RYOBI 9 in. BAND SAW MODEL NO. BS902 REPAIR SHEET
RYOBI 9 in. BAND SAW MODEL NUMBER BS902 FIGURE A
RYOBI 9 in. BAND SAW MODEL NUMBER BS902
The model number will be found on a plate attached to the motor housing. Always mention the model number in all correspondence regarding your BAND SAW or when ordering repair parts.

PARTS LIST FOR FIGURE A

Key No. 25 Part Number 224072-000 240064-000 020301-013 021200-001 303649-000 021118-002 060043-000 020804-000 029185-001 270683-000 270677-000 020102-023 900982-000 270678-000 020102-025 029186-001 021120-003 303650-000 303651-000 021101-008 022111-002 225061-000 021504-009 023102-001 900983-000 Description Qty. Key No. 50 Part Number 020911-001 303652-000 029138-000 021101-013 303653-000 022301-001 303695-000 900984-000 020314-003 021204-001 041002-000 022505-000 900991-000 900998-000 020601-003 090010-000 270689-000 020103-033 080406-002 270679-000 913001-000 021306-000 020103-031 020106-036 351009-000 Description Qty.
FRAME... 1 BASE.. 1 SCREW (M6 X 16 mm).. 4 LOCK WASHER (1/4).. 5 CAM LEVER... 1 WASHER... 2 CAM... 1 SCREW (M4 X 10 mm).. 1 COMPRESSION SPRING.. 1 SLIDE... 1 SLIDE PLATE.. 1 SCREW (M6 X 8 mm)... 4 UPPER WHEEL SUPPORT ASSEMBLY. 1 PLATE... 1 SCREW (M6 X 12 mm).. 4 COMPRESSION SPRING.. 1 WASHER... 3 FINE ADJUST KNOB.. 1 RACK & PINION KNOB.. 1 WASHER... 1 LOCK NUT (M6 X 1P)... 1 WHEEL... 2 WASHER... 4 RETAINING RING (S-10). 2 SUPPORT GUIDE.. 1
* CARRIAGE BOLT (M6 X 72.5 mm). 1 RACK & PINION KNOB.. 1 TENSION SPRING... 2 WASHER... 2 TIGHTENING KNOB.. 2 * NYLON NUT (M5)... 2 HANDLE LOCK END CAP.. 2 MOTOR ASSEMBLY.. 1 * SCREW (M8 X 25 mm).. 2 * LOCK WASHER (5/16 IN.).. 3 GEAR TYPE BELT... 1 NUT... 1 GUIDE BLOCK SUPPORT ASSEMBLY. 1 THRUST BEARING.. 1 * SCREW (M5 X 10 mm).. 2 LOCKING SWITCH.. 1 SWITCH COVER.. 1 * SCREW (M4 X 10 mm).. 4 POWER CORD... 1 PLATE COVER... 1 BEND RELIEF... 1 * LOCK WASHER (M4).. 1 * SCREW (M4 X 8 mm)... 4 * SCREW (M5 X 12 mm).. 3 BLADE... 1
WARNING: Improper repair of a double insulated tool can result in damage to the double insulation system possibly causing electrical shock or electrocution. Any repairs requiring disassembly of your tool requires safety testing and should only be performed by a Ryobi Authorized Service Center. For the service center nearest you call 1-800-525-2579. * Standard Hardware Item May Be Purchased Locally
PARTS LIST FOR FIGURE A CONTINUED
Key No. 75 Part Number 303655-000 270680-000 024201-000 290270-000 022111-007 028977-000 022306-000 224077-000 303660-000 028976-000 021403-007 021103-010 900987-000 020106-035 303658-000 020716-000 900989-000 021201-003 303006-000 863209-000 863209-001 871057-000 863209-002 863209-007 863209-009 Description Qty. Key No. 98 Part Number 863209-010 863209-003 863209-004 863209-005 870037-000 303656-000 029187-001 303657-000 020132-001 050013-000 330023-000 020132-000 290273-000 303665-000 028967-000 021101-011 022603-000 020505-031 020808-001 303659-000 021118-001 020401-000 901001-000 983000-267 983000-267R 12-2-03 Description Qty.
COVER... 1 HINGE... 2 RIVET... 8 LOCK PIN.. 2 NUT (M6 X 4.8 mm).. 2 TRUNNION SHAFT LOCK.. 1 NYLON NUT (M6).. 1 TRUNNION.. 1 RACK & PINION KNOB.. 1 SHOULDER SCREW.. 1 SPRING WASHER... 1 WASHER... 1 BRUSH... 2 SCREW (M5 X 8 mm)... 2 INDICATION B.. 1 SCREW, BUTTON HEAD CAP.. 1 TABLE... 1 LOCK WASHER (M4).. 1 CORD CLAMP... 1 LOGO PLATE.. 1 WARNING LABEL.. 1 DATA PLATE.. 1 BLADE TRACKING & ADJUSTING LABEL. 1 BLADE CHART (FRENCH).. 1 BLADE CHART (ENGLISH).. 1

* * * *

BLADE CHART (SPANISH).. 1 KEEP HANDS AWAY WARNING LABEL. 2 TRACKING VIEW WINDOW. 1 LOCK LABEL.. 1 DEPTH SCALE.. 1 DOOR LOCK KNOB.. 2 COMPRESSION SPRING.. 2 TRACKING WINDOW... 1 SCREW, SELF-TAPPING (M4 X 10 mm). 1 BEARING.. 4 TIRE WHEEL.. 2 SCREW, SELF-TAPPING (M4 X 14 mm). 3 LOWER WHEEL SHAFT.. 1 IDLER PULLY.. 1 SCREW, TRUSS HD. (M6 X 19 mm). 1 WASHER... 1 WING NUT (M6).. 1 SET SCREW (M8 X 15 mm). 1 SCREW (M6 X 20 mm).. 3 TABLE INSERT.. 1 WASHER... 1 WING SCREW (M6 X 25 mm) (NOT SHOWN). 1 LIGHT ACCESSORY COMPLETE (NOT SHOWN). 1 OPERATOR'S MANUAL REPAIR SHEET
RYOBI 9 in. BAND SAW MODEL NUMBER BS902 FIGURE B

PARTS LIST FOR FIGURE B

Key No. Part Number 900983-8

Description

SUPPORT GUIDE ASSEMBLY.. 1 UPPER SLIDE... 1 GUIDE SUPPORT.. 1 90* BLOCK GUIDE... 1 45* BLOCK GUIDE... 1 * SCREW (M5 X 10 mm).. 6 BEARING THRUST.. 1 BLADE GUIDE.. 1 * SCREW (M5 X 8 mm)... 2
224073-000 260010-000 060044-000 060045-000 020601-003 900998-000 270684-000 020106-035
RYOBI 9 in. BAND SAW MODEL NUMBER BS902 FIGURE C

PARTS LIST FOR FIGURE C

Key No. Part Number 900988-8 9
MITER GAUGE ASSEMBLY. 1 MITER GAUGE... 1 PIN... 1 BAR... 1 MITER GAUGE KNOB.. 1 INDICATOR.. 1 * SEMS SCREW (M5 X 12 mm).. 1 WASHER... 1 LOGO PLATE.. 1 MITER SCALE... 1

224074-000 026205-001 203037-000 900990-000 303663-000 020103-031 021101-039 863209-006 870037-002
RYOBI 9 in. BAND SAW MODEL NUMBER BS902 FIGURE D

PARTS LIST FOR FIGURE D

Key No. Part Number 880059-12
RIP FENCE ASSEMBLY.. 1 CLAMP ROD.. 1 REAR CLAMP... 1 COMPRESSION SPRING.. 1 REAR SLIDING PAD.. 2 FENCE... 1 * SCREW (M6 X13 mm).. 2 * LOCK WASHER (M6).. 1 RIP FENCE HOUSING.. 1 WASHER... 1 ROLL PIN.. 1 PIN... 1 CAM FENCE LEVER.. 1
290274-000 270682-000 029136-000 303212-000 203012-000 020301-012 021300-000 224076-000 021109-000 022813-000 026104-009 225069-000

OPERATOR'S MANUAL 9 in. (229 mm) BAND SAW BS902
Your new Band Saw has been engineered and manufactured to Ryobi's high standards for dependability, ease of
operation, and operator safety. Properly cared for, it will give you years of rugged, trouble-free performance.
WARNING: To reduce the risk of injury, the user must read and understand the operator's manual before using
this product. Thank you for buying a Ryobi tool.
SAVE THIS MANUAL FOR FUTURE REFERENCE

TABLE OF CONTENTS

Introduction...... 2 Rules for Safe Operation..... 3-5 Electrical...... 6 Glossary of Terms..... 7 Features...... 7-9 Unpacking..... 9 Tools Needed...... 10 Loose Parts List..... 10 Assembly..... 11-14 Operation...... 14-16 Adjustments..... 17-20 Maintenance..... 20-21 Troubleshooting..... 22 Parts Ordering / Service..... 24

INTRODUCTION

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

WARNING:

Do not attempt to use the tool until you read thoroughly and understand completely the operators manual. Pay close attention to the safety rules, including Dangers, Warnings, and Cautions. If you use this tool properly and only for what it is intended, you will enjoy years of safe, reliable service.
The operation of any power tool can result in foreign objects being thrown into your eyes, which can result in severe eye damage. Before beginning tool operation, always wear safety goggles or safety glasses with side shields and a full face shield when needed. We recommend Wide Vision Safety Mask for use over eyeglasses or standard safety glasses with side shields. Always wear eye protection which is marked to comply with ANSI Z87.1.
Look for this symbol to point out important safety precautions. It means attention!!! Your safety is involved.

Page 2

RULES FOR SAFE OPERATION
The purpose of safety symbols is to attract your attention to possible dangers. The safety symbols, and the explanations with them, deserve your careful attention and understanding. The safety warnings do not by themselves eliminate any danger. The instructions or warnings they give are not substitutes for proper accident prevention measures. Symbol 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. It may also be used to alert against unsafe practices that may cause property damage.
NOTE: Advises you of information or instructions vital to the operation or maintenance of the equipment.
SAFETY AND INTERNATIONAL SYMBOLS
This operator's manual describes safety and international symbols and pictographs that may appear on this product. Read the operator's manual for complete safety, assembly, operating and maintenance, and repair information.

SYMBOL

MEANING
Do not expose to rain or use in damp locations.

NO HANDS SYMBOL

Failure to keep your hands away from the blade will result in serious personal injury.

Page 3

Safe operation of this power tool requires that you read and understand this operator's manual and all labels affixed to the tool. Safety is a combination of common sense, staying alert, and knowing how your band saw works. DO NOT OVERREACH. Keep proper footing and balance at all times. MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories. DISCONNECT ALL TOOLS. When not in use, before servicing, or when changing attachments, blades, bits, cutters, etc., all tools should be disconnected from power source. REDUCE THE RISK OF UNINTENTIONAL STARTING. Be sure switch is off when plugging in. USE RECOMMENDED ACCESSORIES. Consult the operators manual for recommended accessories. The use of improper accessories may cause risk of 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. 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 POWER OFF. Dont leave tool until it comes to a complete stop. DONT 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 TURN OFF. 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. INSPECT TOOL CORDS AND EXTENSION CORDS PERIODICALLY and, if damaged, have repaired by a qualified service technician. Stay constantly aware of cord location and keep it well away from the rotating wheel. NEVER USE IN AN EXPLOSIVE ATMOSPHERE. Normal sparking of the motor could ignite fumes. USE ONLY OUTDOOR EXTENSION CORDS with approved ground connection that are intended for use outdoors and so marked. BE SURE THE BLADE PATH IS FREE OF NAILS. Inspect for and remove nails from lumber before cutting.

READ ALL INSTRUCTIONS

KNOW YOUR POWER TOOL. Read the operator's manual carefully. Learn the applications and limitations as well as 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 working order. Never operate the tool with any guard or cover removed. Make sure all guards are operating properly before each use. REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see keys and adjusting wrenches are removed from tool before turning it on. KEEP THE WORK AREA CLEAN. Cluttered work areas and work benches invite accidents. DONT 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 work area well lighted. 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. DONT FORCE THE TOOL. It will do the job better and safer at the 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. When using an extension cord, be sure to use one 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 gage 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 gage. The smaller the gage number, the heavier the cord. WEAR PROPER APPAREL. Do not wear loose clothing, neckties, or jewelry that can get caught in the tools moving parts and cause personal injury. Nonslip footwear is recommended when working outdoors. Wear protective hair covering to contain long hair. ALWAYS WEAR SAFETY GLASSES WITH SIDE SHIELDS. Everyday eyeglasses have only impactresistant lenses; they are NOT safety glasses. SECURE WORK. Use clamps or a vise to hold work when practical. Its safer than using your hand and it frees both hands to operate tool.

Page 4

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 Ryobi 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. FIRMLY CLAMP OR BOLT your saw to a stable, level workbench or table. The most comfortable table height is approximately waist height. DO NOT FEED THE MATERIAL TOO QUICKLY. Do not force the workpiece against the blade. USE ONLY CORRECT BLADES. Use the right blade size, style and cutting speed for the material and the type of cut. Blade teeth should point down toward the table. BEFORE MAKING A CUT, BE SURE ALL ADJUSTMENTS ARE SECURE. 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 START THE TOOL when the blade is in contact with the workpiece. 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. DO NOT OPERATE THIS TOOL WHILE UNDER THE INFLUENCE OF DRUGS, ALCOHOL OR ANY MEDICATION. 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. 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, blade guide support, and blade guides procedures explained in the adjustments section of this operators manual. 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.

Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to cause cancer, birth defects or other reproductive harm. 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.

SAVE THESE INSTRUCTIONS

Page 5

ELECTRICAL

EXTENSION CORDS
Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the tool's plug. When using a power tool at a considerable distance from the power source, use an extension cord heavy enough to carry the current that the tool will draw. An undersized extension cord 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. Length of Extension Cord Wire Size (A.W.G.) Up to 25 feet 16 26-50 feet 16 51-100 feet 16 When working with the tool outdoors, use an extension cord that is designed for outside use. This is indicated by the letters WA on the cord's jacket. Before using an extension cord, inspect it for loose or exposed wires and cut or worn insulation.

ELECTRICAL CONNECTION

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

CAUTION:

Keep the cord away from the cutting area and position the cord so that it will not be caught on materials, tools, or other objects during cutting.

GROUNDING INSTRUCTIONS

In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This tool is equipped with an electric cord having an equipment-grounding 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 equipment-grounding conductor can result in a risk of electric shock. The conductor, with insulation having an outer surface that is green with or without yellow stripes, is the equipment-grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal. Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the tool is properly grounded.
GROUNDING PIN COVER OF GROUNDED OUTLET BOX Fig. 1
Repair or replace a damaged or worn cord immediately. This tool is intended for use on a circuit that has an outlet like the one shown in Figure 1. It also has a grounding pin like the one shown.

Page 6

GLOSSARY OF TERMS FOR WOODWORKING
Bevel Cut A cutting operation made with the saw table at any angle other than 90 to the blade. Compound Cut A compound cut is a cut made using a miter angle and a bevel angle at the same time. Crosscut A cutting or shaping operation made across the grain or the width of the workpiece. Freehand (for band saw) Performing a cut without the workpiece properly supported on the saw table. Gum A sticky, sap-based residue from wood products. Kerf The material removed by the blade in a through cut or the slot produced by the blade in a non-through cut or partial cut. Kickback A hazard that can occur when the blade binds or stalls, throwing the workpiece back toward operator. Leading End The end of the workpiece pushed into the cutting tool first. Miter Cut A cutting operation made with the workpiece at any angle to the blade other than 90. Push Stick A device used to feed the workpiece through the saw blade during narrow cutting operations. It helps keep the operator's hands well away from the blade. Resaw A cutting operation to reduce the thickness of the workpiece to make thinner pieces. Resin A sticky, sap-based substance that has hardened. Ripping A cutting operation along the length of the workpiece. Saw Blade Path The area directly in line over, under, behind or in front of the blade. As it applies to the workpiece, that area which will be or has been cut by the blade. Set The distance that the tip of the saw blade tooth is bent (or set) outward from the face of the blade. SFPM 3,000 surface feet per minute, used in reference to surface speed of blade. Throw-Back Saw throwing back a workpiece in a manner similar to a kickback. Usually associated with a cause other than the kerf closing, such as a workpiece being dropped into the blade or being placed inadvertently in contact with the blade. Through Sawing Any cutting operation where the blade extends completely through the thickness of the workpiece. Workpiece The item on which the cutting operation is being done. The surfaces of a workpiece are commonly referred to as faces, ends, and edges. Worktable The surface on which the workpiece rests while performing a cutting or sanding operation.

FEATURES

PRODUCT SPECIFICATIONS:
Blade Width Blade Length Frame to Blade Capacity Cutting Thickness Capacity Table Size 1/8 in. to 3/8 in. (3 mm to 10 mm) 59-1/4 - 59-1/2 in. (1505mm - 1511mm) 9 in. (229 mm) 3-5/8 in. (92.07 mm) 11-13/16 in. x 11-13/16 in. (30 cm x 30 cm) Input Rating No Load Speed Net Weight Dust Port 2.5 Amperes 120 Volt, 60Hz AC Only 3,000 SFPM 37 lbs. (17.8 kg) 2-1/4 in. (57.15 mm)

Page 7

RAPIDSET BLADE TENSION LEVER

WORKLIGHT

TRACKING KNOB

LOCK KNOB

TABLE LOCK KNOB SCALE ANGLE ADJUSTMENT KNOB DUST EXHAUST PORT BLADE TENSION KNOB TRACKING VIEW WINDOW
SCALE INDICATOR BLADE GUARD TRACKLOCK BLADE GUIDE SAW BLADE MITER GAUGE

SWITCH AND SWITCH KEY

SAW TABLE RIP FENCE LATCH

Fig. 2 Page 8

KNOW YOUR BAND SAW
Before attempting to use, familiarize yourself with all the operating features and safety requirements of your saw.

Saw Blade

Saw comes with a standard 1/4 in. (6 mm) blade.
Saw Table with Throat Plate
Your band saw has a square 11-13/16 in. (30 cm) aluminum saw table with tilt control for maximum accuracy. The throat plate, installed in the saw table at the factory, allows for blade clearance.

Angle Adjustment Knob

Tilts the saw table for bevel cutting.

Blade Guard

Protects the operator from coming in contact with the blade.
Blade Guide Knob with Lock Lever
Use the blade guide knob and lock lever to adjust the blade guide assembly to keep the blade from twisting or breaking. Always lock the blade guide assembly in place before turning on the band saw.
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.

Dust Exhaust Port

A 2-1/4 in. (57.15 mm) dust exhaust port makes dustless cutting possible by blowing the dust away from the user. Attach to the dust exhaust port when using a dust collection system or shop vac.

Fig. 3

LOOSE PARTS LIST
Check all loose parts from the box with the list below. Assemble according to the instructions on the following pages. Hex Key, 4 mm... 1 Rip Fence... 1 Miter Gauge... 1 Saw Table.. 1 Wing Screw... 1 Wing Nut... 1 Table Aligning Bolt... Flat Head Screw.. Worklight... Washer.... Switch Key... Operators Manual (not shown).. 1 1
WORKLIGHT SWITCH KEY SAW TABLE

MITER GAUGE

RIP FENCE WING SCREW 4 mm HEX KEY
WING NUT WASHER TABLE ALIGNING BOLT FLAT HEAD SCREW

Fig. 4 Page 10

ASSEMBLY
MOUNTING BAND SAW TO WORKBENCH
If the band saw is to be used in a permanent location, we recommend that you secure it to a workbench or other stable surface. When mounting the saw to a workbench, holes should be drilled through the supporting surface of the workbench. Each hole in the saw base should be bolted securely using bolts, lock washers, and hex nuts (not included). 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. Supporting surface where band saw is mounted should be examined carefully after mounting to insure that no movement during use can result. If any tipping or walking is noted, secure workbench or support surface before beginning cutting operation.

HOLES IN SAW BASE

Fig. 5
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. (19 mm) thickness is recommended. 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. 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.

SAW TABLE

SAW TABLE BRACKET

MOUNTING THE SAW TABLE

See Figures 6 and 7.

Standing at the front of the band saw, slide the saw table pass the blade and through the slot moving from the right side of the saw table to the left.

Fig. 6

Page 11
Align the screw holes in the saw table with the holes in the saw table bracket. Using the phillips screws, attach the saw table to the saw table bracket. Tighten phillips screws securely. Attach the table aligning bolt, washer, and wing nut to the saw table. NOTE: The wing nut goes below the saw table.
LOCK KNOB TABLE ALIGNING BOLT BLADE GUIDE KNOB
SQUARING THE SAW TABLE TO THE BLADE

See Figure 8.

Failure to turn the saw off, remove the switch key, and unplug the saw could result in accidental starting causing possible serious personal injury. WASHER Turn the lock knob counterclockwise to unlock the blade guide assembly. Turning the blade guide 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 knob 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 knob. Using a hex key, adjust the zero stop set screw until the set screw just touches the saw housing. Check squareness of the saw table to the blade. Make readjustments if necessary. Loosen screw on scale indicator with a phillips screwdriver and align scale indicator to zero. Tighten all screws securely. WING NUT

Fig. 7

ZERO STOP SET SCREW

BLADE GUARD

SAW BLADE

SMALL COMBINATION SQUARE

Fig. 8

Page 12

ADJUSTING BLADE TENSION
See Figures 9 and 10. Turn off and unplug the saw. Remove the switch key.
Check the position of the blade on the lower tire. The blade should be completely on the tire. 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 cover and relatch. NOTE: The 1/8 in. (3 mm) blade may not track properly in the center of the wheel. It may be better to track this blade on the back half of the upper wheel.

Failure to turn the saw off, remove the switch key, and unplug the saw could result in accidental starting causing possible serious personal injury. Before using the band saw, turn the blade tension knob on the top of the saw clockwise to engage tension. See Figure 9. NOTE: Adjustments of blade tension can be made at anytime. Another method of checking blade tension has to do with the sound the blade makes when plucked like a guitar string. Pluck the back straight edge on the coasting side opposite the blade guides while turning the tension knob. Sound should be a musical note. Sound becomes higher pitched as tension increases. Using either method to check blade tension can be developed with practice. 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. NOTE: Too much tension may cause the blade to break. Too little tension may cause the blade to slip on the wheels.

TO DECREASE TENSION

TO INCREASE TENSION
BLADE TENSION KNOB Fig. 9

TRACKING THE BLADE

See Figure 10.

BLADE TENSION KNOB

Failure to turn the saw off, remove the switch key, and unplug the saw could result in accidental starting causing possible serious personal injury. NOTE: Adjust blade tension properly before making tracking adjustments. Check that the blade guides are not interfering with the blade. BLADE ON WHEEL TRACKING VIEW WINDOW BLADE TRACKING KNOB

To Adjust:

Open the front cover by releasing the upper and lower latches. Watch the blades position on the upper tire through the tracking view window 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. Retighten hex nut.
If the blade has moved left or right of center:
NOTE: It may be necessary to loosen the hex nut for a larger range of adjustments. Be sure to retighten after adjusting. Turn the blade tracking knob (clockwise if blade has moved left and 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.

To avoid blade contact, adjust the blade guide assembly to just clear the workpiece. Failure to do so could result in serious personal injury.
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, ripping, mitering, beveling, compound cutting, and resawing. It is not capable of making inside or non-through cuts. This band saw is designed to cut wood and wood composition products only. 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.

Page 14

kerf or when the blade comes out of the guides. If this happens: Wait until the saw has come to a full and complete stop. Place the switch in the OFF position 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. 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.
Wait until the saw has come to a full and complete stop. Place the switch in the OFF position, remove the switch key from the switch assembly. Store key in a safe place.

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 cutoff of curve relieving blade pressure.

BEFORE LEAVING THE SAW

Wait until the saw has come to a full and complete stop. Place the switch in the OFF position, remove the switch key from the switch assembly. Store key in a safe place. Unplug the saw from the power source. Make workshop childproof. Lock the shop. ON OFF

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.

MITER GAUGE SLOT

USING THE RIP FENCE

See Figure 15.

From either side of the saw table, slide the rip fence onto the saw table. Check for a smooth, gliding action. Push the locking handle down to automatically align and secure the fence. Note: Rip fence may be used on either side of the saw table.

Fig. 14

To reduce the risk of injury, always make sure the rip fence is parallel to the blade before beginning any operation.

RIP FENCE

Fig. 15

Page 16

ADJUSTMENTS
Failure to turn the saw off, remove the switch key, and unplug the saw could result in accidental starting causing possible serious personal injury.
INSTALLING AND ADJUSTING THE BLADE

See Figures 16 and 17.

SET SCREWS
Failure to turn the saw off, remove the switch key, and unplug the saw could result in accidental starting causing possible serious personal injury. WING NUT TABLE ALIGNING BOLT

SAW TABLE Fig. 16

Always wear safety goggles or safety glasses with side shields to protect your eyes while uncoiling band saw blades. Failure to heed this warning could result in a serious eye injury. Loosen and remove the wing nut and table aligning bolt from the saw table. See Figure 16. Open the front cover by releasing the upper and lower latches. Loosen the two set screws that hold the blade guard in place using the 4 mm hex key provided then remove the blade guard. See Figure 16. 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. Release blade tension by pushing the RapidSetblade tension lever to the left. See Figure 17. Carefully remove the old blade. Wearing gloves, carefully uncoil the 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 front of the saw and facing downward, place the blade through the lower blade guides and around the lower wheel. Pull down on the upper wheel to place the saw blade on the wheel.

UPPER WHEEL

BLADE GUIDE ASSEMBLY

LOWER BLADE GUIDES

LOWER WHEELS

Fig. 17 Page 17

Slowly turn the upper wheel to the right or clockwise by hand to center the blade on the rubber tires. Adjust the blade tension; check or adjust the blade tracking and re-engage the RapidSetblade tension lever. Adjust both upper and lower blade guides and thrust bearings. Reattach the aligning bolt, washer, and wing nut. Tighten securely. Reattach the blade guard. Close front cover. BLADE GUIDE KNOB
ADJUSTING BLADE GUIDE ASSEMBLY

See Figures 18 and 19.

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, blade guide support, and blade guides procedures explained in the adjustments section of this operators manual. To prevent the blade from twisting or breaking, the blade guide assembly should always be set approximately 1/8 in. (3 mm) 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.

Fig. 18

UNLOCK
To avoid personal injury, maintain proper adjustment of blade tension, blade guides, and thrust bearings. To check tension, raise the blade guide assembly all the way up to expose the blade. Push the blade to the side with moderate force; the blade should flex approximately 1/8 in. (3 mm).

Fig. 19

Page 18
ADJUSTING THRUST BEARINGS, BLADE GUIDE SUPPORT, AND BLADE GUIDES
See Figures 20 - 22. The upper and lower blade guides and thrust bearings support the band saw blade during cutting operations. The adjustment of the guides and bearings should be checked whenever a different blade is installed.
NOTE: The lower blade guide support screw is the top screw located on the right of the saw housing under the table. See Figure 21.
Never operate saw without blade guard secured in place. To do so could result in possible serious personal injury.
BLADE GUIDE ASSEMBLY UPPER BLADE GUIDE SUPPORT THRUST BEARING THRUST BEARING SCREW BLADE GUIDE SUPPORT SCREW
To Adjust Thrust Bearings:

MAINTENANCE

To ensure safety and reliability, all repairs should be performed by an authorized service center.
If the power cord is worn, cut or damaged in any way, have it replaced immediately by a qualified service technician. Failure to do so could result in serious personal injury.

GENERAL MAINTENANCE

Avoid using solvents when cleaning parts. Most plastics are susceptible to damage from various types of commercial solvents and may be damaged by their use. Use clean cloths to remove dirt, carbon dust, etc.
To avoid fire or electrocution, reassemble electric parts with only identical replacement parts. Reassemble exactly as originally assembled.
Do not, at any time, let brake fluids, gasoline, petroleumbased products, penetrating oils, etc., come in contact with plastic parts. They contain chemicals that can damage, weaken or destroy plastic. 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 tables top so the wood slides easily while cutting.

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 on Installing and Adjusting the Blade, page 17. 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.
To prevent accidental starting that could cause possible serious personal injury, turn off the saw, remove the switch key, and unplug the saw before working on the band saw.

See Figure 22.

Blade guides may become rounded and worn during use. Remove the blade guides and file or grind flat. Replace blade guides when filing or grinding has worn them down and they can no longer be properly secured in place.

MOTOR/ELECTRICAL

Frequently vacuum or blow out sawdust from the motor. Page 20

LUBRICATION

All 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.
Remove the nut and washer from the middle of the saw housing. See Figure 24. Pull the lower wheel away from the saw housing. Remove the worn drive belt. Place new drive belt on the pulley. As you slide the pulley shaft back into the hole in the saw housing, place the drive belt over the motor pulley. Replace the nut and washer on the pulley shaft and retighten. Replace saw blade. Check thrust bearings and blade guides.