Craftsman 113.234701 Owner`s manual

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owner's
manual
MODEL NO.
113.234701
81/4-1NCH
RADIAL SAW
Serial
Number
Model and serial numbers
may be found on the side
of the support-arm.
You should record both
model and serial number in
a safe place for future use.
FOR YOUR
SAFETY:
SIEAIRS/ r.RRFTSM RN®
81/4-1NCH
RADIAL SAW
• assembly
• operation
• repair parts
READ ALL
INSTRUCTIONS
CAREFULLY
J
Sold by SEARS, ROEBUCK AND CO., Chicago,
Pad No. SP5570
Form No. SP5570
IL 60684 U.S.A.
Printed
in USA
Table of Contents
Section Title
Safety
Page
.........................................
Assembly
3
......................................
Controls
12
.......................................
Alignment
and Adjustment
Electrical
Connections
Crosscutting
Ripping
Cutting
..........................
24
............................
28
...............................
39
.....................................
40
.......................................
Aides
50
....................................
Accessories
.....................................
Maintenance
69
..................................
Repair
Parts
Index
.........................................
73
.....................................
78
87
FULL ONE YEAR WARRANTY
to a defect
67
....................................
Troubleshooting
If within
63
ON CRAFTSMAN
one year from the date of purchase,
in material
or workmanship,
this Craftsman
Sears will repair
WARRANTY SERVICE IS AVAILABLE BY SIMPLY
NEAREST SEARS SERVICE CENTER/DEPARTMENT
UNITED STATES.
This warranty
applies
only while this product
RADIAL ARM SAW
Radial
Saw fails due
it, free of charge.
CONTACTING
THE
THROUGHOUT
THE
is used in the United
States.
This warranty gives you specific legal rights and you may also have other rights
which vary from state to state.
SEARS,
ROEBUCK
AND CO. DEPT. 698/731A
CHICAGO, IL 60684
SEARS TOWER,
Safety
This manual has safety information
and
instructions
to help users eliminate or
reduce the risk of accidents and injuries,
including:
Major Hazards
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
3. Bodily impact injuries, broken bones,
and internal organ damage from being
hit by a thrown workpiece
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
4. Shock or electrocution
_DANGER
5. Burns.
Safety Symbol and Signal
Words
An exclamation
mark inside
the safety alert symbol.
a triangle
is
It is used to draw attention to safety information in the manual and on the saw.
It is followed by a signal word,
DANGER,
WARNING,
or CAUTION,
which tells the level of risk:
i_ DANGER: means
mation is not followed
seriously
injured
if the safety inforsomeone will be
or killed.
i_ WARNING: means if the safety information is not followed someone
could be seriously
injured
or killed.
CAUTION: means if the safety information is not followed someone may
be injured.
Read and follow
and instructions.
the safety
information
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 force 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.
Safety
Kickback
Hazard
Kickback is the uncontrolled
propelling
of the workpiece back toward the user
during ripping.
kWARNING
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 can hit
hard enough to cause internal organ
injury, broken bones, or death.
Read and follow the information
instructions
Wrong
under ripping
and
safety.
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 will
grab and pull the workpiece.
Before you can let go or pull back, the
force can 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
instructions
follow
the information
under
ripping
safety.
and
kWARNING
e
Wrong Way Feed
Safety
Safety Instructions
Read and follow these safety instructions.
Personal
Safety Instructions
1. Wear safety goggles labeled "ANSI
Z87.1" on the package. It means the goggles meet impact standards set by the
American National Standards Institute.
Regular
gles.
eyeglasses
are not safety gogSafety 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.
These can get caught in the spinning
blade and pull body parts into the blade.
Dust Mask
3. Wear dust mask to keep from inhaling fine particles.
4. Wear ear protectors,
you use saw daily.
5. Keep good footing
not over-reach.
plugs or muffs if
and balance;
do
-L
Ear Protectors
Work Area Safety Instructions
1. Keep children,
of work area.
pets, and visitors
out
Safety
2. Turn saw off, remove yellow key, and
unplug before leaving work area. Do
not leave saw until blade has stopped
spinning.
3. Make work area child-proof:
remove
yellow key to prevent accidental startup; store key out of sight and reach;
lock work area.
4. Keep floors clean and free of sawdust, wax and other slippery materials.
5. Keep work area well lighted
cluttered.
and un-
6. Use saw only in dry area. Do not use
in wet or damp areas.
7. Keep saw table clean and clear of all
objects except workpiece to be cut and
necessary fixtures, clamps, or featherboards before turning saw on.
8. Do not layout, assemble, or setup
work with saw on, or while blade is spinning.
9. Store items away from saw. Do not
climb on saw or stand on saw table to
reach items because
saw can tip over.
Saw Safety Instructions
1. Use guard, hold down, pawls and
spreader 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 mounting.
Direction
of Feed
6
Safety
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.
6. Cut only wood, woodlike or plastic
materials. Do not cut metal.
7. Secure saw to workbench,
leg set.
table,
or
8. Lock all locks before moving saw to a
new location.
9. If blade
remove
jams,
yellow
try to free blade
turn saw off immediately,
key, then free blade.
Do not
with saw on.
10. Turn saw off if it vibrates too much
or makes an odd sound. Correct any
problem before restarting saw.
Safety
Workpiece Safety Instructions
1. Cut only one workpiece at a time. Do
not stack workpieces
or lay them edge
to edge.
2. Rip only workpieces longer than the
diameter of the blade. Do not rip workpieces that are shorter than the diameter
the blade.
of
3. 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.
4. To prevent tipping, support outer
ends of extensions with sturdy legs or an
outrigger.
5. Other persons can be hit by a thrown
workpiece, workpiece chips or pieces of
blade. Do not allow other persons in the
work area.
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.
7. Use clamps or vice to hold workpiece.
It's safer than using your hands.
Safety
Blade Safety Instructions
5. Do not overtighten
blade to saw because
1. Use only blades marked for at least
5500 rpm.
2. Use only blades
diameter.
3. Use blades
cutting
warp.
6. Do not turn saw on and off in rapid sequence because blade can loosen.
81/4 inches in
7. Blade should stop within 15 seconds
after saw is switched
"off". If blade takes
for their recommended
procedures.
4. Keep blade sharp and clean.
On-Product
nut when securing
blade collar could
longer
than
15 seconds
needs
ter.
repair.
Contact
to stop, the motor
Sears
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.
Note where they are located on the saw.
Read and follow the safety information
and instructions
in these labels. Refer
to themanual
for detailed explanations
and instructions.
On the outfeed
these two safety
wrong way feed:
side of the guard
labels
to alert you
are
to
DANGERM
TO AVOID
INJURY
DO NOT
FEED MATERIAL
INTO CUTTING
TOOL FROM
THIS END
Service
Cen-
Safety
kWARNING
On the infeed side of the guard is this
safety label to alert you to kickback:
KICKBACK
IIII
DANGER
On the side surface of the motor, visible
from the in_feed side when the saw is in
a rip position, is this safety label to alert
you to outfeed zone hazard:
kDANGER
On the bottom
surface
visible when the blade
this safety label to alert
guarded
molding
head:
10
of the motor,
is horizontal
is
you to un-
Safety
Near
the saw handle
to alert
you to thrown
remind
you to wear
is this safety
objects
safety
On the top of the radial
general
safety
instruction
, WARNING
label
and
to
goggles:
arm
is this
label:
1. Read manual
before using saw.
2. Wear safety goggles that meet
ANSI Z87.1 Standards.
3. Do not do freehand
cuts.
4. Push carriage to full rear position
after each cross cut.
5. Know how to reduce the risk of
kickback. See instructions for
ripping.
6. When ripping, use push stick when
blade is set 2 inches or more from fence.
7. When ripping, use push block and
auxiliary fence when blade is set
between 1/2 and 2 inches from fence.
Do not make rip cuts narrower than
1/2 inch.
8. Keep hands out of path of blade.
9. Do not reach around saw blade.
10. Turn power off and wait for blade to
stop before adjusting or servicing.
11
Assembly
It is important for your safety and to get
accurate cuts that you put the saw
together according to these instructions.
Identifying
The following
Parts
parts are included:
Note: Before beginning assembly, check
that aU parts are included. If you are missing any part do not assemble saw. Contact your Sears Service Center or Retail
Store and get the missing part. Sometimes
small parts can get lost in packaging
material Do not throw away any packaging until saw is put together. Check packaging for missing parts before contacting
Sears. A complete parts list (Repair
Parts) is at the end of the manual
Use
the list to identify the number of the missing part.
A. Radial Arm ................................. 1
B
C
D
B. Blade Carriage ............................ 1
C. Base .............................................. 1
D. Side Frame .................................. 2
E. Table Support ............................. 2
F. Front Stiffener ............................. 1
G. Rear Table .................................. 1
H. Spacer Table ............................... 1
I. Rip Fence ...................................... 1
J. Front Table ................................... 1
K. Dust Elbow .................................. 1
12
F
Assembly
A
I]
c
D
M
E
N
F
O
G
H
I
J
@
O
The following
@
o
hardware
is included:
A. Phillips Pan Head Screw, v4"
diameter
by 1" ..................................
B. Carriage
Bolt, Y,6" diameter
by a/4"..................................................
C. Carriage
4
4
Bolt, Y16"diameter
by _" ..................................................
4
D. Truss head bolt, s/16"diameter
by s_". .................................................
G. Lock Washer,
s¢16"diameter
.... 12
H. Lock Washer,
v4" diameter
....... 4
I. Nut, s¢16".......................................
12
J. Nut, v4"...........................................
4
K. Yellow Key ..................................
1
L. Table
Clamp
M. Table Clamp
4
E. Flat Washer,
Y16"diameter
...... 12
F. Flat Washer,
v4" diameter
.......... 4
N. Blade Wrench
Screw ..................... 2
Washer
.............................
O. Rip Scale Indicator
P. Grease
................ 2
2
.................... 2
Packet ..............................
1
13
Assembly
Tools Needed for Assembly
and Alignment
1
iI
•
,lli
I ,L,L,I
,i
,i
,
i,
I,_,
*l
Framing Square
_
3/8" Wrench
12-Inch Combination
@
Square
1/8" Hex Wrench
3/16" Hex Wrench
G
7/16" Wrench
#2 Phillips
Screwdriver
#3 Phillips Screwdriver
1/2" Wrench
6
Socket Wrench
Assembly
Follow
these
3/4" Wrench
Socket Extension
1/2" Socket
Steps
steps
in order.
WARNING:
Plugging
in saw during assembly
can 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.
o
0
Base Assembly
1. Set out:
-base
-two
side frames
-four
-four
carriage
bolts, _¢16"diameter
g16" diameter
flat washers
-four
s/16" diameter
lock washers
-four
s/16" diameter
nuts.
by _4"
5/16"
Carriage
x 3/4"
Bolt
5/16"
Flat
5/16"
14
Hex Nut
Washer
5/16"
Lock
Washer
Assembly
2. Position base so that edge is off work
surface.
3. From inside surface, put carriage bolt
through slot in base and hold in place at
highest point.
Table Clamp
Screw Mount
Notch
4. Slide side frame into place on base so
that table clamp screw mount fits into
notch on side frame.
5. On end of bolt put flat washer, then
lock washer, then nut and finger tighten.
Note: Later in assembly, these will be
wrench tightened.
6. Repeat for other slot of base.
7. Repeat
for other side frame.
8. Set out:
-front stiffener
,four truss head bolts 5/16'' diameter
by s_"
-four s'16"diameter
-four 5/16"diameter
-four s'16"diameter
flat washers
lock washers
nuts.
_
9. Place front stiffener
between
frames so that tabs of stiffener
inside of side frames.
stay on
10. Put bolt through hole in front stiffener tab and through side frame.
11. On end of bolt put flat washer,
lock washer, then nut and wrench
tighten.
12. Repeat
5/16"
Hex Nut
side
5/16" x 5/8"
Truss Head Bolt
Side
5/16"
Lock Washer
_
Frame
\
_
,)
_
5116"
Flat
Washer
then
for other 3 holes.
Front
Stiffener
15
Assembly
Blade Carriage
Assembly
Note:
It may
to Radial Arm
be easier
with the parts
by a cord; otherwise
may need help to lift both parts
box at the same time.
Screws
Carriage
Bearings
they
you
Stop
Screw
out of the
Front Trim
1. Set out:
-radial arm
-blade
Remove
These
to do this assembly
still in the box because
are connected
Do Not
Radial
Arm
carriage.
Blade
2. Look inside
arm towards
Carriage
switch hous-
ing to locate two screws that hold front
trim to switch housing. Remove these
two screws and front trim.
WARNING-
/F_ont
Do not remove screws
radia!
arm. Removal
on top of
of these
screws
affects
integrity
assembly and can create
cal hazard.
of switch
an electri-
20:
)..
St°BPuS:;eer_
/
_
Screws
screwdriver
remove
front
carriage
bumper
from
end of arm.
stop screw
to
and
4. Use v2"wrench to loosen carriage
stop screw on top of radial arm about
a/4"(enough to let blade carriage clear
when inserted).
16
Switch
Housing
Radial A_rm
3. Use a No. 3 Phillips
Trim
Assembly
5. Position radial arm so that arm is
CAUTION:
straight up in air.
6. Slide blade carriage onto radial arm, so
that carriage bearings fit into radial arm
track. NOTE: In correct orientation,
single bearing is on left, two bearings are on
right as you look down radial arm. Insure
that the wrench is in the disengaged position, and spread the rip lock plates such
that one rip lock plate is on the left side of
the arm, and one is on the right side (see
illustration).
NOTE: If the carriage can be moved by
pushing
and pulling
on the saw handle
when the rip lock is locked, the lock needs
adjustment. To adjust:
a. Lock rip lock. Use screwdriver
to pop
out "e" ring.
b. Remove
rip lock handle
and use as
wrench to tighten nut.
c. Test for desired locked/unlocked
condi-
Blade Carriage
/
Blade is exposed.
\
(
Carriage
,Bearings
Arm
Track
Rip Lock ¢
Rip
Radial Arm
.
_._adia
tion. Repeat step b if necessary.
d. Re-insert "e" ring.
7. Push rip lock lever clockwise
to lock
blade carriage in place on radial arm.
8. Re-install
front
and bumper,
in bumper
bumper
carriage
making
and
faces
that
switch
sure
larger
stop
that
screw
nut
opening
housing.
is still
of
(.
Wrench
tighten.
9. Re-install
front trim.
DANGER:
Re-install carriage stop screws and
bumper, and tighten. These stop
screws are necessary to insure that
the carriage stays on the arm at all
times. Never operate the saw without
stop screws firmly tightened in
position.
10. Wrench tighten carriage
on top of radial arm.
Front
Carriage
Stop
Screw
Larger
Opening
stop screw
Nut
17
Assembly
Radial Arm to Base Assembly
1. Remove column retaining screw from
base enough so column can clear when
inserted.
2. Unlock
Miter
Lock
Unlock
€
IndMeitxepin"_-_"_
_--i
miter lock. Pull out miter
index pin and turn 90 ° to lock out.
3. Get grease packet. Being careful of
sharp edges which may be present in
base opening, evenly spread grease
around inside of base opening. Notice
shoulder at bottom of base.
4. Insert column into base opening,
pushing down until column goes all the
way down to rest on shoulder at bottom
of base.
5. Use a wrench to re-install column
retaining screw and tighten securely.
6. Turn miter index pin 90° to allow it to
engage indexed position.
7. Lock miter lock.
18
"-4
\
,
Column
Retaining
Screw
Assembly
Making
Radial Arm Parallel to Frame
The radial arm must be parallel to the
frame so that when lowered onto the
table, the blade will be the same distance from the table at all points.
1. Lock miter lock.
2. Unlock rip lock. Pull blade carriage
to mid-way position along radial arm.
Lock rip lock.
3 Turn
elevation
handle
to raise
arm. Lift front end of radial
front
table
towards
between
radial
arm
Elevation Handwheel
radial
and slide
arm and frame,
rear.
4. Continue to support front end of
radial arm while using elevation handle
to lower radial arm until it just rests on
edge of front table. Note: You will have
to remove table without changing radial
arm elevation.
5. Leave front table in place. Wrench
tighten, until just snug, front bolt on
each side where side frame attaches to
base.
6. Without changing elevation
arm, remove front table.
of radial
19
Assembly
7. Lift front end of radial arm and slide
front table between radial arm and
frame, towards front. Do not let table
edges rest in notches of side frame.
8. Leave front table in place. Wrench
tighten rear bolt on each side where
side frame attaches to base.
9. Further
tighten
10. Remove
11. Check
front bolt.
front table.
that distance
between
radial
arm and frame is approximately
same at
front and rear. Re-adjust if necessary.
Rear
Bolt
Front
Bolt
Table Support
Table Support
Assembly
1. Set out:
-two
-four
-four
-four
-four
table supports
carriage bolts
s/16"diameter
5/16"diameter
s/16"diameter
s/16"diameter
flat washers
lock washers
nuts.
by v'2"
5/16" x 1/2"
Carriage
Q
5/1 6"
Flat Washer
2O
Bolt
Lock
5/16"
Washer
5116" Hex
Nut
Assembly
2. Place table support against side frame
so that rectangular
openings line up
with square openings in side frame, and
narrow edge is on top and outside.
3. Put bolt through square opening
side frame from inside surface.
Table Suppo_
Side Frame
in
4. On end of bolt put flat washer, then
lock washer, then nut and finger tighten.
Note: Later, in alignment, these will be
wrench tightened.
5. Repeat
for other
6. Repeat
for other table support.
FrontTable
opening.
Assembly
1. Set out:
-front table
-four phillips pan head screws v'4"
diameter by 1"
-four 1/4"diameter flat washers
-four 1/4"diameter lock washers
-four 1/4"diameter nuts.
1/4" x 1" Phillips
Pan Head Screw
1/4"
Flat Washer
Q
1/4"
Q
1/4" Hex Nut
Lock Washer
21
Assembly
2. Place table so that larger holes face
up. Align table over middle and front
holes in table supports.
Note: Table will
extend over front edge of frame.
Larger
Opening
Up
3. Drop flat washer into each hole, then
insert screw. From underneath
surface,
on end of each screw put lock washer,
then nut. Hold in place and tighten with
screw driver.
®
Miter
Lock Assembly
The miter lock is factory assembled, but
it may need adjustment.
Follow these
steps to see if adjustment
is needed and
how to make adjustment.
1. Pull out miter index pin and turn 90 °
to lock out.
2. Unlock
when
miter
unlocked.
and left, through
move
lock.
It should
Move
radial
miter
range.
feel loose
arm to right
It should
freely.
3. Lock miter lock. It should feel tight
when locked. Try to move radial arm
through miter range. It should not
Miter
move.
4. If step 3 is not met,
nut retainer. Tighten
Replace nut retainer
steps 2, 3, and 4 until
remove screw and
nut as needed.
and screw. Repeat
lock is adjusted.
Miter
5. Turn
engage
miter
miter
index
0 ° indexed
scale
pin 90 ° to allow
position.
Index
it to
Rotate
to line up 0 with arrow.
0
22
Mark
Lock
Assembly
Install Rip Scale Indicators, Table
Clamp Screws, and Dust Elbow
1. Set out:
Radial
-two
-two
-two
-dust
rip scale indicators
table clamp screws
table clamp washers
elbow.
/
i_"_
2. Snap one indicator
blade carriage.
Arm
Rip Scale
Indicator
Blade
Carriage
onto each side of
Table Clamp
Screw
Table
Screw
Clamp
Mount
/
Table Clamp
Washer
3. From rear, screw table clamp screws
through holes in table clamp mounts,
until screw protrudes
enough to tap on
washer. Note: Concave side of washer
faces table edge.
4. Push dust elbow onto opening
of guard.
on top
Dust
Elbow
You cannot use the saw until it is
aligned. Go to Alignment and Adjustment Section and follow all instructions. It may be helpful to read the
Controls Section before proceeding
with alignment and adjustment.
23
Controls
Elevation
Rip Lock
On-Off
Switch
Rip
\
Scale
Rip
Indicator
Bevel Index Pin
Yellow
Key
Saw
Handle
Bevel
Lock
I
Control
Operation/Commentt
On-off Switch
Turns motor
Yellow
Allows
Key
Elevation
Handle
on/off
Pull on, push off
Requires yellow key
saw to be switched
on
Insert into on-off switch,
remove after turning saw off
Lowers/raises
radial arm
Turn clockwise
counterclockwise
Rip Scale and
Rip Indicator
Tells distance
between
Move blade carriage along
arm to align line on indicator
with desired number on scale
Rip Lock
Frees carriage to move along
radial arm; locks at desired
position
Bevel I_x)ck
Bevel
Index
Pin
and fence when saw is in rip
position
Move clockwise
counterclockwise
to lock,
to unlock
Lock before ripping
Frees motor to rotate;
locks in desired position
Pull to unlock,
After bevel lock is unlocked,
allows motor to rotate to in-
Push to right and hold while
rotating motor, then release.
Then lock bevel lock
dexed
24
blade
to lower,
to raise
positions
at 0°, 45 °, 90 °
Works
with
push to lock
bevel
index pin
Controls
Swivel
Index
_
Pin
Swivel
Lock
Miter Index Pin
Miter
Lock
_
o
Table Clamp
Screw
Control
Function
Operation!Comments
Swivel Lock
Frees blade carriage to rotate
between crosscut and rip position; locks in place
Pull to unlock; push to lock
Works with swivel index pin
Swivel Index Pin
After
allows
dexed
in-rip,
Push down and hold while
Miter Lock
Miter Index Pin
Table Clamp
Screw
swivel lock is unlocked,
carriage to rotate to inpositions for crosscut,
out-rip
rotating carriage, then release
Then lock swivel lock
position
Move clockwise to lock,
counterclockwise
to unlock
Works with miter index pin
Locates radial arm and column
Pull out and hold while
in indexed miter positions at
0 °, 22.5 ° right and left, and 45 °
right; allows arm to be set at
any miter position
moving arm to any indexed
position, then release. To set
to a non-indexed
position,
pull out, turn 90° and release
to lock out; move arm to any
miter position
Then lock miter lock
Frees table sections
fence changing
Turn clockwise
counterclockwise
Frees radial arm and column
to rotate into desired miter
to allow
to tighten,
to loosen
25
Controls
\
Pawls/Spreader
Lock
Spreader
Pawls
Spreader
Nut
Control
Operation/Comments
Pawls/spreader
Lock
Frees pawls/spreader
to desired position
to move
Pawls/spreader
Reduce kickback by keeping
kerr open (spreader function); slow or stop kickback
by digging into workpiece
(pawls function)
Move counterclockwise
to
unlock, clockwise to lock
Set pawls/spreader
before ripping
Set as unit. See ripping set-up
for details and illustrations.
With blade in table kerr,
place workpiece
alongside
blade so part of it extends
beyond pawls.
Move unit until pawl rests
level on workpiece and
spreader hangs below
workpiece
surface, in line
with blade, then lock.
Test by pulling workpiece
in
kickback direction to see that
pawls grab into and stop
workpiece. Re-set if needed.
Set pawls/spreader
before rip-
ping
Spreader
Nut
Frees spreader
to side
to move side
Loosen to make adjustment,
then tighten
Spreader must be & line with
blade. If it is not, kickback can
OCClAF
26
Controls
/Hold
Hold
Lock
Down
Control
Hold
Down
Operation/Comment
Down
Hold Down
Lock
Frees hold down to move to
desired position; locks in
place
Move
Keeps workpiece from fluttering; acts as partial barrier to
blade; acts as sawdust deflector
With blade
unlock,
counterclockwise
clockwise
Set hold down
to
to lock
before
ripping
in table kerf and
workpiece
against blade,
move hold down until it just
clears workpiece,
then lock
Set hold down before ripping
27
Alignment
and Adjustment
The saw and blade must be aligned
rectly for two reasons:
1) to make
cor-
cuts accurate
2) to prevent binding of the blade and
workpiece, which can cause jams, kickbacks, or thrown workpieces.
Alignment
Steps
and Adjustment
The following adjustments
must be
made in order before using the saw for
the first time. If you miss an adjustment,
you must go back, make the missed adjustment,
and repeat all steps from that
point on.
_WARNING:
Plugging
in saw during alignment
can result in severe cuts from contact with spinning
Do not plug in
during alignment
Plug in saw only
used.
blade.
saw at any time
or adjustment.
when it is to be
These adjustments are like fine tuning a
piece of equipment. Often, a series of
steps must be repeated more than once
in order to get the adjustment right.
Checking
Framing Square
This Edge Must
Be Straight
/
rL_
......
I
I
I
!
You will need the tools listed in the Assembly section. Before you start, make
sure the framing square is true.
, .....
I
I
Draw Light
Line On Board
Along
This
Edge
I
!
-%
LJ
28
Should
Be No Gap
Square
Is Flipped
Or Overlap
Over
Here
In Dotted
When
Position
Alignment and Adjustment
Adjustable
Adjusting
Carriage
Bearings
Carriage
Bearing
_
Front Carriage
Bearing
\
The goal of this adjustment
is to
eliminate looseness between the carriage bearings and the radial arm. The
blade carriage should roll freely along
the entire length of the radial arm, but
with some resistance.
1. Unlock rip lock and push blade carriage to rearward position.
2. Grasp
thumb
front
beating
forward.
from
turning
beating
needs
If you cannot
carriage
is needed.
bearing
finger.
and at same
riage
while
carriage
and index
between
Apply
time,
force
pull blade
to
car-
If you can stop bearing
while
carriage
is moving,
adjustment--go
stop bearing
is moving,
to step 3.
from
Access
Hole
turning
no adjustment
Go on to Adjusting
Swivel
Lock
Column
Support.
3. Unlock swivel
swivel index pin
position (motor
swivel index pin
lock, press and hold
to set blade to out-rip
toward rear). Release
and lock swivel lock.
Index
3/16"
_[
4. Push blade carriage to rear. Insert _/16"
hex wrench into access hole in top of
radial arm. Look up under radial arm
and pull blade carriage forward until
hex wrench lines up with and fits into adjustable carriage bearing screw. Lock
"rip lock.
!1
]
/
;djustable
Hex Wrench
Carriage
1
F
29
Alignment and Adjustment
3/16"
Hex
5. Hold hex wrench in place and use 1/2"
socket wrench to loosen nut on underside of carriage just enough to allow adjustable carriage bearing screw to turn.
(Nut is accessible through hole in direct
line with hex wrench.)
Wrench
_,._
6. Turn adjustable carriage bearing
screw partial turn to take up looseness.
7. Hold hex wrench
nut.
in place and tighten
8. Put saw in crosscut position, lock
swivel lock, and repeat steps 1 and 2.
Adjusting Column Support
The combined goal of this adjustment
is
a) to eliminate movement
(looseness)
between the column and arm support,
and b) to make raising and lowering the
radial arm a smooth and firm action.
1. Index arm at 0° miter position
lock miter lock.
2. Use elevation
handle
and
to raise radial
arm to maximum height. If elevation
handle is difficult to turn, slightly loosen
gib adjustment
screw and !/2-13 hex bolt.
3. Hold
Arm
Suppo_
end of radial arm with one
hand, and place fingers of other hand
against column and arm support.
4. Feel for movement
between
column
and arm support as you push radial arm
up and down. If there is movement,
go
to step 5. If there is no movement,
go to
step 6.
5. If you have not already done so, slightly loosen gib adjustment
screw. Slightly
tighten v2-13 hex bolt. Repeat steps 3
and 4.
3O
Gib
Adjustment
Screw
1/2"-13
Hex
Bolt
Alignment and Adjustment
6. Use elevation handle to raise and
lower radial arm a few turns in each
direction. Movement
should be smooth
but firm. If movement seems difficult,
Arm Suppo_
slightly loosen v2-13 hex bolt.
7. Position
movement
hands as in step 3. Feel for
between column and arm
support as you push radial arm side to
side. If there is movement,
slightly
tighten gib adjustment
screw. If there is
no movement,
go to step 8.
8. Use elevation handle to raise and
lower radial arm a few turns to make
sure this movement
is still smooth and
firm. If movement
is difficult, slightly
loosen gib adjustment
screw.
Gib
Adjustment
Screw
/
1/2"-13
Hex
Bolt
Column
9. Re-check for up and down and side to
side movement between column and
arm support. Adjustment
is finished
when radial arm raises and lowers
smoothly, and there is no movement
tween arm support and column.
Leveling
be-
the Front Table
The goal in leveling the front table is to
make the clearance between the blade and
table the same at all points.
1. Unlock rip lock and pull blade carriage
out to end of radial arm.
2. Unlock miter lock. Pull out miter index
pin and turn it 90 ° to lock it out.
r
3. Turn
elevation
handle
to raise
arm until the blade is approximately
inch above front table.
radial
one
4. Unlock bevel lock, push bevel index
pin to right and hold in place, turn motor
so blade is parallel to table. Release bevel
index pin and lock bevel lock.
31
Alignment
and Adjustment
5. Find out which point on table is the
highest by positioning blade as close as
possible over each of the four mounting
holes in table top. It will be necessary to
use elevation handle to slowly lower radial arm until blade starts to make contact
with edge of framing
square.
6. Start with blade over highest point of
table as found in Step 5. Once again use
elevation handle to slowly lower radial
arm until blade touches edge of framing
square.
7. Adjust table support so blade is in full
contact with edge of framing square as
much as possible.
8. Tighten table support bolt that is in line
with blade. (If blade is over rear table
hole, tighten rear table support bolt on
that side.)
9. Without changing elevation of radial
arm, position biade over other hole on
same side of table.
10. Adjust table support so blade is in full
contact with edge of framing square as
much as possible.
11. Tighten table support
line with blade.
bolt that is in
12. Repeat steps 7 and 8 for holes on
other side of table.
13. Check for equal clearance at all points
between blade and table. Re-adjust table
supports as needed.
14. Rest level on radial ann. If needed,
put shim under front frame to make saw
slant slightly toward rear.
WARNING:
Saw must slant slightly toward rear to
keep blade carriage from rolling forward. Whenever saw is moved, check
to be sure it is slightly lower in rear.
15. Bolt frame to mounting surface.
(These bolts are not provided.)
32
Framing Square
Alignment and Adjustment
Squaring
Blade Crosscut
Travel
Swivel
Lock
The goal of this adjustment
is to make
accurate crosscuts. To do so, the blade
must travel along the radial arm, perpendicular
to the fence, otherwise,
there will be a slight miter angle in all
crosscuts.
Bevel
Lock
Miter Lock
1. Set radial arm to 0° miter (crosscut)
position. Turn miter index pin 90 ° and
release it to index arm. Lock miter lock.
Check that bevel and swivel locks are
locked.
2. Position blade slightly above
edge of front table.
Miter Index Pin
rear
3. Place square on front table, so that
long side of square is off rear edge of
table, and short side of square just
touches a blade tooth. Mark this tooth.
4. Move blade carriage all along radial
arm to see if marked tooth just touches
square at all points. If it does, no adjustment is needed. If tooth moves into or
away from square,
go to step 5.
5. Slightly loosen four screws on arm
near elevation handle. Move arm to
make adjustment. Tighten screws.
Repeat step 4.
6. If additional movement is necessary or
in order to make a more precise adjustment the gibb screws located on the back
of the arm support can be adjusted.
If the saw blade tried to move away
from the square, slightly loosen the
left gibb screw with a 3/16" hex
wrench and tighten the right screw
maintaining column support adjustment to move the arm to the left.
If the saw blade tried to "walk"
Loosen These
Four Screws
Elevation
Handle
on
the square, slightly loosen the right
gibb screw with a 3/16" hex wrench
and tighten the left gib screw maintaining column support adjustment
to move the arm to the right.
33
Alignment
Squaring
and Adjustment
Cover
Plate
Screw
Blade to Table
The goal of this adjustment
is to make
the blade perpendicular
to the table so
that cuts will be accurate; otherwise all
cuts will have a slight bevel angle. The
bevel scale will also be adjusted.
cover
Plate
1. Position blade carriage so that rear 3/4
of blade is beyond rear edge of front
table. Lock rip lock.
2. Loosen
coverplate
coverplate
screw and rotate
out of way.
_""_
Combination
Square
Rear Edge
of Front Table
3. Rest combination
square on table and
against blade so that short edge of
square rests on table and long edge rests
against blade. Make sure edge of square
is against blade surface, not on a tooth.
Right
Square
4. Look to see if space between blade
and square stays same at all points.
Check different points along blade surface by making quarter turns and looking for gaps each time. If space stays
same at all points, no adjustment
is
needed--go
to step 7. If space varies, go
to step 5.
Combination_
Table _
I
Wrong
Wrong
Combination[][]
Combination
Square
_'_
'_
S uare i
i
[
I
Table
Table
5. Use 3/16"hex wrench to loosen socket
head screws on either side of saw handle, behind bevel scale. (Make sure bevel
lock stays locked.) Make adjustment
by
turning motor. Note: Not all blades are
perfectly flat. Find best position for whole
blade. Tighten screws.
6. Repeat
:7. Use
steps
3 and
3/16" hex wrench
4.
to slightly
loosen
screw
small
in saw handle.
Slightly loosen
screw below saw handle.
Rotate
bevel
scale
Tighten
to line up 0 with
screws.
Socket
Head
arrow.
Loosen
These
Screws
To Adjust
Bevel Scale
34
Alignment and Adjustment
Squaring
Table Clamp
Screw
Blade to Fence
The goal in setting the blade perpendicular to the fence is to reduce the risk
of kickback when ripping. This adjustment will also reduce splintering
of the
workpiece and burning of the kerr
during ripping and crosscutting.
1. Insert rip fence, then table spacer,
then rear table, and tighten in place
with table clamp screws.
t O
Table
Spacer
Rip Fence
\
2 Position blade carriage
fence and lock rip lock.
in front of
3. Place combination
square so that
short edge is against fence and table,
and long edge is against flat surface of
blade, just below blade collar. Make
sure edge of square is against blade surface; not on a tooth.
\
\,
Combination
Square
Fence
\
\
Right
/
Fence
Combination
4. Look to see if space between blade
and square stays same at all points.
Check different points along blade surface by making quarter turns, and looking for gaps each time. If space stays
same at all points, no adjustment
is
needed--go
to step 7. If space varies, go
to step 5.
Square
Wrong
J
Combination
Square
Combination
Square
35
Alignment
and Adjustment
5. Unlock swivel lock, but do not move
swivel index pin. Use 3/16"hex wrench to
loosen two adjusting screws under carriage. (There are two access holes to
these screws, one on each side of swivel
handle.) Make adjustment
by rotating
motor. Note: Not all blades are perfectly
fiat. Find best position for whole blade.
Tighten two adjusting screws and lock
swivel lock.
Swivel
Rip Lock
"Locked"
Lock
6. Repeat steps 3 and 4.
7. Return c0verplate to original position
and tighten coverplate screw.
Aligning
Spreader
Adjusting
Screws
to Blade
The goal of this adjustment
is to make
the spreader directly in line with the
blade. The spreader has an important
safety role. It rides in the kerf of the cut
workpiece
during ripping to help keep
the two sides of the workpiece
from
pinching on the blade. Blade pinching is
a cause of kickback.
Right
Pawl--... l
1. Unlock swivel lock, depress swivel
index pin, and move blade carriage to inrip position (motor towards table front).
Lock swivel lock.
Fence
_---
_
Spreader
I--
Saw Blade
a-m/
Wrong
Wrong
2. Lower radial arm until blade just
clears table.
3. Unlock rip lock and move blade carriage back until blade touches fence.
Lock rip lock.
4. Unlock pawls/spreader
lock and
lower pawls/spreader
until pawl on left
side of spreader rests on top of fence.
Lock pawls/spreader
lock.
5. If spreader rests fiat against fence, no
adjustment is needed--go to step 7. If
36
Spreader
Pawl
_
Spreader
.,,_.__.- Saw
Table
Blade
Table
Alignment and Adjustment
spreader does not rest flat against
fence, go to step 6.
6. Use a/2"wrench
to loosen both
spreader nuts. Slide spreader against
fence. Tighten spreader nuts.
7. Unlock pawls/spreader
lock, raise
pawl/spreader
unit up to guard and lock
in place. Leave saw in this position to
adjust in-rip scale indicator.
Adjusting
Spreader
Nut
In-Rip Scale Indicator
1. With saw in in-rip position and blade
against fence, align in-rip scale indicator
with 0.
r
J
In-Rip Scales
In-Rip Scale__
Indicator
37
Alignment and Adjustment
Adjusting
Out-Rip
Scale Indicator
1. Unlock rip lock and pull blade carriage forward. Unlock swivel lock,
depress swivel index pin, and set blade
carriage in out-rip position (motor
towards fence). Lock swivel lock.
2. Push blade carriage back until blade
is against fence. Lock rip lock.
3. Align out-rip
scale indicator
with 0.
Out-Rip Scales
ScalOUltndlcPtor "__
The saw is aligned and ready to use
for cutting. It is important that you
periodically
check alignment and adjustment to insure accurate cuts and
improve the safety of cutting procedures.
38
Electrical Connections
Motor Specifications
The double
insulated
saw has the following
Rated
motor
used in this
Maximum
Developed
Hertz
120
.........................................
13
(cycles) .................................
60
RPM ............................................
Arbor
1.0
H.P .......... 2.5
Voltage ..........................................
Amperes
No grounding
specifications:
H.P ......................................
Shaft Rotation
This tool is equipped with a two wire
cord and two prong plug which can be
used in standard 120 volt A.C. outlets.
5100
of the tool is necessary.
The housing is a dielectric material.
This helps protect you in case of failure
of the standard functional insulation
within the electrical
system.
Use only identical replacement
parts
when service is required. This tool is intended for residential
use only.
Extension Cords
...... Clockwise
Power Supply
_WARNING:
The saw is factory wired for 120V
operation.
Connect
to 120V, 15AMP branch circuit and use 15-AMP
time delay fuse or circuit breaker.
Failure to connect in this way can
result in injury from electric shock
or fire.
The use of any extension cord will cause
some loss of power. Replace damaged
or worn cords immediately.
The following table shows the correct
size cord to use. If in doubt, use the next
heavier gauge. An undersized
cord will
cause a drop in line voltage, resulting in
loss of power and overheating.
Note:
The smaller the gauge number, the
heavier the cord.
Wire Gauge Chart (AWG #) for 120 Volt
Lines
_WARNING:
To avoid electric shock or fire, immediately
replace
worn, cut, or
damaged power cord.
If an electrical shock occurs, your
reaction to the shock may bring
your hands into contact with the
blade.
Cord Length (feet)
AWG #
0-25
No. 16
26-50
No. 12
51-100
No. 10
For circuits
electrical
that
circuit
be increased
deliver
ample
are
box,
farther
the wire
proportionately
voltage
away
size
from
must
in order
to
to the saw motor.
39
Crosscutting
Crosscutting
Defined
Straight
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, miter, bevel, and compound cuts can be made.
Miter
Bevel
Basic Crosscuts
Crosscutting
The hazards
Safety
associated
with crosscut-
ting include: exposed blade teeth, rolling carriage, thrown chips, and thrown
workpiece. This section explains these
hazards and tells how to avoid them or
reduce the risk of their happening.
Read the crosscutting safety information and instructions
before making
any type of crosscut. Follow these steps
every time you make a crosscut.
Exposed
Blade Teeth
_WARNING:
During crosscutting,
blade teeth
can be exposed. To reduce risk of
having fingers, hand or arm cut off"
1. Lower pawls to clear fence or
workpiece, whichever is higher, by v's".
Lowered pawls will cover most front
teeth of blade.
2. Keep hands away from blade and out
of blade path. Keep hand holding down
workpiece at least 6" from blade.
3. Do not cut freehand.
able to control
You will not be
Fence
workpiece.
4. If blade jams, turn off saw, remove
yellow key, wait for blade to stop spinning, then free blade.
Workpiece
4O
Compound
Crosscutting
Rolling Carriage
_WARNING:
When saw is turned on, blade can
suddenly
come toward
you. To
reduce risk of this happening:
1. Keep one hand on saw handle when
turning saw on.
2. Make sure saw slants slightly toward
rear. If needed, put shim under front
frame.
3. Whenever saw is moved, check to be
sure that it is slightly lower in rear.
Thrown Chips
WARNING:
The
saw
can violently
throw
workpiece
chips. Pieces of blade
can break off and be thrown violently. To reduce
blindness:
risk of eye injury and
WARNING
1. Wear safety goggles labeled "ANSI
Z87.1" on package. Regular eyeglasses
are not safety goggles.
2. Check blades
for damage.
3. Keep saw table clean and clear of all
objects except workpiece to be cut and
necessary fixtures or clamps.
41
Crosscutting
Thrown
Workpiece
CAUTION"
Workpiece
could be picked up by
spinning
blade and thrown. You
could be hit by thrown workpiece,
or your fingers
or hand could be
pulled into blade. To reduce risk of
thrown workpiece:
1. Make
sure installed
fence is at least
half as high as the workpiece,
less than 3/4".
and never
2. Start cut with blade in rearmost position, behind fence.
3. Firmly hold workpiece flat on table
and up against fence. Cut only one
workpiece
at a time. Stacking or placing workpieces
edge to edge can cause
user to lose control of workpiece.
4. Pull blade through workpiece only distance needed to complete cut, and
never more than half diameter of blade.
5. Push blade carriage to rearmost position, behind fence, after each cut.
6. Do not reach for or touch cut off end
of workpiece
until cut is complete,
blade is behind fence, saw is turned
and blade has stopped spinning.
off,
7. Do not use length stop on cut-off end
of the workpiece because it can cause
cut-off end to be thrown and hit user.
Use length stop only on end of
workpiece which is held down.
8. Use table extensions
workpieces
that extend
42
to support
beyond table.
Crosscutting
Crossscutting
Refer
to the following
making
crosscut
will remind
your
cutting
Crosscutting
Checklist
kerfs
checklist
before
or crosscutting.
you of things
It
to do to make
safer.
Crosscutting
1. Prevent
accidental
Checklist
start-up.
Saw un-
2. Safety goggles on.
3. Blade sharp and correctly installed.
and table spacer; at least half as high
as wor_xece,
and never less than 4.
, ....,:_.:i,
' or
5. Pawls
lowered ii_to .._'i,_'....
above fence
0vorkpiece, whichever is higher.
6. Hold down raised and locked.
7. Swivel, miter, and bevel locks locked; table clamps tightened.
8. One hand always on saw handle
9. Blade pulled
through
workpiece
blade:
Hints
1. To extend the life of the table top,
make an additional top out of 72'
plywood or masonite. Clamp or nail
original table top, section by section.
you use nails, nail in the four corners
make sure the blade will not contact
nails.
to
If
to
the
2. Instead of using one fence for all cutting paths, make several fences, each
with only a few kerfs. (See Cutting
Aides--Fences.)
Too many kerfs in a
fence weaken it.
3. When making miter or bevel cuts, use
extra force in holding the workpiece
down because it tends to move during
these types of cuts.
4. When cutting hard woods, like oak,
pull blade through more slowly.
5. Keep table clean of chips and sawdust.
6. Use the right blade for each job.
7. Use sharp blades.
8. To keep cut line accurate, periodically check blade alignment by following instructions
in Alignment
and
Adjustment
section.
9. Do not cut severly warped or crooked
workpieces.
10. For workpieces
with one smooth
and one rough surface, cut with smooth
surface down on table.
ning before reaching for cut-off end of
wor_iece.
43
Crosscutting
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.
Follow these steps to make
proximately
1/16"deep kerf:
ap-
1. Check that saw is unplugged,
"off' and yellow key is out.
switch is
Elevation Handle
2. Put fence between front table and
spacer board. Tighten table clamps.
3. Set desired bevel angle. Move arm to
desired miter position. Lock bevel,
miter and swivel locks.
4. Unlock rip lock and push blade carriage to rearmost position, behind fence.
5. Turn elevation
lower radial
table.
handle
clockwise
to
arm until blade just clears
@
@
0
6. Lower
44
pawls to clear fence by v'8".
Crosscutting
7. Plug saw in.
8. Put yellow key in switch.
9. Grasp and hold onto saw handle,
turn saw on.
then
10. Slowly turn elevation handle clockwise to lower radial arm until blade
touches table, then continue to lower by
half turn of elevation handle.
11. Hold hand in straight line with saw
handle and pull blade through fence
and across table as far as it will go.
[
12. Push blade carriage to rearmost position, behind fence, and turn saw off.
Continue to hold saw handle until blade
stops spinning.
13. Remove yellow key and unplug saw.
45
Crosscutting
Making Straight and Miter
Crosscuts
Follow these steps to make straight and
miter crosscuts. Note: There are four indexed miter positions, 0°, 22!/2° right and
left, and 45 ° right. To move to an indexed
position, unlock miter lock and pull and
hold out miter index pin while moving
arm to desired angle. Release miter index
pin and lock miter lock. To move to a
non-indexed position, unlock miter lock,
pull out miter index pin and turn it 90 ° to
lock it out. Move arm to desired angle
and lock miter lock.
1. Check that saw is unplugged,
"off" and yellow key is out.
2. Put fence between
spacer board.
switch is
front table and
Tighten
table clamps.
3. Move arm to desired miter position.
Lock miter, bevel and swivel locks.
4. Unlock rip lock and push blade carriage to rearmost position, behind fence.
5. Lower blade into kerr, but not touching kerf bottom. Blade should move
freely. If there is no kerf in table for
path you want to cut, make one following instructions
for kerfs.
6. Place workpiece
against
fence.
7. Lower pawls to clear fence or
workpiece, whichever is higher, by 1/8".
46
Kerr
Crosscutting
8. Plug saw in.
9. Put yellow
key
in switch.
10. Grasp and hold onto saw handle,
then turn saw on.
Yellow Key
11. Hold workpiece
down and against
fence, keeping hand at least 6" away
from blade.
Fence
Workpiece
12. Hold hand in straight line with saw
handle and pull blade through fence
and Vcorkpiece only far enough to complete cut, and never more than half
diameter of blade.
13. Push blade carriage to rearmost position, behind fence, and turn saw off.
Continue to hold saw handle until blade
stops spinning.
14. Remove
yellow
key and unplug
saw.
47
Crosscutting
Making Bevel and Compound
Crosscuts
Bevel
Follow these steps to make bevel and
compound
crosscuts.
1. Check that saw is unplugged,
"off" and yellow key is Out.
2. Put fence between
spacer
board.
Index
Pin
switch is
front table and
Tighten
table clamps.
3. Turn elevation handle counter-clockwise to raise radial arm so blade will not
L(
o/ lt
oove,.o°
jam into table top when bevel is set.
4. Unlock
bevel lock. Slide bevel index
pin to right and set bevel angle. Release
pin and lock bevel lock.
5. Move arm to desired miter position.
Lock miter and swivel locks.
Lock
\
6. Unlock rip lock and push blade carriage to rearmost position, behind
fence.
7. Lower blade into kerf, but not touching kerf bottom. Blade should move
freely. If there is no kerf in table for
path you want to cut, make one following instructions
for kerfs.
8. Place workpiece
48
against fence.
Miter
Index
Pin
Crosscutting
9. Lower pawls to clear fence or
workpiece, whichever is higher, by v'8".
10. Put yellow key in switch.
11. Grasp and hold onto saw handle,
then turn saw on.
Bevel Angle
12. Hold workpiece down and against
fence, keeping hand at least 6" away
from blade.
13. Hold hand in straight line with saw
handle and pull blade through fence
and workpiece only far enough to complete cut, and never more than half
diameter of blade.
14. Push blade carriage to rearmost position, behind fence, and turn saw off.
Continue to hold saw handle until blade
stops spinning.
15. Remove
Repetitive
yellow key and unplug
saw.
Crosscutting
Repetitive
crosscutting
is the repeated
and continuous
cutting of many pieces
of lumber to the same length with the
saw_placed in the crosscut position.
See Accessories
for information
on a
lower blade guard for use in repetitive
90 ° (0 miter) crosscutting.
Use a carriage stop to define distance
needed to pull blade through to cornplete each cut. To make a carriage stop:
1. Cut piece of lxl lumber
2. Clamp
piece
on right
the radial
arm, so that blade
at distance
needed
that clamp
does
inside
to complete
not interfere
grip on saw handle.
to 2" long.
Re-adjust
surface
carriage
of
stops
cut. Check
with hand
if needed.
49
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, a set distance from the
fence. A solid fence (no kerfs) serves as
a guide for the workpiece.
Middle Fence Position
l
r:
""
s I
A A
LI
Rear
Fence
Position
gl
Front
Fence
Position
Place the fence the in front, middle, or
rear position. Generally,
the front position is for narrower workpieces,
the rear
for wider workpieces.
In-Rip and Out-Rip Positions
In-rip and out-rip
tion.
refer
to blade posi-
In-rip: the blade is toward the fence,
and the motor is toward the table front.
Hold
Down
In-rip is recommended
because this
position allows better visibility of the
workpiece
and your hands.
Side
Out-rip: the blade is toward the table
front, and the motor is toward the fence.
Use out-rip only for cutting workpieces
wider than 13".
Infeed and Outfeed
refer
In-Rip Position
Directions
Infeed
blade.
and outfeed
to sides of the
Infeed:
the side of the blade where
the
hold down is. Always start a rip cut at
the infeed side and push the workpiece
through to the outfeed side.
Ouffeed:
the side of the blade where
the
pawls and spreader are. Never start a
rip cut at the outfeed side. This is wrong
way feed.
Hold
JJ
Side
Infeed
__
I',,_, Out-Rip
5O
Down
Position
Ripping
Workpiece
Positioning
Always set up so that the widest part of
the workpiece is between the blade and
fence. For example, if you want to rip 1"
off a 10" wide workpiece, set the saw
blade 9" from the fence.
Widest Part
of Workpiece
Push Sticks and Push Blocks
Push sticks and push blocks are used instead of the hands to push the
workpiece through to complete the cuts.
A push block is used with an auxiliary
fence. See Cutting Aides.
Push Stick
Use a push stick when the space between the blade and fence is 2" or more.
2" or More
Use a push block and auxiliary fence
when the space between the blade and
fence is v'2to 2".
Do not make rip cuts when space between blade and fence is narrower than
1/2 _1•
,,2,,,02,,
51
Ripping
Ripping Safety
The hazards associated with ripping are
outfeed zone hazard, kickback, wrong
way feed, and thrown chips. This section
explains these hazards and tells how to
avoid them or reduce the risk of their
happening.
formation
Read the ripping safety inand instructions
before
making any type of rip cut. Follow these
steps every time you make a rip cut.
Outfeed
Zone Hazard
DANGER:
Rotational
force of blade will pull
hands and fingers back into blade.
Touching,
holding,
or pulling on
outfeed
side of workpiece
can
result in fingers, hand or arm being
cut off.
To reduce risk of outfeed hazard:
1. Lower and correctly set pawls and
spreader. They act as a partial barrier
outfeed side.
2. Start and finish cut from infeed
of blade.
3. Keep both hands on infeed
blade.
side of
4. Keep hands away from outfeed
of blade.
5. Push workpiece
through
cut. Do not pull workpiece.
side
side
to complete
6. If blade jams, turn saw off, remove
yellow key, wait for blade to stop spinning, then free blade.
52
to
DANGER
Ripping
Kickback
Kickback is the uncontrolled
propelling
of the workpiece back toward the user
during ripping.
_WARNING:
Kickback
pinched
Pinching
when:
can happen when blade is
or bound by workpiece.
or binding can happen
WARNING
• pawls and spreader are not used or
not set correctly
• spreader is not aligned with blade
• blade is not parallel to rip fence
• edge of workpiece is not in contact
with rip fence at all points, or is not
straight
• workpiece is twisted or warped and
rocks on table top
• feed pressure is put on part of
workpiece away from fence
• workpiece is released before being
pushed past the pawls and spreader
• user reaches for, touches, or tries to
pull the workpiece through the outfeed
side of the saw
• making
non-through
cuts
53
Ripping
To reduce
1. Correctly
Spreader
set pawls
keeps
or pinching
workpiece
one
risk of kickback:
and spreader.
workpiece
blade;
pawls
from
grab
binding
into
to stop or slow kickback
if
happens.
2. Check that spreader is in line with
blade. See Alignment and Adjustment.
3. Cut only straight workpieces
so surface will lie flat on table and edge will
stay tight against fence. If you must cut
an irregular workpiece, attach a straight
edge. See Cutting Aides.
4. Apply feed pressure to part of
workpiece
next to fence.
5. Push workpiece through from infeed
to outfeed side until it passes pawls and
spreader.
6. Keep hands away from outfeed
of blade.
side
7. If blade jams, turn saw off, remove
yellow key, wait for blade to stop spinning, then free blade.
8. When cutting composition materials,
put rough side up so pawls will grab.
9. Avoid cutting
like knots.
through
10. Use featherboard.
Aides.
See Cutting
11. Stand out of workpiece
54
very hard areas
path.
Ripping
Wrong
Way Feed
Wrong way feed is ripping by feeding
the workpiece into the outfeed side of
the blade.
&WARNING
_WARNING:
Rotational
force of blade will pull
workpiece
through
violently
if
workpiece
is fed in same direction
as blade rotates (wrong way feed).
Hands and fingers can be pulled
along with workpiece
into spinning
blade before you can let go or pull
back. Fingers, hand or arm could be
cut off. Propelled workpiece
could
hit bystander.
To eliminate risk of wrong way feed:
1. Feed workpiece
tion.
Wrong Way Feed
against blade rota-
2. Set pawls and spreader. They act as a
partial barrier to outfeed side.
Thrown
Workpiece
or Blade Chips
_WARNING:
The
saw
workpiece
can break
lently.
can violently
throw
chips. Pieces of blade
off and be thrown viol-
To reduce
blindness:
risk
of eye
injury
& WARNING
and
1. Wear safety goggles labeled "ANSI
Z87.1" on package. Regular eyeglasses
are not safety goggles.
2. Check blades
for damage.
3. Keep saw table clean and clear of all
objects except workpiece
to be cut and
necessary fixtures, clamps or featherboards.
55
Ripping
Pawls and Spreader
The pawls
rectly
and spreader
during
of kickback,
ripping
to prevent
Function
must
to reduce
wrong
be set corthe risk
way
feed,
and to act as a partial barrier to the hazardous outfeed side of the blade.
The spreader
kerf to keep
chances that
spring closed
Pinching the
back.
tides in the workpiece
it open. This reduces the
the cut workpiece
will
and pinch the blade.
blade is a cause of kick-
The pawls rest level on the upper surface of the workpiece. During cutting
they allow the workpiece
to pass freely
from the infeed to the ouffeed side, but
help stop the kickback motion from outfeed to infeed side by grabbing into the
workpiece
surface.
Spreader
Infeed
Side
Pawls
Outfeed
Side
The spreader and pawls must be re-set
each time a different thickness
workpiece
is cut. Follow the Ripping
Set-Up Procedure
to correctly set the
pawls and spreader.
Hold Down Function
The hold down must be set correctly
during ripping to act as a partial barrier
against the in_feed side of the blade, and
to help keep the workpiece flat on the
table. It must be lowered and set to just
clear the workpiece.
The hold down must be re-set each time
a different thickness workpiece is cut.
Follow the Ripping Set-Up Procedure
to correctly set the hold down.
56
Down
Ho,\
Infeed
Side
Outfeed
Side
Ripping
Ripping Checklist
Refer to the following checklist before
making rip kerfs or ripping. It will
remind you of things to do to make your
cutting safer.
Ripping Checklist
1. Prevent accidental start-up.Saw
unplugged, switch "off', and yellow key
out until ready to make actual cut.
10. Swivel, rip, miter, and bevel locks
locked; table damps tightened.
2. Safety goggles on.
4. Fence solid (no kerfs), and secured
in slot. Workpiece
can snag on a fence
kerf.
12. Use push block and auxiliary fence
when space between blade and fence is
1/2to 2". Do not make rip cuts when
space between blade and fence is narrower than 1/2".
5. Installed
workpiece,
13. Use push stick when space between
blade and fence is 2" or more.
3. Blade sharp and correctly
6. Follow
installed.
fence at least half as high as
and never less than 3/4".
ripping
set-up
procedure.
7. Pawls set to rest level on workpiece.
8. Spreader in line with blade
ride in workpiece kerr.
9. Hold down lowered
w-orkpiece.
and set to
to just clear
Ripping Hints
11. Both hands always on infeed
14. Push until workpiece
and spreader.
15. Use table supports
workpieces.
side.
is past pawls
for long
16. Use featherboard.
17. Saw off and blade stopped spinning
before reaching for cut workpiece.
4. Use the right blade
for each job.
1. To extend the life of the table top,
make an additional top out of 1/4"
plywood. Clamp or nail to original table
top, section by section. If you use nails,
nail in four corners where blade cannot
contact nails.
5. For workpiece with one smooth and
one rough surface, cut with rough surface up so pawls will grab better.
2. Keep table clean of chips and sawdust.
7. If you must cut an irregular
workpiece, attach a straight edge. See
Cutting Aides.
3. Use sharp blades.
6. To keep cut line accurate, periodically check blade alignment.
57
Ripping
Kerfs
A kerf or shallow cut is needed
in the
table 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 position.
Follow
these steps to make a kerf:
1. Check that saw is unplugged,
"off', and yellow key is out.
switch is
2. Put solid (no kerfs) fence in desired
position and tighten table clamps.
3. Index arm to 0° miter position.
miter lock.
4. Set desired
bevel lock.
Lock
Swivel Lock
bevel angle and lock
5. Unlock swivel lock, press and hold
swivel index pin and set blade to rip
position. Release swivel index pin, and
lock swivel lock.
Swivel
=====_,
58
Ripping
6. Unlock rip lock, position blade
desired distance from fence, and lock
rip lock.
Rip
In-Rip Position
7. Turn elevation
handle
clockwise
to
lower blade until it just clears table.
8. Plug in saw, put yellow key in switch
and turn saw on.
9. Slowly turn elevation handle clockwise until blade touches table, then continue to turn another half turn.
*_WARNING:
For workpieces
v4" thick or less,
turn elevation handle a full turn after
the blade just touches table. Deeper
kerr will keep saw blade from rising
up on top of workpiece and violently
throwing it.
10. Turn switch off, remove
unplug saw.
yellow key,
59
Ripping
Ripping Set-up Procedure
Follow
steps
ferent
these
must
steps
before
be repeated
thickness
ripping.
each
workpiece
These
time a difis ripped.
1. Check that saw is unplugged,
"off', and yellow key is out.
switch is
2. Put solid (no kerfs) fence in desired
position and tighten table clamps. (Insert auxiliary fence if space between
blade and fence will be 1/2to 2".)
3. Index arm to 0° miter position and
lock miter lock. Set desired bevel angle
and lock bevel lock.
4. Unlock swivel lock, press and hold
swivel index pin, and set blade to in-rip
position. Lock swivel lock. (Set to outrip position only if overall workpiece is
wider than 13".)
5. Unlock rip lock, set blade desired distance from fence, lock rip lock. Always
set blade so wider part ofworkpiece will
be between blade and fence.
6. Ready ' push stick if space between
blade and fence is 2" or more. Ready
push block if using auxiliary fence.
7. Lower blade into kerf, but not touching kerf bottom. Blade should move
freely. If there is no kerr, make one following instructions
for kerfs.
8. Place workpiece on saw table, parallel to and up against blade.
9. Unlock
clear
and set hold
workpiece
surface,
down
then
to just
lock.
Pawls/Spreader
Hold
Down
Hold
10. Unlock and set pawls/spreader so
spreader hangs along side ofworkpiece,
in line with blade, and pawl rests level
on workpiece surface, then lock.
6O
In-Rip
Position
Down
Lock
Ripping
11. Test spreader/pawl
setting by pushing workpiece toward outfeed side to
see that workpiece moves freely, then
pulling toward infeed side to see that
pawl grabs. If these conditions are not
met, repeat steps 10 and 11 until they
are. Correct setting of pawls/spreader
reduces risk of kickback.
Testing Kickback
Push
Pawls
Pull
12. Use table extension of same height
as saw table to support cut workpiece.
If
you do not, cut workpiece will sag and
could put binding pressure on blade, a
cause of kickback. Support outer ends
of extensions. Do not use another person to support workpieces because this
can cause kickback.
13. Remove
workpiece
from table.
61
Ripping
Making Rip Cuts
Follow these steps to make rip cuts:
1. Follow ripping
set-up
procedure.
2. Plug in saw, 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.
Fence-
4. Place workpiece on table, keeping
workpiece
edge against fence.
5. Place one hand flat on workpiece
next to fence.
6. Place other
hand behind
and
first so
fingers are out of blade path, and as
close to fence as possible.
7. Push workpiece under hold down and
into blade, putting pressure on part of
workpiece
between blade and fence. If
you put pressure on part of workpiece
between blade and table front, blade
could be pinched and workpiece will
kickback.
8. As end of workpiece
approaches
hold
down, use push stick or push block on
section between blade and fence, to
push until workpiece
is completely past
pawls/spreader.
9. Turn saw off and wait for blade
stop spinning
workpiece.
10. Remove
62
before
to
touching
yellow key and unplug
saw.
"_
_rkpiece
Cutting Aides
Cutting
aides
include
sticks,
auxiliary
featherboards,
fences,
fences,
and
push
straight
push
blocks,
edges.
Fences
Fences
tions.
are required
for all saw opera-
Crosscutting
requires fences with kerfs
(slots) to match the path of the saw, because the saw blade is pulled through
the kerr in the fence to cut the
workpiece.
Ripping requires a solid fence with no
kerfs or slots, because the fence serves
as a guide for the workpiece being
pushed into the saw blade.
_WARNING:
If workpiece is pushed along fence
with
kerfs,
workpiece
can get
caught on kerr, pinch blade and
cause
kickback.
Do not use
crosscutting
It is a good
crosscutting
fence for ripping.
idea
to have
fence
you rise the same fence
kerfs,
the fence
on the angle,
broad,
kerfs
than one
because
if
with too many
will weaken.
bevel
and may overlap
To make
more
on hand,
Depending
can be very
other
kerfs.
a fence:
1. Use 3/4"knot free lumber cut to 30".
Do not use particle board or other composite materials because they are not
strong enough. Note: Installed fence
must be at least half as high as the
workpiece, and never less than 3/4".The
fence can be as high or higher than the
wor_iece.
63
Cutting Aides
Push Sticks
Push sticks must be used during ripping
to push the workpiece through to complete cuts that would bring your hands
too close to the blade. Use a push stick
when the blade is set 2" or more from
the fence.
45_/_Less
To make
1. Use
a push
_a" solid
2. Cut a piece
(knot
free)
Thickness of Workpiece
up to 3/8"
lumber.
15" by 1_".
3. Cut a 45 ° notch
Auxiliary
Than
stick:
in one
end.
Fence and Push Block
An auxiliary fence must be used when
making very narrow rip cuts that don't
allow enough room for a push stick
without bringing it too close to the
blade. Use an auxiliary fence when the
blade is set 1/2 to 2" from the fence. Do
not make rip cuts when the space between the blade and fence is narrower
than v2".An auxiliary fence must always
be used with a push block.
To make
an auxiliary
fence:
1. Use one piece of _/8"plywood and two
pieces of a/4"plywood.
3/4" Plywood
2. Cut the _'8"plywood
to 30" by 51/2".
3. Cut one piece of a/4"plywood to 30"
by 3_", and the other to 30" by 21/4".
4. Glue two 3/4"plywood pieces together
so they line up square on an edge.
5. Glue the _/8"plywood piece at right
angle to and flush against edge of the
21/4"wide a/4"plywood.
6. Reinforce
64
with nails.
This Face And
This Edge Must
Be Parallel
3/8" Plywood
Cutting Aides
To make a push block:
3/4" Plywood
1. Use one piece of 3/4"plywood
piece of 3/8"plywood.
2. Cut the 3/4" plywood
and one
to 10" by 5".
10
5
3. Cut a triangular piece off each of two
corners by marking with a pencil in and
down 1!/4"from the corners and cutting
along the diagonal formed by joining
the points.
4. Cut the 3/8"plywood
x
1-1/4"
to 10" by 5v'8".
5. Cut out an 8" by 3/8"notch from the
10" side of the 3/8"plywood.
6. Glue the 3/4"plywood on top of the 3/8"
plywood so that their 10" sides are
square.
3/8" Plywood
!
I
_,
II 3/8
3/8 "" '
7. From notch cut out in step 5, cut a
piece of 3" plywood to 2", and glue it to
underside
of the a!8"plywood, in line
with edge that sticks out. Do not use
nails because if you accidently cut into
push block with saw blade, nails will
dull blade.
8. Lay the push block on top of auxiliary
fence-to make sure their widths match
exactly, and are each 43/4".
Featherboard
Use a featherboard
during ripping to
help keep the workpiece
against the
fence. 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 (outfeed side) of
the workpieee. If clamped to the outfeed
side, the featherboard can squeeze the
65
Cutting Aides
kerf closed, put binding pressure
blade, and cause kickback.
on the
To make a featherboard:
1. Use solid (knot free)
wide.
2. Miter crosscut
3/4"lumber
5v2"
5-1/2
at a 30 ° angle to 24".
3. Rip to make 5" long cuts about 1/4"
apart.
4-1/2
Straight Edge for Irregular
Workpiece
If the workpiece you want to rip does
not have a straight edge, attach a
straight edged board to the workpiece.
_WARNING"
If you try to rip an irregular
workpiece,
it could bind blade and
cause kickback.
To attach a straight
1. Place irregular
against fence.
edge:
side of workpiece
2. Place straight edged board
workpiece
and against fence.
on top of
3. Tack straight edged board to
workpiece. Straight edged board must
not extend beyond leading end of
workpiece and should cover workpiece
width only enough to pass between
blade and fence.
4. Use fence at least as high as combined heights of workpiece
and straight
edged board.
66
Accessories
Accessories
Safety
• the blade is in its rearmost
and
1. Use only accessories
listed in this section. Use of any other accessory or attachment might increase the risk of
injury to you or others.
2. Follow
structions
accessory manufacturer's
on proper and intended
inuse.
DANGER"
Use of grinding wheels, abrasive or
cut off wheels, or wire wheels is
dangerous because they can break
explosively
and throw pieces. You
can be blinded
or receive
a life
threatening
puncture
wound. Do
not use grinding wheels, abrasive/
cut off wheels or wire wheels.
Lower
Blade
The following safety information
and instructions apply to all blades and accessories.
The lower blade guard is required by
the Occupational
Safety and Health Administration
(OSHA) if the radial saw is
used commercially.
The lower blade
guard is intended for use only in repetitive 90 ° crosscutting.
repeated
many
length
crosscut
90 ° crosscutting
and
pieces
continuous
of lumber
• the guard is resting on the table so
the leading and trailing teeth of the
blade are not exposed from the sides.
The lower guard ONLY provides
protection
against minor lacerations
and bruises that occur from contact
the fiat sides of the spinning blade.
with
_WARNING:
Lower blade guard will not provide
any protection 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.
_WARNING:
Guard
Repetitive
position
is the
cutting
of
to the same
with the saw placed
Remove lower blade guard for ALL
other types of cuts except repetitive
90 ° crosscutting.
Using lower guard
other
than
for repetitive
90 °
crosscutting
will increase
risk of
certain hazards:
• During rip and bevel cuts, the
workpiece or narrow cut-off pieces can
be pinched between the guard and the
blade. Workpiece or cut-off pieces can
kickback.
• In the bevel position the blade teeth
are fully exposed. Fingers or hand can
be cut off.
in the 90 °
position.
In repetitive 90 ° crosscutting,
the guard
may reduce the chance of accidentally
touching the blade from the side. This
protection
is possible ONLY when:
• Cut off pieces can jam between the
guard and blade. Turn saw off and wait
for blade to stop before freeing a
jammed guard or blade.
67
Accessories
Mounting
Radial Saw to Leg Set
No. 9-22244
• Workpiece
or cut-off pieces can be
violently thrown by the blade. Wear
safety goggles
Table Rail
CAUTION:
Lower
blade guard
can get caught
or jam in fence or table kerfs.
Read and follow the warning
lower outer guard:
on the
Note: Bolts pass thru the second and
third holes in the table rails. Do not use
the first hole.
WARNING:
To avoid injury shut off
power before clearing a
jammed lower guard
o
(_
0
0
0
©
o
CD
o
Accessories
for this
c:3
D
Catalog
.I
with 5/8"
See Catalog
Taper
Jig ..................................
See Catalog
Dado
Set ..................................
See Catalog
Leg Set ...........................................
Books
9-22244
Power
.............
How
0 0
15"
No:
hole) .........................................
Tool Know
0 0
I
o
FRONT OF RADIAL SAW
........................................
(8t/4" diameter
UP
o
that come with accessory.
Saw blades
10"
Saw
These accessories
are designed to fit
this saw. Read and follow instructions
Item
CD
C)
Handbook
.......................................................
9-29117
Guards
Lower
Retractable
Guard*
Repetitive
Crosscut
*See the information
about the lower
section.
For 90 °
Front
Side
Only ............... 9-23473
and instructions
retractable
guard
in this
CATALOG
NO. 9-22244
LEG SET
(not included with radial saw)
Recommended
hardware (not included) for
Mounting Radial Saw to Legset:
4 -- 1/4-20 x 1-1/2 hex head bolts
41/4-20 hex nuts
4 -- 1/4 lock washers
4 -- 1/4 fiat washers
Attach radial saw to holes indicated.
68
Maintenance
_Ib WARNING:
Lubrication
To avoid shock, burns, or lacerations from
accidental
start up of
saw, turn power switch off and unplug saw before doing maintenance
or servicing saw.
General
Information
When new, the saw requires no lubrication. The saw has been partially aligned
and all bearings are lubricated
and
sealed for life. In time, in order to keep
the saw in good working order, it will be
necessa U to clean, lubricate and realign.
Replacing
Pawls
Do not lubricate motor bearings. Motor
bearings are sealed and do not need
added lubrication.
You can lubricate other points if necessary, but only when sticking or binding
occurs.
Adjustments
Bevel
for Wear
Lock
The bevel lock needs adjustment
if the
motor can be moved by hand when the
bevel lock is locked. To make adjustment:
Make sure the teeth of the antikickback
1. Use t!8"hex wrench
panels are always sharp. If they become
dull they must be replaced. To replace:
under right corner (pivot point) of bevel
lock just enough to allow bevel lock
lever to drop down. (See figure 2,
Repair Parts.)
1.Use v_2"wrench
or socket
to remove
s/16"hex nut and old pawls.
2. Assemble
and spreader
new antikickback
to bar.
pawls
3. Align spreader to blade according to
instruvtions
in Alignment
and Adjustment.
Cleaning
Periodically
remove any heavy build-up
of sawdust that may accumulate
on the
saw. The absorbing tendency of sawdust
will draw lubricants away from the areas
where they are needed. Wipe the carriage bearings and track surfaces with a
dry or lightly oiled cloth.
To avoid motor damage due to sawdust
build-up, which interferes with normal
motor ventilation,
blow out or vacuum
the motor often.
to loosen screw
2. Use bevel lock lever as wrench
crease locking characteristics.
to in-
3. Test lock for desired locked/unlocked
condition. Repeat step 2 if necessary.
4. Tighten
screw.
Swivel Lock
The swivel lock is a friction
lock that
prevents play between the yoke and carriage (#41 and #12, figure 2, Repair
Parts). It needs adjustment
if the lock
handle has to be moved more than 90 °
to lock. To make adjustment:
1. Use 15/1#wrench to tighten
figure 2, Repair Parts).
2. Test lock, and repeat
nut (# 1,
step 1 as needed.
69
Maintenance
Carriage
Bearings
The carriage should roll freely but with
some resistance for the entire length of
travel. If the carriage moves too freely
or with too much resistance,
the bearings need adjustment.
To adjust, follow
the instructions
under Carriage Bearings in Alignment
and Adjustment.
Miter Lock
Hold Down and Pawls/Spreader
Locks
If the hold down or the pawl/spreader
do not hold when locked, or if the lock
lever has to be turned more than 90 ° to
lock, the lock needs
make adjustment:
adjustment.
To
1. Lock hold down or pawls/spreader
lock. Use screwdriver to pop out "e" ring.
If the radial arm can be moved by hand
when the miter lock is locked in an unin-
2. Remove lock handle and re-position
at 90°.
dexed position, the lock needs adjustment. To adjust, follow the instructions
under Miter Lock Assembly.
3. Re-insert
4. Check
"e" ring.
that hold down or
pawls/spreader
unlocked.
move freely when lock is
Motor
To avoid motor damage due to sawdust
buildup, which interferes
with normal
motor ventilation,
blow out or vacuum
the motor often.
7O
Maintenance
Motor
Brush Assemblies
The motor
brush assemblies
that come
with the saw will last about 100 cutting
hours. Replace both carbon brushes
when either has v4" length or less of
carbon left. To inspect brushes:
1. Check that saw is unplugged,
"off', and yellow key is out.
2. Remove
Motor End
Cap
switch is
two screws that hold motor
end cap in place, and take off end cap.
Screwdriver
3. Use fiat head screwdriver to gently
pry each motor brush assembly forward.
Rotate slightly to remove.
Motor Brush
Assembly
Motor Brush
4. Inspect length of brush. If length of
either brush is v'4"or less, replace both
with new assemblies; otherwise, put
back same assemblies.
5. Re-install
motor
end cap and screws.
1/4" or Less
71
Maintenance
Blade Changing
To change
steps:
the saw blade,
follow these
1. Check that saw is unplugged,
"off", and yellow key is out.
switch is
2. Unlock rip lock, pull blade carriage
out to end of radial arm, and lock rip
lock.
3. Unlock swivel lock, depress swivel
index pin, and put blade in out-rip position (motor toward fence). Lock swivel
lock.
4. Loosen
coverplate
5. Use
coverplate
screw and rotate
out of way.
both
blade
tion to loosen
left hand
blade
wrenches
in scissor
nut. Note:
ac-
Nut has
threads.
6. Remove nut, blade collar, and blade.
Insert new blade, making sure that
blade rotation arrow points in same
direction as arrow on guard points.
7. Re-install
blade
collar
and nut.
Tighten
nut. Note: Do not overtighten
nut because this can cause blade collar
warp and blade
to wobble
Loosen
during
to
cutting.
8. Rotate coverplate
back into position
and tighten coverplate
screw.
_WARNING:
Never
use the saw without
the
coverplate
securely
in place.
It
keeps the nut from falling off if it
accidentally
loosens, and prevents
the spinning blade from coming off
the machine.
72
Troubleshooting
Motor Problem
Possible
Motor
Excessive feed rate when
crosscutting
or ripping
Slow rate of feed
Improper
Clean out sawdust from
motor to allow normal air
circulation
overheats
or stalls
Blown fuses or tripped
circuit breakers
What to Do
Cause(s)
motor
cooling
Undersized
extension
Inadequate
house wiring
Need
Motor
cord
15 amp circuit
overload
Check wire gauge chart
Electrical Connections
in
Call your electrician
Check that house has adequate wiring. Call your
electrician
Check blade alignment
Slow rate of feed
Low voltage
Check voltage. Normal
loads can be safely handled
at 10% above or below
nameplate
voltage; heavy
loads need same voltage at
motor terminal as on
nameplate
Cutting Problem
Possible Cause(s)
What to Do
Inaccurate
Loose
Check miter, rip, bevel, and
swivel locks. See Adjustments for Wear
cut
locks
Saw blade
out of alignment
Check
alignment
73
TroubleshoOting
Cuffing Problem
Crosscuts
miter
not accurate
indexed
Possible
at
positions.
Crosscut travel not square
with fence
See Squaring Blade
Crosscut Travel
Arm not indexing properly
See Miter Lock Assembly
Carriage
arm
See Swivel Lock or Carriage Bearings Adjustment
assembly
Keep front table clean
Fence
Replace fence
not straight
Table not parallel
radial arm
Saw cuts
Blade
bevel
Workpiece
kerf rough with
tooth marks from blade
Blade tends to advance
through workpiece too fast
during crosscutting
74
loose on
Sawdust between
workpiece and fence
Depth
of cut varies from
one end of workpiece
to
other
at slight
What to Do
Cause(s)
See Leveling
Table
the Front
See Squaring
Table
Blade to
Table not parallel to radial
arm
See Leveling
Table
the Front
Bevel lock loose
See Adjustment,
Lock
Work table not flat
Replace
Blade not square
See Squaring Blade to
Fence
not square
with
to table
to fence
Bevel
table
Using improper blade for
desired finish cut
Use proper smooth-cutting
blade
Blade dull
Sharpen
User pulls blade through
workpiece too fast
Pull blade slowly and steadily through workpiece
or replace
blade
Troubleshooting
Possible Cause(s)
What to Do
Board pulls away from
fence during ripping
Blade out of alignment
Check
Workpiece
strikes spreader
during ripping
Spreader not in line with
blade
See Alignment,
Workpiece
binds, smokes,
and motor slows or stops
when ripping
Saw blade
Check alignment
Cutting
Problem
out of alignment
Dull or incorrect
Fence
blade
not straight
Warped
workpiece
Carriage
assembly
alignment
Spreader
Sharpen
or replace
Replace
fence
Do not cut severely
pieces
loose
See Adjustment,
Bearings
blade
warped
Carriage
Feed rate too fast
Slow feed rate
Saw Problem
Possible Cause(s)
What to do
Radial-arm
moves when
locked in an un-indexed
miter position
Miter lock needs adjustment
See Miter Lock Assembly
Motor moves when bevel
lock is locked
Bevel lock needs
ment
See Adjustment,
Lock
adjust-
Bevel
75
TroubleshoOting
Saw Problem
Possible Cause(s)
What to Do
Blade carriage does not
travel smoothly on arm
Dirty track
Clean track
Bad bearing
Replace
Bearing
See Adjustment,
Bearings
Table
cannot be leveled
Blade does not stop spinning within 15 seconds after
saw is turned off
76
set too tight
bearing
Carriage
Worn arm track
Replace
Rip lock too tight
See Adjustment,
Base has shifted
Remove front table.
Loosen four bolts thaf hold
base to frame. Follow steps
under Making Radial Arm
Parallel to Frame in Assembly section. Then realign saw
on frame
radial arm
Rip Lock
Blade nut loose
Tighten
Internal
Take saw back to Sears for
service
damage
blade nut
Note: This
page intentionally
left blank.
77
\\
\
\
13
10
I
/
Repair Parts
PARTS LIST FOR 8 1/4" RADIAL ARM SAW MODEL NO. 113.234701
Always order by Part Number -- Not by Key Number
FIGURE
Key
No.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
STD512510
60128
818745
818703
818693
818744
3540
819447
818746
818928
STD551125
STD541025
818747
818929
806150-2
16
809019-1
17
455722
1
Description
Key
No.
Part
No.
*Screw-Pan Hd 1/4-20 x 1
Washer- 17/64 x 5/8 x 1/32
Table-Rear
Table-Spacer
Fence-Rip
Table-Front
Wrench
Grip
Lever-Tube Locking
Mount-Table Angle
* Lockwasher- 1/4
* Nut-Hex 1/4-20
Rail-Table
Stiffener Rail
Screw-Truss Hd
5/16-18 x 5/8
Bolt-Rd Hd Short Neck
5/16-18x 1/2
Bolt-Rd Hd Short Neck
5/16-18 x 3/4
18
19
20
21
22
23
24
25
818161
9418304
STD551131
STD541031
818162
STD541050
818702
816333-2
26
815865-1
27
28
29
30
31
818762
STD581037
818719
STD5712O7
820005
SP5570
Description
Shoe-Table Clamp
Washer-21/64 x 3/4 x 1/32
* Lockwasher-5/16
* Nut-5/16-18
Screw-Clamp
*Nut-Hex Jam 1/2-13
Retainer-Nut
Screw-Pan Hd TY "TT"
10-32 x 3/8
Screw-Hex Wash Hd
1/4-20x3/4
Base
* Ring-Retaining 5133-37
Spring-Miter Index
*Pin-Roll 1/8 x 3/4
Pin-Miter Index
Owners Manual
(Not Illustrated)
* Standard Hardware Item -- May Be Purchased Locally.
±Stock Item -- May Be Secured Through The Hardware Department Of Most Sears Retail Stores Or Catalog
Order Houses.
79
Repair Parts
PARTS LIST FOR 8 1/4" RADIAL
ARM SAW MODEL NO. 113.234701
FIGURE
2
48
47_
46_
49
45_
\
44_
11
10
12 NOTE HOLE & SLOT
POSITIONS
17
/
18
19
2O
,/
31
22
24
23
8O
49
22
21
Repair Parts
PARTS LIST FOR 8 1/4" RADIAL ARM SAW MODEL NO. 113.234701
Always order by Part Number -- Not by Key Number
FIGURE
Key
No.
Part
No.
1
2
3
STD541462
60047
815865
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
818883
805644-6
818900
818902
STD551012
802279-1i
821186
818901-1
818749
63658
818713
818710
820013
818733
802884-25
818726
810232-1
141594-47
22
23
STD551225
816333-2
24
431957
25
818757
Description
*Nut-Lock 5/8-11
Washer-.630 x 1 x 1/32
Screw- Hex Washer Hd
1/4-20 x 1/2
Catch-Safety
* Ring-Retaining 5131-43
Wrench
Nut-Hex Double Lead 1/4-20
*Washer-17/64 x 9/16 x 1/16
Bushing
Lock-Rip
Screw-Rip Lock
Plate-Index
Spring-Index
Pin-Index
Grip
Nut-Square L.H. 5/16-18
Cam-Bevel Index
Grip
Scale-Bevel
Handle-Yoke
* Screw-Soc Cap
1/4-20 x 2
* Lockwasher- 1/4
Screw-Pan Hd TY"T"
10-32 x 3/8
* Screw-Soc Cap
1/4-20 x 1-5/8
Ring-Index
2
Key
No.
Part
No.
26
27
28
818711
STD55121
806214
29
805797-1
30
31
32
33
34
35
36
9418304
818765
808380-7
818714
818722
818708
806828
37
38
39
40
818712
818886
818717
817398-1
41
42
43
44
45
134556-1
STD551131
818882
821188
STD551031
46
47
48
49
37386
62636
818887
60442
Description
Lever-Bevel Lock
* Lockwasher-lnt N 10
*Screw-Soc Button Cap
10-32 x 5/8
Screw-Hex L.H.
5/16-18 x 2-3/4
Washer-21/64 x 3/4 x 1/32
Yoke
Screw-Pan Hd 10-14x 1/2
Plate-Bevel
Nut-Double
Pin-Yoke Index
Screw-Round Hd TY"TT"
1/4-20 x 1/2
Lever
Stud-Yoke Clamp
Spring-Yoke Index
*Screw-Soc Cap Lock
1/4-20 x 5/8
Nut-Hex Jam 5/16-18
* Lockwasher-Ext 5/16
Indicator-Rip
Carriage
*Washer
21/64 x 5/8 x 1/32
Bearing-Carriage
Nut-Square 1/4-20
Eccentric
Washer-17/64 x 7/16 x 1/16
* Standard Hardware Item -- May Be Purchased Locally.
_ Stock Item -- May Be Secured Through The Hardware Department Of Most Sears Retail Stores Or Catalog
Order Houses.
81
Repair Parts
PARTS LIST FOR 8 1/4" RADIAL ARM SAW MODEL NO. 113.234701
FIGURE
43
3
1
41
40
36_
39
I
I
38
37
10
20
21
2_
30
\
F
23
22
24
/
29
24
27 MARKING
('P') UP
28
82
Repair Parts
PARTS LIST FOR 8 1/4" RADIAL ARM SAW MODEL NO. 113.234701
Always order by Part Number -- Not by Key Number
FIGURE
Key
No.
Part
No.
!
2
3
4
818754
818697
STD375006
819449
5
6
7
8
9
10
11
12
13
14
15
16
17
808380-5
818758
818921
818718
808380
63467
818879
9-22256
816113
818934
STD541008
818881
STD510807
18
19
20
21
22
820092
815868
818773
818880
817398
23
STD525025
Description
Relief-Strain
Cord-Motor
*Connector-Wire
Screw-Hex Washer Hd
TY"TT" 5/16-18 x 1-1/2
Screw-Pan Cr #8
Label Trim R.H.
Arm
Insulator
Screw-Pan Hd 8-16 x 1/2
Cap-Flag Terminal
Trim-Front Arm
_ Key-Switch
Switch-Locking
Housing-Switch
*Nut-Hex 8-32
Bumper-Front
* Screw-Pan Hd
8-32 x 5/8
Cord w/Plug
Relief Strain
Support-Arm
Bumper-Rear
Screw-Soc Cap Locking
1/4-20 x 3/4
*Bolt-Hex 1/2-13 x 2-1/2
3
Key
No.
Pa_
No.
24
25
STD551050
815992-1
26
27
28
29
30
31
32
STD551225
818737
818926
STD541450
818706
818731
816333-2
33
34
35
36
818705
818224
818878
63500
37
38
39
818709
818759
815865-1
40
41
42
43
STD551043
818735
STD551025
815865-2
Description
*Washer-17/32 x I x 1/16
Screw-Soc Cap TY"TT"
1/4-20 x 3/4
* Lockwasher- 1/4
Latch-Arm
Scale-Miter
* Nut-Hex Lock 1/2-13
Gib
Cover Plate-Gib
Screw-Pan Hd TY"TT"
10-32 x 3/8
Tube
Nut-Elevation
Shaft-Elevation
Washer-Thrust
.502 x .927 x .031
Cover-Channel
Label Trim L.H.
Screw-Hex Wash
Hd 1/4-20 x 3/4
*Washer-15/32 x 47/64 x 1/16
Crank
"Washer- 17/64 x 5/8 x 1/32
Screw-Hex Washer Hd
TY"TT" 1/4-20 x 5/8
* Standard Hardware Item -- May Be Purchased Locally.
_-Stock Item -- May Be Secured Through The Hardware Department Of Most Sears Retail Stores Or Catalog
Order Houses.
83
Repair Parts
PARTS
LIST
FOR
8 1/4" RADIAL
1
ARM
SAW
MODEL
NO. 113.234701
2
10
9 /
25
s
11
13
24
14
26
24
13
12
23
20
22
15
18
16
18
21
Always
order
19
by Part Number
FIGURE
Part
No.
Key
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
63258
818741
818742
169123-11
808380-5
803709
355594
819029-!
354653
352813
805644-6
818900
818902
STD551012
Standard
t-
Hardware
Elbow-Dust
Cover-Connection L.H.
Cover- Connection R.H.
Relief-Strain
Screw-Pan Hd#8 x 3/4
Connector-Wire
Brush & Holder
eMotor
Bumper
Cap End
Ring-Retaining 5131-43
Wrench
Nut-Hex 1/4-20 DBL Lead
*Washer-17/64 x 1/2 x 1/32
Item -- May Be Secured
Order Houses.
Through
The Hardware
4
Key
No.
Description
Item -- May Be Purchased
-- Not by Key Number
Part
No.
15
16
17
818738
818756
818895
18
19
2O
21
22
23
24
25
26
STD541231
815815
STD581050
63270
816341
819425
62498
9-32546
816333-2
Description
Bar-Anti Kickback
Guard-Hold Down
Bolt-Crge DBL Lead
1/4-20 x 3/4
* Nut-Hex Jam 5/16-18
Pawl
* Ring- Retaining
Spreader
Bearing
Nut-Brass
Collar-Blade
1 Blade-8-1/4" 44 Tooth
Screw-Pan HdTY"TT"
10-32 x 3/8
Locally.
Department
Of Most Sears
Retail Stores
Any Attempt To Repair This Motor May Create A Hazard Unless Repair Is Done By Qualified
Repair Service Is Available At Your Nearest Sears Store.
84
Or Catalog
Service Technician.
NOTES
85
NOTES
86
Index
Accessories
67
Adjustment
Bevel Lock 69
Carriage Bearings 29, 70
Column Support 30
Hold Down Lock 70
In-rip Scale 37
Leveling Front Table 31
Miter Lock 22, 70
Out-rip Scale 38
Pawls/Spreader
Lock 70
Rip Lock 70
Swivel Lock 69
Alignment
Spreader 36
Squaring Blade Crosscut
Travel 33
Squaring Blade to Fence 35
Squaring Blade to Table 34
Assembly
Arm to Base 18
Base 14
Blade Carriage to Arm 16
Front Table 21
Making Arm Parallel
Frame 19
Miter Lock 22
Table Support
Blades
Changing 72
Safety 9
Carriage Bearings
Carriage Stop 49
Cleaning 69
Crosscutting
Bevel 48
Checklist 43
Compound
Definition
Hints 43
Miter 46
48
40
Repetitive
Safety 40
49
to
20
29, 70
Straight 4
Electrical Connections 39
Extension Cords 39
Featherboard 65
Fences 63
Hints
Crosscutting 43
Ripping 57
Hold Down
Function 27, 56
Setting 27, 60
In-rip 50
Infeed 50
Kerfs
Crosscutting 44
Ripping 58
Kickback 4, 53
Leveling Front Table 31
Locks
Bevel 24
Hold Down 27
Miter 25
Pawls/Spreader 26
Rip 24
Swivel 25
Lubrication 69
Maintenance
Adjustments for Wear 69
Cleaning 69
General 69
Lubrication 69
Motor 70
Motor Brush Assemblies 71
Miter Lock Assembly 22
Motor
Maintenance 70
Motor Brush Assemblies 71
Specifications 39
Out-rip 50
Outfeed 50, 52
Pawls
Pawls/Spreader
Function 26, 56
Setting 26, 60
Power Supply 39
Push Blocks
Making 65
Using 51
Push Sticks
Making 64
Using 51
Ripping
Checklist 57
Definition 50
Hints 57
In-rip 50
Making Rip Cuts 62
Out-rip 50
Safety 52
Set-Up Procedure 60
Workpiece Positioning 51
Safety
Accessories 67
Blade 9
Crosscutting 40
General 3
Personal 5
Ripping 3, 52
Saw 6
Work Area 5
Workpiece 8
Spreader 26
Alignment 36
Squaring Blade Crosscut
Travel 33
Squaring Blade to Fence 35
Squaring Blade to Table 34
Straight Edge 66
Wrong Way Feed 4, 55
Crosscutting Position 40
Replacing 69
87
81/4-1NCH
RADIALSAW
owner's
manual
Now that you have purchased
your 8Y4-inch radial saw,
should a need ever exist for repair parts or service, simply
contact
any Sears Service Center and most Sears, Roebu_ck
and Co. stores. Be sure to provide all pertinent facts when
you call or visit.
SERVICE
MODEL NO.
113.234701
The model
on a plate
number of your 8Y4-inch radial saw will be found
attached
to your saw, at the Rear of the base.
81/4-1NCH
RADIAL SAW
HOW TO ORDER
REPAIRPARTS
WHEN ORDERING REPAIR PARTS,ALWAYS GIVE THE FOLLOWING
iNFORMATION:
PARTNUMBER
PARTDESCRIPTION
MODEL NUMBER
113.234701
NAME OF ITEM
8_/4-1NCHRADIAL SAW
All parts listed may be ordered from any Sears Service Center
and most Sears stores. If the parts you need are not stocked
locally, your order will be electronically
transmitted to a Sears
Repair Parts Distribution Center for handling.
j
J
Sold by SEARS, ROEBUCK AND CO., Chicago,
Part No. SP5570
Form
No, SP5570
IL 60684 U.S.A.
Printed
in USA 1/92