Ryobi BS904, BS904G Manual

INTRODUCTION

This tool has many features for making its use more pleasant and enjoyable. Safety, performance, and dependability have been given top priority in the design of this product making it easy to maintain and operate.

GENERAL SAFETy RULES

Read and understand all instructions. Failure to follow all instructions listed below, may result in electric shock, fire and/or serious personal injury.
READ ALL INSTRUCTIONS

• KNOW yOUR POWER TOOL. Read the operator's manual carefully. Learn the applications and limitations as well as the specific potential hazards related to this tool.
• GUARD AGAINST ELECTRICAL SHOCK by preventing body contact with grounded surfaces. For example: pipes, radiators, ranges, refrigerator enclosures.
• KEEP GUARDS IN PLACE and in good working order.
• REMOVE ADJUSTING KEyS AND WRENCHES. Form habit of checking to see that keys and adjusting wrenches are removed from tool before turning it on.
• KEEP WORK AREA CLEAN. DO NOT leave tools or pieces of wood on the saw while it is in operation.
• DO NOT USE IN DANGEROUS ENVIRONMENTS. Do not use power tools near gasoline or other flammable liquids, in damp or wet locations or expose them to rain. Keep the work area well lit.
• KEEP CHILDREN AND VISITORS AWAy. All visitors should wear safety glasses and be kept a safe distance from work area.
• MAKE WORKSHOP CHILDPROOF with padlocks, master switches, or by removing starter keys.
• DON'T FORCE THE TOOL. It will do the job better and safer at the feed rate for which it was designed.
• USE THE RIGHT TOOL. Do not force the tool or attachment to do a job for which it was not designed.
• USE THE PROPER EXTENSION CORD. Make sure your extension cord is in good condition. Use only a cord heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. A wire gauge size (A.W.G.) of at least 16 is recommended for an extension cord 25 feet or less in length. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.
• DRESS PROPERLy. Do not wear loose clothing, gloves, neckties, or jewelry. They can get caught and draw you into moving parts. Rubber gloves and nonskid footwear are recommended when working outdoors. Also wear protective hair covering to contain long hair.
• ALWAyS WEAR SAFETy GLASSES WITH SIDE SHIELDS. Everyday eyeglasses have only impact- resistant lenses, they are NOT safety glasses.
• SECURE WORK. Use clamps or a vise to hold work when practical. It's is safer than using your hand and frees both hands to operate the tool.
• DON'T OVERREACH. Keep proper footing and balance at all times.
• MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for better and safer performance. Follow instructions for lubricating and changing accessories.
• DISCONNECT TOOLS. When not in use, before servicing, or when changing attachments, blades, bits, cutters, etc., all tools should be disconnected from power source.
• AVOID ACCIDENTAL STARTING. Be sure switch is off when plugging in any tool.
• USE RECOMMENDED ACCESSORIES. Consult the operator's manual for recommended accessories. The use of improper accessories may result in injury.
• NEVER STAND ON TOOL. Serious injury could occur if the tool is tipped or if the blade is unintentionally contacted.
• CHECK DAMAGED PARTS. Before further use of the tool, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting and any other conditions that may affect its operation. A guard or other part that is damaged must be properly repaired or replaced by an authorized service center to avoid risk of personal injury.
• USE THE RIGHT DIRECTION OF FEED. Feed work into a blade or cutter against the direction or rotation of the blade or cutter only.
• NEVER LEAVE TOOL RUNNING UNATTENDED. TURN THE POWER OFF. Don't leave tool until it comes to a complete stop.
• DO NOT ABUSE CORD. Never carry tool by the cord or yank it to disconnect from receptacle. Keep cord from heat, oil, and sharp edges.
• PROTECT yOUR LUNGS. Wear a face or dust mask if the cutting operation is dusty.
• PROTECT yOUR HEARING. Wear hearing protection during extended periods of operation.
• BLADE COASTS AFTER BEING TURNED OFF.
• NEVER USE IN AN EXPLOSIVE ATMOSPHERE. Normal sparking of the motor could ignite fumes.
• INSPECT TOOL CORDS PERIODICALLy. If damaged, have repaired by a qualified service technician at an authorized service facility. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipment-grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal. Repair or replace a damaged or worn cord immediately. Stay constantly aware of cord location and keep it well away from the rotating blade.
• INSPECT EXTENSION CORDS PERIODICALLy and replace if damaged.
• GROUND ALL TOOLS. If tool is equipped with threeprong plug, it should be plugged into a three-hole electrical receptacle.
• CHECK WITH A QUALIFIED ELECTRICIAN or service personnel if the grounding instructions are not completely understood or if in doubt as to whether the tool is properly grounded.
• USE ONLy CORRECT ELECTRICAL DEVICES: 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the tool's plug.
• DO NOT MODIFy the plug provided. If it will not fit the outlet, have the proper outlet installed by a qualified electrician.
• KEEP TOOL DRy, CLEAN, AND FREE FROM OIL AND GREASE. Always use a clean cloth when cleaning. Never use brake fluids, gasoline, petroleum-based products, or any solvents to clean tool.
• STAy ALERT AND EXERCISE CONTROL. Watch what you are doing and use common sense. Do not operate tool when you are tired. Do not rush.
• DO NOT USE TOOL IF SWITCH DOES NOT TURN IT ON AND OFF. Have defective switches replaced by an authorized service center.
• BEFORE MAKING A CUT, BE SURE ALL ADJUSTMENTS ARE SECURE.
• BE SURE BLADE PATH IS FREE OF NAILS. Inspect for and remove all nails from lumber before cutting.
• NEVER TOUCH BLADE or other moving parts during use.
• NEVER START A TOOL WHEN ANy ROTATING COMPONENT IS IN CONTACT WITH THE WORKPIECE.
• DO NOT OPERATE A TOOL WHILE UNDER THE INFLUENCE OF DRUGS, ALCOHOL, OR ANy MEDICATION.
• WHEN SERVICING use only identical replacement parts. Use of any other parts may create a hazard or cause product damage.
• USE ONLy RECOMMENDED ACCESSORIES listed in this manual or addendums. Use of accessories that are not listed may cause the risk of personal injury. Instructions for safe use of accessories are included with the accessory.
• DOUBLE CHECK ALL SETUPS. Make sure blade is tight and not making contact with saw or workpiece before connecting to power supply.

• FIRMLy CLAMP OR BOLT THE SAW TO A WORK BENCH OR LEG STAND at approximately hip height.
• NEVER OPERATE THE SAW ON THE FLOOR.
• AVOID AWKWARD OPERATIONS AND HAND POSITIONS where a sudden slip could cause your hand to move into the blade. ALWAyS make sure you have good balance.
• ALLOW THE MOTOR TO COME UP TO FULL SPEED before starting a cut to avoid binding or stalling.
• DO NOT USE TOOL IF SWITCH DOES NOT TURN IT ON AND OFF. Have defective switches replaced by an authorized service center.
• REPLACEMENT PARTS. All repairs, whether electrical or mechanical, should be made by a qualified service technician at an authorized service center.
• WHEN SERVICING use only identical replacement parts. Use of any other parts may create a hazard or cause product damage.
• KEEP HANDS AWAy FROM CUTTING AREA. Do not hand hold pieces so small that your fingers go under the blade guard. Do not reach underneath work or in blade cutting path with your hands and fingers for any reason.
• NEVER CUT MORE THAN ONE PIECE AT A TIME or stack more than one workpiece on the saw table at a time.
• DO NOT FEED THE MATERIAL TOO QUICKLy. Do not force the workpiece against the blade.
• USE ONLy CORRECT BLADES. Use the right blade size and style for the material and the type of cut. Blade teeth should point down toward the table.
• ALWAyS SUPPORT LARGE WORKPIECES while cutting to minimize risk of blade pinching and kickback. Saw may slip, walk or slide while cutting large or heavy boards.
• DO NOT REMOVE JAMMED CUTOFF PIECES until blade has stopped.
• NEVER TOUCH BLADE or other moving parts during use.
• BEFORE CHANGING THE SETUP, REMOVING COVERS, GUARDS OR BLADES, unplug the saw and remove the switch key.
• HOLD THE WORKPIECE firmly against the saw table.
• TO AVOID ACCIDENTAL BLADE CONTACT, minimize blade breakage, and provide maximum blade support, always adjust the blade guide assembly to just clear the workpiece.
• KEEP BLADES CLEAN, SHARP, AND WITH SUFFICIENT SET. Sharp blades minimize stalling and kickbacks.
• ALWAyS TURN OFF SAW before disconnecting it to avoid accidental starting when reconnecting to a power source.
• MAKE SURE WORK AREA HAS AMPLE LIGHTING to see the work and that no obstructions will interfere with safe operation BEFORE performing any work using your saw.
• THE BLADE GUIDES HAVE BEEN PRESET AT THE FACTORy. These settings are functional for some applications. We recommend that you check and adjust blade guide settings before first use of your saw. Refer to Adjusting thrust bearings and blade guide support procedures explained in the adjustments section of this operator's manual.
• DO NOT USE TOOL TO CUT METAL.
• THIS TOOL should have the following markings:
  1. Wear eye protection.
  2. Keep fingers away from the blade.

3. Do not remove jammed or cutoff pieces until the blade has stopped.
4. Be sure blade is installed with teeth pointing down.
5. Maintain proper adjustment of the blade tension, blade guides, and thrust bearings.
6. Adjust the upper guide to just clear the workpiece.
7. Hold the workpiece firmly against the table when cutting.

• IF THE POWER SUPPLy CORD IS DAMAGED, it must be replaced only by the manufacturer or by an authorized service center to avoid risk.
• SAVE THESE INSTRUCTIONS. Refer to them frequently and use them to instruct other users. If you loan someone this tool, loan them these instructions also.

CALIFORNIA PROPOSITION 65

This product and some dust created by power sanding, sawing, grinding, drilling, and other construction activities may contain chemicals, including lead, known to the State of California to cause cancer, birth defects, or other reproductive harm. Wash hands after handling.
Some examples of these chemicals are:

• lead from lead-based paints,
• crystalline silica from bricks and cement and other masonry products and,
• arsenic and chromium from chemically-treated lumber.

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

SYMBOLS

The following signal words and meanings are intended to explain the levels of risk associated with this product.

SyMBOL	SIGNAL	MEANING
	DANGER:	Indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.
	WARNING:	Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.
	CAUTION:	Indicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury.
	NOTICE:	(Without Safety Alert Symbol) Indicates important information not related to an injury hazard, such as a situation that may result in property damage.

Some of the following symbols may be used on this tool. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to operate the tool better and safer.

SyMBOL	NAME	DESIGNATION/EXPLANATION
	Safety Alert	Indicates a potential personal injury hazard.
	Read Operator's Manual	To reduce the risk of injury, user must read and understand operator's manual before using this product.
	Eye Protection	Always wear eye protection with side shields marked to comply with ANSI Z87.1.
	No Hands Symbol	Failure to keep your hands away from the blade will result in serious personal injury.
	Wet Conditions Alert	Do not expose to rain or use in damp locations.
V	Volts	Voltage
A	Amperes	Current
Hz	Hertz	Frequency (cycles per second)
min	Minutes	Time
	Alternating Current	Type of current
n o	No Load Speed	Rotational speed, at no load
	Class II Construction	Double-insulated construction
.../min	Per Minute	Revolutions, strokes, surface speed, orbits, etc., per minute

ELECTRICAL

EXTENSION CORDS

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

When working with the product outdoors, use an extension cord that is designed for outside use. This is indicated by the letters "W-A" or "W" on the cord's jacket.
Before using an extension cord, inspect it for loose or exposed wires and cut or worn insulation.

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

Check extension cords before each use. If damaged replace immediately. Never use the product with a damaged cord since touching the damaged area could cause electrical shock resulting in serious injury.

ELECTRICAL CONNECTION

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

SPEED AND WIRING

The no-load speed of this product is approximately 2,500 sfpm. This speed is not constant and decreases under a load or with lower voltage. For voltage, the wiring in a shop is as important as the motor's horsepower rating. A line intended only for lights cannot properly carry a power tool motor. Wire that is heavy enough for a short distance will be too light for a greater distance. A line that can support one power tool may not be able to support two or three products.

GROUNDING INSTRUCTIONS

This product must be grounded. In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This product is equipped with an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances.
Do not modify the plug provided. If it will not fit the outlet, have the proper outlet installed by a qualified electrician.

Improper connection of the grounding plug can result in a risk of electric shock. When repair or replacement of the cord is required, do not connect the grounding wire to either flat blade terminal. The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire.
Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the product is properly grounded.
Repair or replace a damaged or worn cord immediately.
This product is for use on a nominal 120 V circuit and has a grounding plug similar to the plug illustrated in figure 1. Only connect the product to an outlet having the same configuration as the plug. Do not use an adapter with this product.

FEATURES

PRODUCT SPECIFICATIONS

Blade Width 1/8 in. to 3/8 in.
Blade Length 62 in.
Frame to Blade Capacity 9 in.
Cutting Thickness Capacity 3-5/8 in.
Table Size 11-3/4 in. x 11-3/4 in.
Input 120 V~, 2.5 Amps, 60 Hz.
No Load Speed 2,500 FPM (1,270 cm/s)
Dust Port 2-1/2 in.

KNOW yOUR BAND SAW see Figure 2
The safe use of this product requires an understanding of the information on the tool and in this operator's manual as well as a knowledge of the project you are attempting. Before use of this product, familiarize yourself with all operating features and safety rules.

ANGLE ADJUSTMENT KNOB
Tilts the saw table for bevel cutting.

BLADE GUARD
Protects the operator from coming in contact with the blade.

BLADE GUIDE ADJUSTMENT KNOB

Use the blade guide adjustment knob to adjust the blade guide assembly up and down, and to keep the blade from twisting or breaking. Always lock the blade guide assembly in place before turning on the band saw.

BLADE GUIDES

Upper and lower blade guides helps keep the blade from twisting during operation.

DUST EXHAUST PORT

A 2-1/2 in. dust exhaust port makes dustless cutting possible. Attach a dust bag or a shop vac to the dust exhaust port.

LATCH

Easy open latches allow front cover to be opened for making adjustments.

MITER GAUGE

This gauge aligns the wood for a crosscut. The easy-to-read indicator shows the exact angle for a miter cut at 90° and 45°.

RAPID SET BLADE TENSION LEVER

Controls blade tension when changing blades and making adjustments for various sawing applications.

SAW BLADE
Saw comes with a standard 1/4 in. blade.

SAW TABLE WITH THROAT PLATE

Your band saw has a saw table with tilt control. The throat plate, installed in the saw table at the factory, allows for blade clearance.

SCALE AND SCALE INDICATOR

The scale and scale indicator show the angle or degree the saw table is tilted for bevel cutting.

SWITCH AND SWITCH KEy

Your band saw has an easy access power switch. To lock in the OFF position, remove the yellow switch key. Place the key in a location inaccessible to children and others not qualified to use the tool.

TABLE LOCK LEVER

Loosening the table lock lever allows the saw table to be tilted at different angles. Tightening the table lock lever locks the saw table in place.

TRACKING KNOB
Adjusts tracking to keep blade centered on the wheels.

TRACKING VIEW WINDOW

The tracking view window makes tracking adjustments easier to see.

ASSEMBLY

LOOSE PARTS LIST see Figure 4.
The following items are included with the saw:

UNPACKING

This product requires assembly.

• Carefully lift the saw from the carton and place on a level work surface.
  
  Do not use this product if any parts on the Loose Parts List are already assembled to your product when you unpack it. Parts on this list are not assembled to the product by the manufacturer and require customer installation. Use of a product that may have been improperly assembled could result in serious personal injury.
• Inspect the tool carefully to make sure no breakage or damage occurred during shipping.
  NOTE: This saw has been shipped with no blade tension. Do not turn this saw on until blade tension has been properly set.
• Do not discard the packing material until you have carefully inspected and satisfactorily operated the tool.
• If any parts are damaged or missing, please call 1-800-525-2579 for assistance.

If any parts are damaged or missing do not operate this product until the parts are replaced. Use of this product with damaged or missing parts could result in serious personal injury.

Do not attempt to modify this tool or create accessories not recommended for use with this tool. Any such alteration or modification is misuse and could result in a hazardous condition leading to possible serious personal injury.

Do not connect to power supply until assembly is complete. Failure to comply could result in accidental starting and possible serious personal injury.

MOUNTING BAND SAW TO WORKBENCH

If the band saw is to be used in a permanent location, the band saw must be mounted to a firm supporting surface such as a workbench. Four bolt holes have been provided in the saw's base for this purpose. Bolts should be of sufficient length to accommodate the saw base, lock washers, hex nuts, and the thickness of the workbench. Tighten all four bolts securely.
Carefully check the workbench after mounting to make sure that no movement can occur during use. If any tipping, sliding, or walking is noted, secure the workbench to the floor before operating.

• Place band saw on the workbench. Using the saw base as a pattern, locate and mark the holes where the band saw is to be mounted.
• Drill holes through the workbench.
• Place band saw on the workbench aligning holes in the saw base with the holes drilled in the workbench.
• Insert bolts (not included) and tighten securely with lock washers and hex nuts (not included).
  NOTE: All bolts should be inserted from the top. Install the lock washers and hex nuts from the underside of the bench.

CLAMPING BAND SAW TO WORKBENCH see Figure 5.
If the band saw is to be used as a portable tool, it is recommended that you fasten it permanently to a mounting board that can easily be clamped to a workbench or other supporting surface. The mounting board should be of sufficient size to avoid tipping of saw while in use. Any good grade plywood or chipboard with a 3/4 in. thickness is recommended.
If lag bolts are used, make sure they are long enough to go through holes in the saw base and material the saw is being mounted to. If machine bolts are being used, make sure bolts are long enough to go through holes in the saw base, the material being mounted to, and the lock washers and hex nuts.
NOTE: It may be necessary to countersink hex nuts and washers on bottom side of mounting board.

• Mount saw to board using holes in saw base as a template for hole pattern. Locate and mark the holes where the band saw is to be mounted.
• Follow the last three steps in the section Mounting Band Saw to Workbench, shown above.

MOUNTING THE SAW TABLE see Figures 6 - 7.

• Remove the D-nut, washers, and wing screw on the saw table.
• Standing at the front of the band saw, slide the saw table past the blade and through the slot moving from the right side of the saw table to the left.
• Holding the saw table with your left hand while pulling the angle adjustment knob away from the saw frame, align the teeth on the saw table bracket into the teeth on the angle adjustment knob. Release the knob.
• Fit the pins on the frame into the slots of the saw table bracket.
• Insert the washer on the threaded end of the table lock lever. Tighten the saw table to the saw frame by turning the table lock lever clockwise.
• Attach the D-nut, washers, and wing screw to the saw table.
  NOTE: The wing screw goes below the saw table.

SQUARING THE SAW TABLE TO THE BLADE see Figures 8 - 9

• Turn the lock knob counterclockwise to unlock the blade guide assembly. Turning the blade guide adjustment knob clockwise, raise the blade guide assembly as far as it will go. Turn the lock knob clockwise to retighten.
• Place a small combination square on the saw table beside the blade.
• Loosen the table lock lever and rotate the angle adjustment knob to tilt the saw table up or down to align table 90° to blade (0° position). Retighten the table lock lever.
• Using an adjustable wrench, loosen the jam nut.
• Turn the adjusting bolt until the bolt just touches the saw housing.
• Check squareness of the saw table to the blade. Make readjustments if necessary.
• Once squareness is confirmed, retighten the jam nut.
• Set scale indicator to zero and tighten screw with a phillips screwdriver.

NOTE: Always make a test cut to insure the squareness of the blade prior to beginning any new project. If not square, it may be necessary to loosen the screws under the saw table to make the adjustment (miter slot must be parallel to the saw blade). Once square, retighten screws.

ADJUSTING BLADE TENSION see Figures 10 - 11.

• Remove the switch key.
• Before using the band saw, turn the blade tension knob on the top of the saw clockwise to engage tension.
  NOTE: Adjustments of blade tension can be made at anytime.
• Pluck the back straight edge of the saw blade like a guitar string while turning the tension knob.

Sound becomes higher pitched as tension increases. Never increase blade tension so tight as to completely compress the spring. When completely compressed, the spring can no longer act as a shock absorber.
Too much tension may cause the blade to break. Thicker workpieces require higher tension; maximum tension is not needed for all cuts. Too little tension may cause the blade to slip on the wheels.

TRACKING THE BLADE see Figure 11.
Adjust blade tension properly before making tracking adjustments. Check that blade guides do not interfer with the blade. Blade gullet (the deepest part of the blade tooth) should be in the center of the tire.

To adjust:

• Open front covers by releasing the upper and lower latches. Watch the blade's position on the upper tire as, by hand, you slowly turn the upper wheel clockwise. If the blade moves away from the center of the tire, the tracking must be adjusted.

If the blade has moved left or right of center:

• Turn the blade tracking knob (clockwise if blade has moved left; counterclockwise if blade has moved right) while turning the wheel by hand until the blade moves back and rides in the center of the tire.
• Check the position of the blade on the lower tire. The blade should be completely on the tire (gullet of the blade teeth in the center). If not, adjust the tracking until the blade is on both tires.
• Rotate the upper wheel by hand in a clockwise direction for a few more turns. Make sure the blade stays in the same location on the tires. Readjust, if necessary, until blade is tracking properly.
• Close front covers and relatch.
• Turn on saw.
• Verify saw blade is centered on the tire (through the tracking view window). If not centered, repeat above steps.

The blade guides have been preset at the factory. These settings are functional for some applications. We recommend that you check and adjust blade guide settings before first use of your saw. Refer to Adjusting Blade Guide Support and Thrust Bearings procedures explained in the adjustments section of this operator's manual.

OPERATION

Do not allow familiarity with tools to make you careless. Remember that a careless fraction of a second is sufficient to inflict serious injury.

Always wear eye protection with side shields marked to comply with ANSI Z87.1. Failure to do so could result in objects being thrown into your eyes, resulting in possible serious injury.

Do not use any attachments or accessories not recommended by the manufacturer of this tool. The use of attachments or accessories not recommended can result in serious personal injury.

To avoid blade contact, adjust the blade guide assembly to just clear the workpiece. Failure to do so could result in serious personal injury.

Never operate saw without the blade guard secured and the front covers locked. To do so could result in possible serious personal injury.

APPLICATIONS

You may use this tool for the purposes listed below:

• Scroll cutting and circle cutting of wood and wood composition products
• Various straight line cutting operations in wood and wood composition products

BASIC OPERATION OF THE BAND SAW

A band saw is basically a "curve cutting" machine that can also be used for straight-line cutting operations like cross cutting, mitering, beveling, compound cutting, and resawing. When using the band saw for straight line cutting, the user can install a fence using an appropriately sized piece of wood clamped to the table with "C" clamps. It is not capable of making inside or non-through cuts.
Before starting a cut, watch the saw run. If you experience excessive vibration or unusual noise, stop immediately. Turn the saw off, remove the switch key, and unplug the saw. Do not restart until locating and correcting the problem.

CUTTING PROCEDURES

• Hold the workpiece firmly against the saw table.
• Use gentle pressure and both hands when feeding the work into the blade. Do not force the work; allow the blade to cut.
• The smallest diameter circle that can be cut is determined by blade width. A 1/4 in. wide blade will cut a minimum diameter of 1-1/2 in.; a 1/8 in. wide blade will cut a minimum diameter of 1/2 in.
• Keep your hands away from the blade. Do not hand hold pieces so small your fingers will go under the blade guard.
• Avoid awkward operations and hand positions where a sudden slip could cause serious injury from contact with the blade. Never place hands in blade path.
• Use extra supports (tables, saw horses, blocks, etc.) when cutting large, small, or awkward workpieces.

• Never use a person as a substitute for a table extension or as additional support for a workpiece that is longer or wider than the basic saw table.
• When cutting irregularly shaped workpieces, plan your work so it will not pinch the blade. For example, a piece of molding must lay flat on the saw table. Workpieces must not twist, rock, or slip while being cut.

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

• Place the switch in theOFF position. Wait until the saw has come to a full and complete stop, then remove the switch key from the switch assembly. Store key in a safe place.
• Unplug the saw from the power source.
• Wedge the kerf open with a flat screwdriver or wooden wedge.
• Open front cover and turn the upper wheel by hand while backing up the workpiece.

RELIEF CUTS

Relief cuts are made when an intricate curve (too small a radius for the blade) is to be cut. Cut through a scrap section of the workpiece to curve in pattern line then carefully back the blade out. Several relief cuts should be made for intricate curves before following the pattern line as sections are cut off of curve "relieving" blade pressure.

SCROLL CUTTING

For general type scroll cutting, follow the pattern lines by pushing and turning the workpiece at the same time. Do not try to turn the workpiece while engaged in the blade without pushing it – the workpiece could bind or twist the blade.

REMOVING JAMMED MATERIAL

Never remove jammed cutoff pieces until the blade has come to a full and complete stop.

• Place the switch in theOFF position. Wait until the saw has come to a full and complete stop, then remove the switch key from the switch assembly. Store key in a safe place.
• Unplug the saw from the power source before removing jammed material.

AVOIDING INJURY

• Make sure saw is level and does not rock. Saw should always be on a firm, level surface with plenty of room for handling and properly supporting the workpiece.
• Bolt saw to the support surface to prevent slipping, walking, or sliding during operations like cutting long, heavy boards.
• Turn sawOFF, remove switch key, and unplug cord from the power source before moving the saw.
• Do not remove jammed cutoff pieces until blade has come to a full and complete stop.
• Choose the right size and style blade for the material and type of cut you plan to do.
• Make sure that the blade teeth point down toward the saw table, that the blade guides, thrust bearings, and blade tension are properly adjusted, that the blade guide knob is tight, and that no parts have excessive play.
• To avoid accidental blade contact, minimize blade breakage, and provide maximum blade support, always adjust the blade guide assembly to just clear the workpiece.
• Use only recommended accessories.
• With the exception of the workpiece and related support devises, clear everything off the saw table before turning the saw on.
• Properly support round materials such as dowel rods or tubing because they have a tendency to roll during a cut causing the blade to "bite". To avoid this, always use a "V" block or clamp workpiece to a miter gauge.
• Before removing loose pieces from the saw table, turn saw off and wait for all moving parts to stop.

LOCKING THE SWITCH see Figure 12.

• Place the switch in the OFF position. Wait until the saw has come to a full and complete stop, then remove the switch key from the switch assembly. Store key in a safe place.

BEFORE LEAVING THE SAW see Figure 12.

• Place the switch in theOFF position. Wait until the saw has come to a full and complete stop, then remove the switch key from the switch assembly. Store key in a safe place.
• Unplug the saw from the power source.
• Make workshop childproof.
• Release the tension from the saw blade using the RAPID SET blade tension lever to prolong the life of the blade.
• Lock the shop.

TILTING THE TABLE see Figure 13.

• Loosen the table lock knob slightly.
• Turn the angle adjustment knob, tilting the saw table until it reaches the desired angle.
• Using the scale indicator, check angle markings.
• Retighten the table lock knob to hold saw table securely in place.

USING THE MITER GAUGE see Figures 14 - 15.
The miter gauge can be turned 30° to the right or left.

• Loosen the lock knob on the miter gauge.
• With the miter gauge in the miter gauge slot, rotate the gauge until the desired angle is reached on the index scale.
• n Retighten the lock knob.

Before performing any adjustment, make sure the tool is unplugged from the power supply and the switch is in the off position. Failure to heed this warning could result in serious personal injury.

To avoid personal injury, maintain proper adjustment of blade tension, blade tracking, blade guides, and thrust bearings.

INSTALLING AND ADJUSTING THE BLADE see Figure 16.

• Loosen and remove the wing screw, washers, and D-nut from the saw table.
• Open the front covers by releasing the upper and lower latches.
• Turn the lock knob counterclockwise to unlock the blade guide assembly. Turning the blade guide knob (clockwise raises the blade guide assembly; counterclockwise lowers it), position the blade guide assembly about halfway between the saw table and saw housing. Retighten the lock knob.
• Open the blade guard by pulling the left side of the guard out and away from the wheel.
• Release all blade tension from the blade.
• Carefully remove the old blade.
• Wearing gloves, carefully uncoil the new blade at arms length. If the new blade was oiled to prevent rusting, it may need to be wiped to keep the oil from your workpiece. Carefully wipe in the same direction the teeth are pointing so the rag does not catch on the teeth of the saw blade.
  NOTE: The blade may need to be turned inside out if the teeth are pointing in the wrong direction. Hold the blade with both hands and rotate it inward.
• With the teeth of the blade toward the left of the saw and facing downward, place the blade through the lower blade guides and around both wheels.
• Slowly turn the upper wheel to the right or clockwise by hand to center the blade on the rubber tires.
• Re-engage the RAPID SET blade tension lever then adjust the blade tension; check or adjust the blade tracking.
• Adjust both upper and lower blade guides and thrust bearings as explained later in this Operator's Manual.
• Reattach the wing screw, washers, and D-nut. Tighten securely.
• Close the blade guard and front cover. Relatch.

ADJUSTING BLADE GUIDE ASSEMBLy see Figures 17 - 18.
To prevent the blade from twisting or breaking, the blade guide assembly should always be set approximately 1/8 in. above the workpiece.

• Turn the lock knob counterclockwise to unlock the blade guide assembly.
• As a guide, use a scrap piece of the same wood you are about to cut to set the height of the blade guide assembly. Adjust the blade guide assembly by turning the blade guide knob.
• Lock blade guide assembly in place by turning the lock knob clockwise.
• Always lock the blade guide assembly in place before turning on the band saw.

ADJUSTING BLADE GUIDE SUPPORT AND THRUST BEARINGS see Figure 19.
NOTE: Tighten the lock knob and refer to Adjusting Blade Tension and Tracking the Blade procedures explained in the assemBLY section of this operator's manual prior to making adjustments.
The upper and lower blade thrust bearings support and bearing guides the saw blade during cutting operations. The adjustment of the bearings and guides should be checked whenever a different blade is installed.

To Adjust Thrust Bearings:
The thrust bearings support the back edge of the blade during cutting. The blade should not contact the thrust bearings when you stop cutting. It is important that both upper and lower thrust bearings be adjusted equally.

• Open the front covers and blade guard.
• Using a hex key, loosen the upper and lower thrust bearing screws and push thrust bearings to the back of the saw.
• Verify that saw blade is tracking correctly, then slide the thrust bearing forward until the bearing is within 1/64 in. of the blade. Tighten the thrust bearing screw securely.
• Slide lower bearing forward until it has proper clearance.
  Tighten the thrust bearing screw securely.

To Adjust Blade Guide Support:

• Loosen the blade guide support and blade guide set screws using hex keys.
• Slide the upper blade guide support on the shaft until the front edge of the guides contact the saw blade behind the gullet. Tighten the screw securely.
• Push the right guide to contact the blade and release. Slowly rotate wheel one full rotation. Tighten blade guide set screws.
• Adjust left side guide to allow 1/64 in. clearance between the blade and guide (about the thickness of a dollar bill) by inserting dollar bill between left guide and blade.
• Apply pressure to left guide pin to hold dollar bill in place. Tighten set screw and remove dollar bill.
• Rotate, by hand, a full three rotations to make sure blade will not bind.
• n Close the blade guard and front cover. Relatch.
  Repeat this procedure for the lower blade guide support.

MAINTENANCE

When servicing, use only identical replacement parts. Use of any other parts can create a hazard or cause product damage.

Always wear eye protection with side shields marked to comply with ANSI Z87.1 during product operation. If operation is dusty, also wear a dust mask.

Before performing any maintenance, make sure the tool is unplugged from the power supply and the switch is in the off position. Failure to heed this warning could result in serious personal injury.

GENERAL MAINTENANCE

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

Do not at any time let brake fluids, gasoline, petroleumbased products, penetrating oils, etc., come in contact with plastic parts. Chemicals can damage, weaken or destroy plastic which may result in serious personal injury.

• Keep your band saw clean.
• Remove sawdust from the inside frequently.
• Do not allow pitch to accumulate on the saw table, blade guides, or thrust bearings. Clean them with gum and pitch remover.
• Apply a thin coat of automobile type wax to the saw table's top so the wood slides easily while cutting.

LUBRICATION

All of the bearings in this tool are lubricated with a sufficient amount of high grade lubricant for the life of the unit under normal operating conditions. Therefore, no further lubrication is required.

MOTOR/ELECTRICAL

• Frequently vacuum or blow out sawdust from the motor.

TIRES

Cleaning tires:

• Pitch and sawdust accumulates on tires and needs to be removed with a fine wire brush or a piece of wood. Do not use a sharp knife or any kind of solvent.

Replacing tires:

• Open front cover and remove saw blade. See section onInstalling and Adjusting the Blade
• Pry the worn tire away from the wheel carefully.
• Stretch the new tire around the wheel.
• Replace the saw blade and close the front cover.

BRUSH

see Figure 21.
There is a brush located inside the saw housing next to the wheel. It helps protect the tire and wheel by brushing off saw dust. As the brush becomes worn, it will need to be adjusted or replaced.

• Remove the screw and washer then pull the brush off.
• Place the new brush in the groove.
• Reinstall using the washer and screw.

TROUBLESHOOTING

NOTE: FIGURES (ILLUSTRATIONS) START AFTER FRENCH AND SPANISH LANGUAGE SECTIONS.

Your band saw has been engineered and manufactured to our high standard for dependability, ease of operation, and operator safety. When properly cared for, it will give you years of rugged, trouble-free performance.

To reduce the risk of injury, the user must read and understand the operator's manual before using this product.
SAVE THIS MANUAL FOR FUTURE REFERENCE