RYOBI 9 in. BAND SAW MODEL NO. BS901 REPAIR SHEET
RYOBI 9 in. BAND SAW MODEL NUMBER BS901
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

Key No. Part Number BS90100100 BS90100200 BS90100300 BS90100400 BS90100500 BS90100600 BS90100700 BS90100800 BS90100900 BS90101000 BS90101100 BS90101200 BS90101300 BS90101400 BS90101500 BS90101600 BS90101700 BS90101800 BS90101900 BS90102000 BS90102100 BS90102200 BS90102300 BS90102400 BS90102500 BS90102600 Description Qty. Key No. Part Number BS90102700 BS90102800 BS90102900 BS90103000 BS90103100 BS90103200 BS90103300 BS90103400 BS90103500 BS90103600 BS90103700 BS90103800 BS90103900 BS90104000 BS90104100 BS90104200 BS90104300 BS90104400 BS90104500 BS90104600 BS90104700 BS90104800 BS90104900 BS90105000 BS90105100 BS90105200 Description Qty. 4 4
* SCREW (M4 X 8 mm). 6 WASHER... 4 HINGER... 2 COVER... 1 * NUT (M3)... 8 BUCKLE SPRING.. 2 CLAMP BRACKET... 2 * SCREW (M3 X 8 mm). 8 LATCH.. 2 BLADE.. 1 RETAINING RING.. 2 BEARING.. 4 UPPER WHEEL.. 1 LOWER WHEEL.. 1 BOLT.. 1 BRACKET.. 1 GEAR... 1 BEARING.. 2 PIN... 1 GUIDE (B).. 2 * SCREW (M5 X 10 mm).. 3 GUIDE (A).. 2 UPPER GUIDE BRACKET.. 2 BLADE GUIDE.. 1 * SCREW (M5 X 12 mm).. 6 TENSION KNOB.. 1
WASHER... STEEL PLATE.. SPRING... ALUMINUM HOUSING. ELEVATING PLATE.. SCREW (M6 X 8 mm).. SCREW... WASHER... SHAFT.. ADJUSTING PLATE.. ELASTIC PIN.. SWITCH... SCREW (M4 X 10 mm).. SWITCH PLATE... BRUSH... WHEEL TIRE.. BELT WHEEL.. BELT... BELT WHEEL.. SHAFT.. BASE.. WASHER... WASHER... BOLT (M10 X 16 mm).. BOLT (M6 X 16 mm).. WASHER...
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
Key No. Part Number BS90105300 BS90105400 BS90105500 BS90105600 BS90105700 BS90105800 BS90105900 BS90106000 BS90106100 BS90106200 BS90106300 BS90106400 BS90106500 BS90106600 BS90106700 BS90106800 BS90106900 BS90107000 BS90107100 BS90107200 BS90107300 BS90107400 BS90107500 BS90107600 BS90107700 BS90107800 Description Qty. Key No. 99 Part Number BS90107900 BS90108000 BS90108100 BS90108200 BS90108300 BS90108400 BS90108500 BS90108600 BS90108700 BS90110101 BS90113800 BS90108800 BS90108900 BS90109000 BS90109100 BS90109200 BS90109300 BS90109400 BS90109800 BS90109900 BS90110000 972000-883 972000-883R 1-13-04 Description Qty. 1
WASHER... TRUNNION BRACKET. WASHER... TABLE LOCKING HANDLE.. SCREW (M6 X 30 mm).. NUT (M6).. TABLE.. TABLE INSERT... GUIDE BAR.. POINTER... SCREW (M5 X 6 mm).. MITER GUAGE.. RUBBER WASHER... KNOB.. BOLT (M8 X 25 mm).. MOTOR... POINTER... NUT (M4).. SCREW (M6 X 20 mm).. WING NUT (M6)... LOCK KNOB... WASHER... SPRING... ADJUSTING KNOB... TRACKING KNOB.. WINDOW VIEWER..
FIXING PLATE.. POWER CORD.. STRAIN RELIEF.. BOLT.. KNOB.. SPRING... * NUT (M6).. ANGLE SCALE LABEL.. ADAPTOR.. RUBBER BUMPER... SWITCH KEY (NOT SHOWN).. DATA PLATE (NOT SHOWN).. BOTTOM WARNING LABEL (NOT SHOWN). LOGO PLATE (NOT SHOWN).. TENSION LABEL (NOT SHOWN). DANGER LABEL (NOT SHOWN).. DEPTH SCALE LABEL (NOT SHOWN).. WINDOW VIEWER LABEL (NOT SHOWN).. 3 mm HEX KEY (NOT SHOWN). 4 mm HEX KEY (NOT SHOWN). 5 mm HEX KEY (NOT SHOWN). OPERATOR'S MANUAL REPAIR SHEET

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 ATTENTION:
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. 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 2,900 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.

UNPACKING

To prevent accidental starting that could cause possible serious personal injury, assemble all parts to your saw before connecting it to power supply. Saw should never be connected to power supply when you are assembling parts, making adjustments, installing or removing blades, or when not in use. s Carefully remove all parts from the carton and place the saw on a level work surface. Separate and check against the list of loose parts.

If any parts are missing, do not operate this tool until the missing parts are replaced. Failure to do so could result in possible serious personal injury. s Do not discard the packing materials until you have carefully inspected the saw, identified all parts, and satisfactorily operated your new saw. Note: If any parts are damaged or missing, do not attempt to plug in the power cord and turn the switch on until the damaged or missing parts are obtained and are installed correctly.

Page 7

LOOSE PARTS LIST
Check all loose parts from the box with the list below. Assemble according to the instructions on the following pages. 3 mm Hex Key... mm Hex Key... mm Hex Key... 1 Miter Gauge.. 1 Saw Table... 1 Table Lock Handle.. 1 Washer... 1 Operators Manual (not shown).. 1
3 mm HEX KEY SAW TABLE 4 mm HEX KEY MITER GAUGE 5 mm HEX KEY WASHER
The following tools (not included) are needed for checking adjustments of your saw or for installing the blade: Adjustable Wrench Combination Square Phillips Screwdriver ADJUSTABLE WRENCH

COMBINATION SQUARE

TABLE LOCK HANDLE

Fig. 2

TOOLS NEEDED
PHILLIPS SCREWDRIVER Page 8

FEATURES

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 11-3/8 in. (28.9 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 Support

Helps keep the blade from twisting during operation.
Scale and Scale Indicator
The scale and scale indicator show the angle or degree the saw table is tilted for bevel cutting.
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.

WING NUT

WASHER

Fig. 4

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. s Each hole in the saw base should be bolted securely using bolts, lock washers, and hex nuts (not included). s 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. s Drill four holes through the workbench. s Place band saw on the workbench aligning holes in the saw base with the holes drilled in the workbench. s Insert all four 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. NUT SPRING WASHER
ANGLE ADJUSTMENT KNOB Fig. 5

Page 10

CLAMPING BAND SAW TO WORKBENCH
See Figure 6. 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. s 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. s Follow the last three steps in the section Mounting Band Saw to Workbench, page 10. 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.

REMOV E TO LOCK

Fig. 6

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. BLADE GUIDE KNOB BLADE GUIDE ASSEMBLY LOCK LEVER
ADJUSTING BLADE GUIDE ASSEMBLY
See Figure 7. 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. s Turn the lock lever counterclockwise to unlock the blade guide assembly. s 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 blade guide assembly by turning the blade guide knob. s Lock blade guide assembly in place by turning the lock lever clockwise. s Always lock the blade guide assembly in place before turning on the band saw.

To avoid personal injury, maintain proper adjustment of blade tension, blade guides, and thrust bearings. Page 11 Fig. 7
INSTALLING AND ADJUSTING THE BLADE

See Figures 8 and 9.

Failure to turn the saw off, remove the switch key, and unplug the saw could result in accidental starting causing possible serious personal injury. s Loosen and remove the wing nut and table aligning bolt from the saw table. See Figure 8. s Remove the saw table before opening the front cover of the saw housing. s 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 8. s Turn the lock lever 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 lever.

MOV E LOCK

BLADE GUARD

SET SCREWS

SAW TABLE TABLE ALIGNING BOLT Fig. 8
s Reattach the saw table and the aligning bolt, washer, and wing nut. Tighten securely. s Reattach the blade guard. s Close front cover.
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. s Release blade tension by loosening the 8 mm hex nut then turning the blade tension knob counterclockwise. See Figure 9. s Carefully remove the old blade. Note: The spring on the upper wheel allows the wheel to be pulled down for easier removal of the blade. s 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. s 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. s Slowly turn the upper wheel to the right or clockwise by hand to center the blade on the rubber tires. s Adjust the blade tension; check or adjust the blade tracking. See page 13. s Adjust both upper and lower blade guides and thrust bearings. See page 14. Page 12 UPPER WHEEL 8mm HEX NUT BLADE TENSION KNOB

BLADE GUIDE ASSEMBLY SAW BLADE

LOWER BLADE GUIDES

LOWER WHEEL

Fig. 9

ADJUSTING BLADE TENSION
See Figures 10 and 11. s Turn off and unplug the saw. Remove the switch key.
Failure to turn the saw off, remove the switch key, and unplug the saw could result in accidental starting causing possible serious personal injury. s Before using the band saw, turn the blade tension knob on the top of the saw clockwise to engage tension. See Figure 10. s To check tension, raise the blade guide assembly all the way up to expose the blade. s Push the blade to the side with moderate force; the blade should flex approximately 1/8 in. (3 mm). 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. s 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. s 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. BLADE ON WHEEL

TRACKING VIEW WINDOW

BLADE TRACKING KNOB
Fig. 11 Note: Adjust blade tension properly before making tracking adjustments. Check that the blade guides are not interfering with the blade.

To Adjust:

TO DECREASE TENSION s 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.

TO INCREASE TENSION

If the blade has moved left or right of center:
s 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. s 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. s 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. s 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.

Fig. 10

TRACKING THE BLADE

See Figure 11.

Failure to turn the saw off, remove the switch key, and unplug the saw could result in accidental starting causing possible serious personal injury.

Page 13

ADJUSTING THRUST BEARINGS, BLADE GUIDE SUPPORT, AND BLADE GUIDES
See Figures 13, 14, and 15. 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.

BLADE GUIDE ASSEMBLY

MAX CUTIMUM CAP TING ACIT Y

ZERO STOP SET SCREW

SAW BLADE SMALL COMBINATION SQUARE
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. Note: The thrust bearing screw is the upper cap screw located on the right side of the blade guide assembly. It is the lower cap screw on the right side of the saw housing below the saw table for the lower bearing. See Figures 13 and 14. s Remove the blade guard by loosening the two set screws with the 4 mm hex key. s Turn the lock lever 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 lever.

Fig. 12

SQUARING THE SAW TABLE TO THE BLADE

See Figure 12.

Failure to turn the saw off, remove the switch key, and unplug the saw could result in accidental starting causing possible serious personal injury. s Remove the blade guard by loosening the two set screws with the 4 mm hex key. s Turn the lock lever counterclockwise to unlock the blade guide assembly. Turning the blade guide knob clockwise, raise the blade guide assembly as far as it will go. Retighten the blade guide knob. s Place a small combination square on the saw table beside the blade. s Loosen the table lock handle 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 handle. s Using an adjustable wrench, adjust the zero stop set screw until the set screw just touches the saw housing. s Check squareness of the saw table to the blade. Make readjustments if necessary. s Loosen screw on scale indicator with a phillips screwdriver and align scale indicator to zero. s Tighten all screws securely. s Replace the blade guard once the saw table has been squared.

BLADE GUIDE ASSEMBLY THRUST BEARING THRUST BEARING SCREW
UPPER BLADE GUIDE SUPPORT

BLADE GUIDE SCREWS

BLADE GUIDE SUPPORT SCREW
BLADE GUARD REMOVED FOR CLARIFICATION ONLY Fig. 13

Page 14

s Adjust the thrust bearings first. Using the 4 mm hex key, loosen the thrust bearing screw. s Move the thrust bearing to within 1/64 in. (0.4 mm) of the blade. Tighten the thrust bearing screw securely. Repeat this procedure on the lower thrust bearing located below the saw table. s Replace the blade guard if no additional adjustments are to be made. UPPER BLADE GUIDE SUPPORT THRUST BEARING THRUST BEARING SCREW BLADE GUIDE ASSEMBLY
To Adjust Blade Guide Support:
s Remove the blade guard by loosening the two set screws with the 4 mm hex key. s Adjust the position of the blade guide assembly. Loosen the bottom screw on the right side of the blade guide assembly using the 4 mm hex key. s Slide the upper blade guide support on the shaft until the front edge of the blade guides are about 1/64 in. (0.4 mm) behind the gullet of the blade. Tighten the screw securely. Repeat this procedure for the lower blade guide support. s Replace the blade guard if no additional adjustments are to be made. Note: The lower blade guide support screw is the top screw located on the right of the saw housing under the table. See Figure 14.
BLADE GUIDES BLADE GUIDE SUPPORT SCREW BLADE GUARD REMOVED FOR CLARIFICATION ONLY Fig. 15

To Adjust Blade Guides:

The blade guides help keep the blade from twisting and binding. The blade will be ruined if the blade teeth hit the blade guides while using the band saw. The set of teeth and the sharpened edge of teeth will be damaged by hitting the blade guides. Proper adjustment of the upper and lower blade guides will prevent this from happening. s Remove the blade guard by loosening the two screws set with the 4 mm hex key. s Loosen the two blade guide support screws that lock the upper blade guides. Slide the two guides to within 1/32 in. (0.8 mm) of the blade. Do not pinch the blade. Make sure one guide is not further away from the blade than the other. Retighten the two blade guide support screws securely. s Replace the blade guard if no additional adjustments are to be made. s Repeat this procedure on the lower blade guides located under the saw table. See Figure 14.

Never operate saw without blade guard secured in place. To do so could result in possible serious personal injury.

THRUST BEARING SCREW

LOWER BLADE GUIDE SUPPORT THRUST BEARING Fig. 14

Page 15

OPERATION
To avoid blade contact, adjust the blade guide assembly to just clear the workpiece. Failure to do so could result in serious personal injury. s 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 cutoff of curve relieving blade pressure.
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.

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. s Place the switch in the OFF position, remove the switch key from the switch assembly. s Unplug the saw from the power source before removing jammed material.

CUTTING PROCEDURES

s Hold the workpiece firmly against the saw table. s Use gentle pressure and both hands when feeding the work into the blade. Do not force the work; allow the AVOIDING INJURY blade to cut. s Make sure saw is level and does not rock. Saw should s The smallest diameter circle that can be cut is determined always be on a firm, level surface with plenty of room for by blade width. A 1/4 in. (6 mm) wide blade will cut a handling and properly supporting the workpiece. minimum diameter of 1-1/2 in. (38 mm); a 1/8 in. (3 mm) s Bolt saw to the support surface to prevent slipping, wide blade will cut a minimum diameter of 1/2 in. (13 mm). walking or sliding during operations like cutting long, s Keep your hands away from the blade. Do not hand hold heavy boards. pieces so small your fingers will go under the blade guard. s Turn saw off, remove switch key, and unplug cord from s Avoid awkward operations and hand positions where a the power source before moving the saw. sudden slip could cause serious injury from contact with s Do not remove jammed cutoff pieces until blade has come the blade. Never place hands in blade path. to a full and complete stop. s Use extra supports (tables, saw horses, blocks, etc.) s Choose the right size and style blade for the material when cutting large, small or awkward workpieces. and type of cut you plan to do. s Never use a person as a substitute for a table extension s Make sure that the blade teeth point down toward the or as additional support for a workpiece that is longer or saw table, that the blade guides, thrust bearings, and wider than the basic saw table. blade tension are properly adjusted, that the blade guide s When cutting irregularly shaped workpieces, plan your knob is tight, and that no parts have excessive play. work so it will not pinch the blade. For example, a piece s To avoid accidental blade contact, minimize blade of molding must lay flat on the saw table. Workpieces breakage, and provide maximum blade support, always must not twist, rock or slip while being cut. adjust the blade guide assembly to just clear the When backing up the workpiece, the blade may bind in the workpiece. kerf (cut). This is usually caused by sawdust clogging the s Use only recommended accessories. kerf or when the blade comes out of the guides. If this s With the exception of the workpiece and related support happens: devises, clear everything off the saw table before turning s Wait until the saw has come to a full and complete stop. the saw on. s Place the switch in the OFF position then remove the s Properly support round materials such as dowel rods or switch key from the switch assembly. Store key in a safe tubing because they have a tendency to roll during a cut place. causing the blade to bite. To avoid this, always use a V block or clamp workpiece to a miter gauge s Unplug the saw from the power source. s Before removing loose pieces from the saw table, turn s Wedge the kerf open with a flat screwdriver or wooden saw off and wait for all moving parts to stop. wedge. Page 16

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. s Keep your band saw clean. s Remove sawdust from the inside frequently. s Do not allow pitch to accumulate on the saw table, blade guides, or thrust bearings. Clean them with gum and pitch remover. s Apply a thin coat of automobile type wax to the saw tables top so the wood slides easily while cutting.
To avoid fire or electrocution, reassemble electric parts with only identical Ryobi replacement parts. Reassemble exactly as originally assembled.

BRUSHES

See Figure 19.
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. There is a brush located inside the saw housing, next to the lower 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. s Remove the screw and washer then pull the brush off. s Place the new brush in the groove with the plastic tabs under the saw housing. s Retighten using the washer and screw.
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.

Cleaning tires:

s 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.

TIRE BRUSH

Replacing tires:
s Open front cover and remove saw blade. See section on Installing and Adjusting the Blade, page 12. s Pry the worn tire away from the wheel carefully. s Stretch the new tire around the wheel. s Replace the saw blade and close the front cover.

BLADE GUIDES

See Figure 15.
s Blade guides may become rounded and worn during use. Remove the blade guides and file or grind flat. s Replace blade guides when filing or grinding has worn them down and they can no longer be properly secured in place. Fig. 19 Page 18

DRIVE BELT

See Figures 20 and 21.
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. Due to wear or breakage, the drive belt may need to be replaced. The drive belt is located behind the lower wheel of the band saw. s Remove the saw blade and set it aside. See section on Installing and Adjusting the Blade, page 12. s Remove the nut and washer from the middle of the saw housing. See Figure 20. s Pull the lower wheel away from the saw housing. s Remove the worn drive belt. s 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. s Replace the nut and washer on the pulley shaft and retighten. s Replace saw blade. s Check thrust bearings and blade guides. Fig. 20 NUT AND WASHER

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. PULLEY SHAFT
DRIVE BELT LOWER WHEEL MOTOR PULLEY

Fig. 21

Page 19

TROUBLESHOOTING

To prevent accidental starting that could cause possible serious personal injury, turn off the saw, remove the switch key, and unplug the saw from the power source before working on the band saw.

PROBLEM

Motor will not run.
1. Problem with On-Off switch or power cord. 2. Motor defective.

SOLUTION

1. Have worn parts replaced before using band saw again. 2. Do not attempt any repair. Have tool repaired by a qualified service technician. 1. Adjust tracking, See Adjustments section, Tracking the Blade. 1. Stop feeding and back up the material slightly until the band saw speeds up. 2. Replace blade. 1. Adjust tension. See Adjustments section, Adjusting Blade Tension. 2. Use correct cutting technique. See section, Operation. 3. Replace the thrust bearings.
Blade does not run in the approximate center of the upper wheel. Band Saw slows down when cutting.
1. Not tracking properly.
1. Cutting too small a radius.
2. Dull blade. Blade breaking. 1. Too much blade tension. 2. Kink in blade caused by cutting too small radius or turning the material too fast when cutting. 3. Thrust bearings scarred or not rotating. Saw is noisy when running. 1. Too much blade tension. 2. Blade guides and bearings are in contact with the blade.
1. Adjust tension. See Adjustments section, Adjusting Blade Tension. 2. Adjust upper and lower blade guides and bearings. See Adjustments sections, Adjusting Thrust Bearings, Blade Guide Support, and Blade Guides. 1. Adjust upper and lower blade guides and bearings. See Adjustments sections, Adjusting Thrust Bearings, Blade Guide Support, and Blade Guides. 2. Replace blade.
Blade will not cut straight.
1. Blade guides and bearings not properly adjusted.
2. Worn or defective blade.
Blade guides will not stay in position.
1. Blade guide screws have loosened.
1. Tighten blade guide screws securely.

Page 20

NOTES NOTES

Page 21

OPERATOR'S MANUAL 9 in. (229 mm) Band Saw Model BS901

EXTENSION CORD CAUTION

When using a power tool at a considerable distance from a power source, be sure to use an extension cord that has the capacity to handle the current the tool will draw. An undersized cord will cause a drop in line voltage, resulting in overheating and loss of power. Use the chart to determine the minimum wire size required in an extension cord. Only round jacketed cords should be used. When working with a 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 any extension cord, inspect it for loose or exposed wires and cut or worn insulation.

**Ampere rating

(on tool data plate)

2.1-3.4

3.5-5.0

5.1-7.0

7.1-12.0 12.1-16.0

Cord Length

Wire Size (A.W.G.)

25' 50' 100'

CAUTION: Keep the extension cord clear of the working area. Position the cord so that it will not get caught on workpiece, tools, or other obstructions while you are working with a power tool.
**Used on 12 gauge - 20 amp circuit.

SERVICE

Now that you have purchased your tool, should a need ever exist for repair parts or service, simply contact your nearest Ryobi Authorized Service Center. Be sure to provide all pertinent facts when you call or visit. Please call 1-800-525-2579 for your nearest Ryobi Authorized Service Center. You can also check our web site at www.ryobitools.com for a complete list of Authorized Service Centers.

MODEL NO.

The model and serial numbers of your tool will be found on a plate attached to the motor housing. Please record the serial number in the space provided below.
MODEL NUMBER SERIAL NUMBER

RYOBI TECHNOLOGIES, INC.

1428 Pearman Dairy Road Anderson SC 29625 Post Office Box 1207 Anderson SC 29622-1207 Phone 1-800-525-2579 www.ryobitools.com 972000-883