Save This Manual For Future Reference owner’s manual 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.
Table of Contents Section Title Page Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety This manual has safety information and instructions to help users eliminate or reduce the risk of accidents and injuries, including: 1. Severe 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, workpiece chips or pieces of blade. 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.
Safety Kickback Hazard Kickback is the uncontrolled propelling of the workpiece back toward 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.
Safety Guard Function and Features The guard is a very important safety 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 for each type of cut. Handle/Squeeze Trigger Guard Features Include: 1.
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. Guard Tab 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.
Safety 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. Regular eyeglasses are not safety goggles. 2. Wear close fitting clothes, short sleeved shirts, and non-slip shoes. Tie up long hair. Do not wear gloves, ties, jewelry, loose clothing, or long sleeves.
Safety Saw Safety Instructions 1. Use guard, pawls and riving knife according 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. 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.
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. Dia. 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 extensions with sturdy legs or an outrigger. 6.
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.
Safety 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: 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) 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 throw away any packaging until guard is put together. Check packaging for missing parts before contacting Emerson Tool Co.
Assembly WARNING WARNING Plugging in saw during assembly could result in electrical shock, or severe cuts from contact with spinning blade. Do not plug in saw at any time during assembly. Plug in saw only when it is to be used. This retro fit guard kit required additional clearance behind fence. New table boards are being supplied for this reason. Remove Sawblade and Guard 1. Tighten carriage lock knob. 2. Loosen guard clamp screw, remove guard. 3. Motor shaft has left hand threads.
Assembly Installing Table Boards (40" Wide Models) For 44" Wide Models Skip to Page 17 Attaching Table Supports Lockwasher 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.
Assembly 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 Tee Nut (Install from bottom) ~ 2. Identify top and bottom of table: top has counterbored holes. Place table bottom side up on solid surface. Hammer tee nut into leveling hole.
Assembly Make Front Table Flat 1. Place rear table on its edge, across center of front table. Check for gap between surfaces. If there is less than 1/32" gap, tighten cup point set screw until 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.
Assembly Installing Table Boards (44" Wide Models) Drill 5/16" Holes Through Sheet Metal Base Installing Front Table 1. Position the front table and insert the front two screws. The rear screw holes in the table do not line up on any holes in the saw base. 2. Using the rear screw holes as a drill guide, drill a 5/16" hole in the saw base for each of the two rear screws. 3. Remove the front table. Reposition U-Clip to New Hole Location 4.
Assembly 7. Stand the front table on one edge. Put a mounting screw with a washer through each of the mounting holes. Then put a rubber grommet on the bottom of each mounting screw. 8. Place the front table on the saw so that the mounting screws line up with the U-clips. The front table should extend about one inch beyond the trim caps. 9. Start the mounting screws into the Uclips using a Phillips screwdriver. Tighten the screws until the heads are just touching the table.
Assembly 3. Unlock the bevel lock to release the motor. Hold onto the motor as you do this. CAUTION: The motor is heavy and can swing down quickly. You can be cut or injured if the arbor shaft hits you. Hold the motor when you unlock the bevel lock. 4. Turn the motor until the arbor shaft is pointing straight down toward the table. 5. Lock the bevel lock to hold the motor in this position. 6. Draw two lines on the front table, over the table rails. 7.
Assembly 16. Move the arbor shaft over the lowest point. 17. Place the handle end of the arbor wrench over this point and lower the arm until the arbor shaft is just touching the wrench. The wrench should slide back and forth with slight contact. 18. Move the arbor shaft over another point. Do not change the elevation of the arm. 19. Tighten the mounting screws and/or leveling screws until the handle of the arbor wrench just fits between this point and the arbor shaft.
Assembly 1. Pull motor/carriage to end of arm and lock the rip lock. Rotate motor to out-rip position. 2. On the rear of the motor is located the motor support cap. Remove this cap. A small screwdriver will assist you in removal of this cap. (This cap is not on all models) 3. Using a 3/4" socket, short extension and ratchet remove nut and washer from motor support. Take care not to drop washer from motor support.
Assembly 7. The following items can now be removed from the front of the yoke as an assembly: a. Shaft support b. Shaft washer c. Washer .505 x 7/8 x 1/16 d. Bevel lock lever e. Square nut 1/2 x 13 f. Bevel spring wedge g. Bevel lock knob h. Screw, pan head plastite no. 8 x 3/8" long 8. Remove the bevel spring wedge from this assembly by rotating shaft support counterclockwise until it comes out of the square nut located between the bevel lock lever and the bevel spring wedge. Do not remove any other items.
Assembly 13. Using the two #8 x 3/4 pan head screws provided, attach the new handle in the same way as the old one was removed. 14. Inspect motor support cone on yoke, and cone on motor for lubrication on contacting surfaces. These surfaces should be generously lubricated. If necessary lubricate with lithium white grease (not supplied). Bevel Control Unit Motor Index Plate 15. Reinstall motor on motor support. Line up the index pin with the slot in the index plate. Reinstall the .
Assembly Installing Guard Adapter 1. Remove the top motor cover screw and lockwasher. Keep the washer. Discard the old screw. 2. 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. Top Motor Cover Screw Motor Cover Panel 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.
Assembly Installing Blade/Squaring Crosscut Travel NOTE: This adjustment helps ensure the blade accurately travels square to the rip fence. Shaft Wrench 1. Index arm at 0° miter and lock. 2. Install sawblade as shown. Motor shaft has left handed threads - turn nut counterclockwise to tighten. End of arbor wrench resting on table CAUTION: Do not overtighten arbor nut. Use arbor wrench to “snug” nut in place. Overtightening could distort the blade collars and cause blade to wobble.
Assembly Install Fence, Rear Tables, and Table Clamps 1. Insert fence, then spacer table, then rear table. Front Table Fence Spacer Table Rear Table 2. Tilt clamp forward and snap into place in opening at rear of table support. 3. Repeat steps for other table clamp. 4. Tighten thumbscrews to clamp table sections in place. (Steps 2, 3 and 4 only apply to models with 40" wide table boards.) Install Guard The guard is a very important safety feature.
Alignment Guard Installation Steps/Align Riving Knife to Blade The goal of this adjustment is to position the riving knife directly in line with the blade. Riving knife alignment is an important safety factor. The riving knife rides in the kerf of the cut workpiece during ripping to keep the two sides of the workpiece from pinching on the blade. Blade pinching is a cause of kickback. Correct 1. Lock yoke in in-rip position (blade towards column, motor towards front of arm). 2.
Controls Miter Lock Yellow Key On-Off Switch Bevel Lock Lever Handwheel 28 Control Function Operation/Comments Miter Lock Frees radial arm to move; locks in Pull out and towards right to unlock, any desired position; pre-set push to lock.
Controls Rip Scale & Rip Indicators Rip Lock Swivel Lock Saw Handle Table Clamp Thumbscrew Control Function OperationlComments Rip Lock Frees carriage to move along radial arm; locks in position Pull to unlock, push to lock Lock before ripping * Rip Scale & Rip Tells distance between blade and Indicators (Notfence when saw is in in-rip or Electronic Models) out-rip position Move blade carriage along arm to align line on indicator with desired number on scale Swivel Lock Frees blade carriage to
Controls Dust Elbow Guard Clamp Screw Guard Pawls/Riving Knife Knob Hold Down Knob Riving Knife Bracket Riving Knife Pawls Hold Down 30 Control Function Operation/Comments Guard Clamp Screw Secures guard to motor; frees guard for removal Turn counterclockwise to loosen, clockwise to tighten Guard Protects against contact with upper blade; partially protects against contact with lower blade; acts as sawdust deflector Upper part remains fixed in level position.
Controls Pawls/Riving Knife Knob Guard Tab Pawls Riving Knife Control Function Operation/Comments Guard Tab Provides manual way to raise clear plastic guard during ripping when workpiece fails to raise it Push and hold until workpiece clears guard, then release Pawls/Riving Knife Knob Frees pawls and riving knife to independently move up and down Turn counterclockwise to loosen, clockwise to tighten Pawls During ripping, slow or stop kickback by digging into workpiece; when lowered during cros
Crosscutting Crosscutting Defined Straight Bevel Miter Crosscutting is cutting a workpiece to length. The workpiece is held firmly against the fence, and the blade is pulled through the workpiece to make the cut. Straight, bevel, miter, and compound cuts can be made. Compound Crosscutting Safety The hazards associated with crosscutting include: exposed blade teeth, rolling carriage, and thrown workpiece.
Crosscutting Crosscut Kerfs A kerf or shallow cut is needed in the table and fence to serve as a path for the blade and to ensure that the blade cuts all the way through the workpiece. A kerf is needed for each different cutting path. To make an approximately 1/16" deep kerf: 1. Prepare table: - put fence in front position - tighten table clamps 2.
Crosscutting Making Crosscuts Follow these steps to make crosscuts. 1. Prepare table: - put fence in front position - tighten table clamps 2. Prepare blade: - lock motor in crosscut position - lock radial arm at desired miter angle - lock motor at desired bevel angle* - unlock carriage lock and push blade to rearmost position, behind fence - lower blade into kerf* but not touching kerf bottom (blade should move freely).
Crosscutting Repetitive Crosscutting Carriage Stop Repetitive crosscutting is the repeated and continuous cutting of many pieces of lumber to the same length. Carriage and length stops can help make this type of crosscutting more efficient. A carriage stop defines the distance needed to pull the blade through to complete each cut. This will prevent pulling the blade through more than the recommended distance.
Ripping Ripping Defined Ripping is changing the width of a workpiece by cutting along its length. The workpiece is fed into the blade, which rotates in a fixed position, parallel to the fence and a set distance from the fence. A solid fence (no kerfs) serves as a guide for the workpiece. Place the fence in the front position for narrower workpieces, or in the rear position for wider ones. Front Fence Position Rear Fence Position In-Rip and Out-Rip Positions In-rip and out-rip refer to blade position.
Ripping Workpiece Positioning Always set up so that the wider part of the workpiece is between the blade and fence. This gives you greater clearance for push sticks, and allows better stability for feeding the workpiece. Example: To rip 2" off a 10" wide board, set blade in in-rip position 8" from rear fence. Push Sticks and Push Blocks Use push sticks and push blocks instead of the hands to push the workpiece through to complete cuts. They help keep hands away from the blade.
Ripping Outfeed Zone Hazard DANGER Rotational force of blade can pull hands and fingers back into blade. Touching, holding, or pulling on outfeed side of workpiece while blade is still spinning will result in fingers, hand or arm being cut off. To reduce risk of outfeed hazard: [Set pawls and riving knife; they act as partial barrier to outfeed side. [Start and finish cut from infeed side. [Keep both hands on infeed side. [Keep hands away from outfeed side. [Push workpiece through to complete cut.
Ripping To reduce risk of kickback: [Set pawls and riving knife according to rip- ping set-up procedure. Correctly set riving knife is more likely to prevent workpiece from binding or pinching blade; correctly set pawls are more likely to grab into workpiece to stop or slow kickback if one happens. [Check that riving knife is in line with blade (see Alignment: Riving Knife to Blade). [Cut only straight workpieces so surface will lie flat on table and edge will stay tight against fence.
Ripping Hold Down Function The hold down must be set correctly during ripping to act as barrier against the infeed side of the blade, to help keep the workpiece flat on the table, and to deflect workpiece chips. It must be lowered to just clear the workpiece. The hold down must be re-set each time a different thickness workpiece is cut. Set Hold-Down to just clear workpiece Follow the Ripping Set-Up Procedure to correctly set the hold down.
Ripping Ripping Set-up Procedure Follow these steps before ripping. These steps must be repeated each time a different thickness workpiece is ripped. A kerf must be made for each different width cut. Also see the special notes for bevel set-up that follow this section. WARNING If workpiece is pushed along fence with kerfs, workpiece could get caught on kerf, pinch blade and cause kickback. Do not use crosscutting fence for ripping. 1.
Ripping 7. Remove workpiece from table. 8. Ready push stick or push block. 9. Set up table extension(s) and support their outer ends. Do not use another person to support workpieces because this can cause kickback and it exposes helper to potential hazards at outfeed side. Special Notes for Bevel Set-Up CAUTION Bevel ripping creates unique problems of visibility and feeding. Before cutting, check the set-up using both in-rip and out-rip.
Ripping 2. Insert yellow key and turn saw on. 3. Stand at infeed side and out of line of workpiece, in case of kickback. Start and finish cut from infeed side. 4. Put workpiece on table, in front of hold down, and tight against fence. To hold workpiece in position, put left hand on table, at least 8" in front of hold down, and lightly press fingers against workpiece. Support workpiece with table extension or right hand. CAUTION For large workpieces use a feather board in place of your hand on the table.
Ripping Dado Blades, Molding Heads See Accessories for information on safety, installation and use of dado blades and molding heads. Edging Edging is the use of a dado blade or molding head in the horizontal position. It is an advanced technique that requires a molding head guard and a special fence. See Accessories for information on safety, installation and use of dado blades and molding heads for edging. See Cutting Aides for information on making the special fence. Ripping Hints 1.
Cutting Aides Before cutting any wood on your saw, study all of the Crosscutting and Ripping Instructions found on pages 45 through 57. As you learn new radial arm saw woodworking techniques, you’ll see that many types of cuts need different support and feeding devices, known as jigs or fixtures. They can help you make cuts more accurately. By helping to steady the workpiece and keep you away from the blade, they can help you safely use your saw for certain cuts.
Cutting Aides Making the Handle: • Miter crosscut a piece of 3/4" thick plywood to the shape and size shown. The mitered corners can be any size that looks like the drawing (about 1-1/2" by 1-1/2"). Putting it together: • Using good quality wood working glue, glue the 2-1/2" strip saved earlier to the base as shown. Important: Do not use nails or screws. This is to prevent dulling of the saw blade in the event you cut in to the push block. • Position the handle at the edge of the plywood base as shown.
Cutting Aides Clamp the featherboard to the front table, so that the angled edge of the featherboard is against the workpiece on the infeed side of the blade. Do not clamp the featherboard against the cut off part (out-feed side) of the workpiece. If clamped to the outfeed side, the featherboard can squeeze the kerf closed, put binding pressure on the blade, and cause kickback. Straight Edge for Irregular Workpiece WARNING If you try to rip an irregular workpiece, it could bind blade and cause kickback.
Maintenance Replacing Pawls Make sure the teeth of the pawls are always sharp. If they become dull the pawls must be replaced: 1. Use 7/16" wrench to remove hex nut. Remove old pawls. 2. Install new pawls. 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.
PARTS LIST CRAFTSMAN 10" RADIAL SAW GUARD KIT #509398 & #509399 Always order by Part Number - Not by Key Number FIGURE 1 Key No.
Repair Parts 50 PARTS LIST CRAFTSMAN 10" RADIAL SAW GUARD KIT #509398 & #509399 Always order by Part Number - Not by Key Number Figure 2 3 2 4 1 30 7 6 5 8 9 31 31 32 33 29 10 8 9 11 17 28 27 16 13 22 14 15 3 21 20 19 23 26 18 24 25 13 14 3 12
PARTS LIST CRAFTSMAN 10" RADIAL SAW GUARD KIT #509398 & #509399 Always order by Part Number - Not by Key Number FIGURE 2 – GUARD Key No Part No. 1 2 3 4 821217 821313 STD551025 815865 5 6 7 8 9 10 11 12 13 14 15 16 STD601105 802392-47 808447-6 827919 STD551031 820521 820515 STD541425 815815 820517 STD512510 820512 Description Screw, Guard Clamp Link, Pull * Washer, 17/64 x 5/8 x 1/16 Screw, Hex Washer Hd Type "TT" 1/4 - 20 x 1/2 * Screw, Pan Hd Type "TT" 10-32 x 5/16 Spacer #10 x .
RZQHU·V PDQXDO 10-INCH RADIAL SAW GUARD KIT MODEL NO. 509398 509399 For Customer Service Questions or Replacement Parts Call 1-800-325-1184 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.
