for mounting retrofit parts.
1. Loosen the table clamps and remove the
rear table, spacer table and rip fence.
Discard the rear table and spacer table.
Save the fence, it 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
fro nt ta ble.
NOTE: On models with 44" wide front tables:
Remove f our screw s from under side of tab le
that secure table clamp channels to table.
Locate and save the five (5) rubber leveling
grommets that are located between the t able
and base assembly. These will be needed to
reinstall the new front t able board.
4. For 40" wide table only. Remove table
clamps and keep for future use. Remove
nuts, bolts and washers that secure the left
and right table support channels. Discard
the support channels.
Bolt
Washer
Lockwasher
Table Support
Screws
Here
Hex Head Bolt
Leveling Hole
Pan Head Screw
Washer
Mounting Holes
Hex Nut
Lockwasher
Nut
Table Support
Flat Washer
13
Assembly
Installing Table Boards (40" Wide Models) For 44" Wide Models Skip to Page 17
Attaching Table Suppor ts
1. Attach a table support to each side of the
saw using the four hex head bolts and flat
washers. Put the bolts through the center of
the enlarged holes in the table supports so
that the supports may slide up or down as
needed. Put a lockwasher and hex nut on
each bolt and hand tighten.
NOTE :
The goal in adjusting the table supports
and leve ling the front tab le is to make sur e that
the table is the same distance from the radial
arm at all points. This ensures that when the
table and blade are installed the clearance
between them will be equal at all points.
Positioning Table Supports
1. Release bevel lock lever, move beve l
index le ver to the left and rotate the motor to
position arbor shaft down. Lock bevel lock.
2. Unlock and hold miter/arm lock lever in
index release position as shown. Position
arm against left stop (approximately 50°
miter). Loosen carriage lock knob (rip lock)
and position arbor shaft directly over left
hand table support.
3. Slide the arbor wrench handle between
end of motor shaft and table support to act
as a feeler gauge. Caref u lly 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:
until both left and right hand table support
channels have ben adjust ed.
4. Move arm and carriage to screw “B”.
Adjust position of table support so that the
arbor wrench just slips between the end of
the motor shaft and the support. Tighten
screw “B”.
5. Move arm and carriage to right hand table support and level in the same manner as in step 4.
6. Recheck both support channels to make
sure that tightening screws did not affect the
accuracy of the adjustment.
7. Elevate the saw and return motor to horizontal position to pro vide clearance for
installation of front work table.
Do not change this elevation setting
Table Support
Screws
Here
Flat Washer
Hex Head
Bolt
Lockwasher
Mount Support
Using These Holes
Arbor Wrench
Screw “A”
Screw “A”
Nut
Table Support
Front
Arbor
Wrench
Screw “B”
Table Support
14
Installing Front Table
1. Set out:
- front table
- tee nut
- 1/4 " U-clip
- 1/4" diam. x 7/8" long cup point set
screw
- four 1/4" diam. x 1" long pan head
screws
- 1/4" dia. x 1-3/4" long pan head screw
- five 17/64" I.D. x 5/8" O.D. flat washers
- four 1/4" lockwashers
- four 1/4" diam. hex nuts
2. Identify top and bottom of table: top has
counterbored holes. Place tabl e bottom side
up on solid surface . Hammer tee n ut i nto leveling hole. (This hole is not counterbored
from the top).
Assembly
Tee Nut
(Install from bottom)
~
Table Mounting Holes
Top of Table
(Counterbored Holes Up
3. Slide a
saw
the
4. Place the
mounting holes
the
holes in the
nel of
5. Drop a flat washer into each counterbored 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
four remaining holes and through matching
holes in table supports. On end of each
screw, put lockwasher then nut and tighten
with screwdriver.
U-Clip
as shown.
saw
.
onto the center channel of
front table
table supports
on the saw so that
in the table line up with
and center chan-
Bolt
Washer
Lockwasher
U-Clip
Set Screw
Leveling Hole
Pan Head Screw
Washer
Mounting Holes
Hex Nut
15
Assembly
Make Front Table Flat
1. Place rear table on its edge, across center of front tabl e. Check for gap between surfaces.
If there is less than 1/32" gap, tighten cup
point set screw unt il it touches frame (look
underneath table), then tighten center (1-3/4"
long pan head screw.
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, mak e sure cup poi nt
set screw touches frame (look underneath
table), and center (1-3/4" long) pan head
screw is tightened.
NOTE:
Measure distance between fence and blade
for correct distance when in rip mode.
Rip fence scale is no longer correct.
16
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