Ryobi Saw BS902 User Guide

OPERATOR’S MANUAL  
9 in. (229 mm) BAND SAW  
BS902  
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.  
WARNING: To reduce the risk of injury, the user must read and understand the operator’s manual before using  
this product.  
Thank you for your purchase.  
SAVE THIS MANUAL FOR FUTURE REFERENCE  
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GENERAL SAFETY RULES  
DO NOT OVERREACH. Keep proper footing and  
balance at all times.  
WARNING:  
MAINTAIN TOOLS WITH CARE. Keep tools sharp  
and clean for better and safer performance. Follow  
instructions for lubricating and changing accessories.  
Read and understand all instructions. Failure to follow  
all instructions listed below, may result in electric shock,  
fire and/or serious personal injury.  
DISCONNECT TOOLS. When not in use, before  
servicing, or when changing attachments, blades, bits,  
cutters,etc.,alltoolsshouldbedisconnectedfrompower  
source.  
READ ALL INSTRUCTIONS  
KNOWYOURPOWERTOOL.Readtheoperator’smanual  
carefully. Learn the applications and limitations as well  
as the specific potential hazards related to this tool.  
REDUCE THE RISK OF UNINTENTIOINAL STARTING.  
Be sure switch is off when plugging in any tool.  
GUARD AGAINST ELECTRICAL SHOCK by preventing  
bodycontactwithgroundedsurfaces.Forexample:pipes,  
radiators, ranges, refrigerator enclosures.  
USE RECOMMENDED ACCESSORIES. Consult the  
operator’s manual for recommended accessories. The  
use of improper accessories may result in injury.  
KEEPGUARDSINPLACEandingoodworkingorder.Nev-  
eroperatethetoolwithanyguardorcoverremoved.Make  
sure all guards are operating properly before each use.  
NEVERSTANDONTOOL.Seriousinjurycouldoccurifthe  
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  
carefullycheckedtodeterminethatitwilloperateproperly  
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.  
REMOVE ADJUSTING KEYS AND WRENCHES. Form  
habitofcheckingtoseethatkeysandadjustingwrenches  
are removed from tool before turning it on.  
KEEPWORKAREACLEAN.Clutteredareasandbenches  
invite accidents.  
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.  
DIRECTION OF FEED. Feed work into a blade or cutter  
KEEP CHILDREN AND VISITORS AWAY. All  
visitors should wear safety glasses and be kept a safe  
distance from work area.  
againstthedirectionorrotationofthebladeorcutteronly.  
NEVERLEAVETOOLRUNNINGUNATTENDED.TURN  
THE POWER OFF. Don't leave tool until it comes to a  
complete stop.  
MAKE WORKSHOP CHILDPROOF with padlocks,  
master switches, or by removing starter keys.  
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.  
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 attach-  
PROTECT YOUR LUNGS. Wear a face or dust mask if  
ment to do a job for which it was not designed.  
the cutting operation is dusty.  
USETHEPROPEREXTENSIONCORD. Makesureyour  
extensioncordisingoodcondition.Useonlyacordheavy  
enough to carry the current your product will draw. An  
undersizedcordwillcauseadropinlinevoltageresultingin  
lossofpowerandoverheating. Awiregaugesize(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.Thesmallerthegaugenumber,theheavierthecord.  
PROTECT YOUR HEARING. Wear hearing protection  
during extended periods of operation.  
BLADE COASTS AFTER BEING TURNED 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  
qualifiedservicetechnician.Stayconstantlyawareofcord  
location and keep it well away from the rotating wheel.  
WEAR THE PROPER APPAREL. Do not wear loose  
clothing, neckties, or jewelry that can get caught in the  
tool’s moving parts and cause personal injury. Nonslip  
footwear is recommended when working outdoors. Wear  
protective hair covering to contain long hair.  
NEVER USE IN AN EXPLOSIVE ATMOSPHERE.  
Normal sparking of the motor could ignite fumes.  
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  
whenpractical. It’sissaferthanusingyourhandandfrees  
both hands to operate the tool.  
USE ONLY OUTDOOR EXTENSION CORDS with ap-  
proved ground connection that are intended for use  
outdoors and so marked.  
BE SURE BLADE PATH IS FREE OF NAILS. Inspect for  
and remove all nails from lumber before cutting.  
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SPECIFIC SAFETY RULES  
AVOID AWKWARD OPERATIONS AND HAND NEVER START THE TOOL when the blade is in contact  
POSITIONS where a sudden slip could cause your  
hand to move into the blade. ALWAYS make sure you  
have good balance. NEVER operate the miter saw  
on the floor or in a crouched position.  
with the workpiece.  
NEVER TOUCH BLADE or other moving parts during  
use.  
BEFORECHANGINGTHESETUP,REMOVINGCOVERS,  
GUARDS OR BLADES, unplug the saw and remove the  
switch key.  
ALLOW THE MOTOR TO COME UP TO FULL SPEED  
before starting a cut to avoid binding or stalling.  
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.  
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.  
KEEPBLADESCLEAN,SHARP,ANDWITHSUFFICIENT  
SET. Sharp blades minimize stalling and kickbacks.  
WHENSERVICINGuseonlyidenticalreplacementparts.  
Use of any other parts may create a hazard or cause  
product damage.  
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.  
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.  
The blade guides have been preset at the factory. These  
settings are functional for some applications. We recom-  
mend 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  
operator’s manual.  
IF THE POWER SUPPLY CORD IS DAMAGED, it must  
be replaced only by the manufacturer or by an authorized  
service center to avoid risk.  
DO NOT FEED THE MATERIAL TOO QUICKLY. Do not  
force the workpiece against the blade.  
USEONLYCORRECTBLADES.Usetherightbladesize,  
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 ADJUST-  
MENTS ARE SECURE.  
ALWAYSSUPPORTLARGEWORKPIECESwhilecutting  
tominimizeriskofbladepinchingandkickback. Sawmay  
slip, walk or slide while cutting large or heavy boards.  
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.  
DO NOT REMOVE JAMMED CUTOFF PIECES until  
blade has stopped.  
WARNING:  
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.  
4
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SYMBOLS  
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  
V
Volts  
Voltage  
Current  
A
Hz  
W
Amperes  
Hertz  
Watt  
Frequency (cycles per second)  
Power  
min  
Minutes  
Time  
Alternating Current  
Direct Current  
Type of current  
Type or a characteristic of current  
Rotational speed, at no load  
Double-insulated construction  
Revolutions, strokes, surface speed, orbits, etc., per minute  
n
o
No Load Speed  
Class II Construction  
Per Minute  
.../min  
Wet Conditions Alert  
Do not expose to rain or use in damp locations.  
To reduce the risk of injury, user must read and understand  
operator’s manual before using this product.  
Read The Operator’s Manual  
Always wear safety goggles or safety glasses with side shields and,  
as necessary, a full face shield when operating this product.  
Eye Protection  
Safety Alert  
Precautions that involve your safety.  
Failure to keep your hands away from the blade will result in  
serious personal injury.  
No Hands Symbol  
To reduce the risk of injury or damage, avoid contact with any  
hot surface.  
Hot Surface  
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SYMBOLS  
The following signal words and meanings are intended to explain the levels of risk associated with this product.  
SYMBOL  
SIGNAL  
MEANING  
Indicates an imminently hazardous situation, which, if not avoided, will result  
in death or serious injury.  
DANGER:  
Indicates a potentially hazardous situation, which, if not avoided, could result  
in death or serious injury.  
WARNING:  
CAUTION  
CAUTION  
Indicates a potentially hazardous situation, which, if not avoided, may result in  
minor or moderate injury.  
(Without Safety Alert Symbol) Indicates a situation that may result in property  
damage.  
SERVICE  
WARNING:  
Servicing requires extreme care and knowledge and should  
be performed only by a qualified service technician. For  
service we suggest you return the product to the nearest  
AUTHORIZED SERVICE CENTER for repair. When servic-  
ing, use only identical replacement parts.  
To avoid serious personal injury, do not attempt to use this  
product until you read thoroughly and understand com-  
pletely the operator’s manual. If you do not understand  
the warnings and instructions in the operator’s manual,  
do not use this product. Call Ryobi customer service for  
assistance.  
WARNING:  
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 power tool operation, always wear safety goggles or  
safety glasses with side shields and, when needed, a full face shield. We recommend Wide Vision  
Safety Mask for use over eyeglasses or standard safety glasses with side shields. Always use eye  
protection which is marked to comply with ANSI Z87.1.  
SAVE THESE INSTRUCTIONS  
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ELECTRICAL  
EXTENSION CORDS  
SPEED AND WIRING  
Use only 3-wire extension cords that have 3-prong ground-  
ing 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.  
The no-load speed of this tool is approximately 3,000  
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 tools.  
GROUNDING INSTRUCTIONS  
**Ampere rating (on tool data plate)  
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 conduc-  
tor 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.  
0-2.0  
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'  
16  
16  
16  
16  
16  
16  
16  
16  
14  
16  
14  
12  
14  
14  
10  
14  
12  
100'  
**Used on 12 gauge - 20 amp circuit.  
NOTE: AWG = American Wire Gauge  
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 conduc-  
tor can result in a risk of electric shock. The conductor with  
insulationhavinganoutersurfacethatisgreenwithorwithout  
yellowstripesistheequipment-groundingconductor.Ifrepair  
or replacement of the electric cord or plug is necessary, do  
not connect the equipment-grounding conductor to a live  
terminal.  
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.  
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.  
WARNING:  
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.  
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.  
WARNING:  
Check extension cords before each use. If damaged  
replace immediately. Never use tool with a damaged cord  
since touching the damaged area could cause electrical  
shock resulting in serious injury.  
ELECTRICAL CONNECTION  
This tool is powered by a precision built electric motor. It  
should be connected to a power supply that is 120 volts,  
60Hz,AConly(normalhouseholdcurrent).Donotoperate  
this tool on direct current (DC). A substantial voltage drop  
will cause a loss of power and the motor will overheat. If the  
saw does not operate when plugged into an outlet, double  
check the power supply.  
GROUNDING  
PIN  
120V GROUNDED OUTLET  
Fig. 1  
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GLOSSARY OF TERMS  
Non-Through Cuts  
Any cutting operation where the blade does not extend  
completely through the thickness of the workpiece.  
Anti-Kickback Pawls (radial arm and table saws)  
A devise which, when properly installed and maintained,  
is designed to stop the workpiece from being kicked back  
toward the front of the saw during a ripping operation.  
Push Blocks (for jointer planers)  
Device used to feed the workpiece over the jointer planer  
cutterhead during any operation. This aid helps keep the  
operator's hands well away from the cutterhead.  
Arbor  
The shaft on which a blade or cutting tool is mounted.  
Bevel Cut  
Push Blocks and Push Sticks (for table saws)  
A cutting operation made with the blade at any angle other  
Devices used to feed the workpiece through the saw blade  
during cutting operations. A push stick (not a push block)  
should be used for narrow ripping operations. These aids  
help keep the operator's hands well away from the blade.  
than 90° to the table surface.  
Chamfer  
A cut removing a wedge from a block so the end (or part of  
the end) is angled rather than at 90°.  
Pilot Hole (drill presses)  
A small hole drilled in a workpiece that serves as a guide for  
drilling large holes accurately.  
Compound Cut  
A cross cut made with both a miter and a bevel angle.  
Crosscut  
Resaw  
A cutting or shaping operation made across the grain or the  
width of the workpiece.  
A cutting operation to reduce the thickness of the workpiece  
to make thinner pieces.  
Cutterhead (planers and jointer planers)  
A rotating cutterhead with adjustable blades or knives. The  
blades or knives remove material from the workpiece.  
Resin  
A sticky, sap-based substance that has hardened.  
Revolutions Per Minute (RPM)  
The number of turns completed by a spinning object in one  
minute.  
Dado Cut  
A non-through cut which produces a square-sided notch or  
trough in the workpiece (requires a special blade).  
Ripping or Rip Cut  
A cutting operation along the length of the workpiece.  
Featherboard  
A device used to help control the workpiece by guiding  
it securely against the table or fence during any ripping  
operation.  
Riving Knife/Spreader/Splitter (table saws)  
A metal piece, slightly thinner than the blade, which helps  
keep the kerf open and also helps to prevent kickback.  
FPM or SPM  
Feet per minute (or strokes per minute), used in reference  
to blade movement.  
Saw Blade Path  
The area 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.  
Freehand  
Performing a cut without the workpiece being guided by a  
fence, miter gauge, or other aids.  
Set  
The distance that the tip of the saw blade tooth is bent (or  
set) outward from the face of the blade.  
Gum  
A sticky, sap-based residue from wood products.  
Snipe (planers)  
Heel  
Depression made at either end of a workpiece by cutter  
blades when the workpiece is not properly supported.  
Alignment of the blade to the fence.  
Kerf  
Through Sawing  
Any cutting operation where the blade extends completely  
through the thickness of the workpiece.  
The material removed by the blade in a through cut or the  
slot produced by the blade in a non-through or partial cut.  
Kickback  
Throw-Back  
A hazard that can occur when the blade binds or stalls,  
The throwing back of a workpiece usually caused by the  
workpiece being dropped into the blade or being placed  
inadvertently in contact with the blade.  
throwing the workpiece back toward operator.  
Leading End  
The end of the workpiece pushed into the tool first.  
Workpiece or Material  
The item on which the operation is being done.  
Miter Cut  
A cutting operation made with the workpiece at any angle  
Worktable  
to the blade other than 90°.  
Surface where the workpiece rests while performing a  
cutting, drilling, planing, or sanding operation.  
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FEATURES  
Table Size ................................ 11-13/16 in. x 11-13/16 in.  
PRODUCT SPECIFICATIONS  
Input ............................... 120 V, 60 Hz, AC only, 2.5 Amps  
No Load Speed ............................3,000 FPM (1,524 cm/s)  
Dust Port ...............................................................2-1/4 in.  
Net Weight............................................................... 37 lbs.  
Blade Width...............................................1/8 in. to 3/8 in.  
Blade Length.........................................59-1/4 - 59-1/2 in.  
Frame to Blade Capacity............................................. 9 in.  
Cutting Thickness Capacity ..................................3-5/8 in.  
RAPIDSET™ BLADE  
TENSION LEVER  
TRACKING  
KNOB  
WORKLIGHT  
LOCK  
KNOB  
BLADE TENSION  
KNOB  
TRACKING  
VIEW WINDOW  
LATCH  
TABLE  
LOCK  
KNOB  
SCALE  
ANGLE  
ADJUSTMENT  
KNOB  
BLADE  
GUARD  
TRACKLOCK®  
BLADE GUIDE  
SCALE  
INDICATOR  
SAW BLADE  
DUST  
EXHAUST  
PORT  
SWITCH  
AND  
SWITCH KEY  
MITER  
GAUGE  
SAW TABLE  
LATCH  
RIP  
FENCE  
Fig. 2  
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FEATURES  
KNOW YOUR BAND SAW  
SAW BLADE  
Saw comes with a standard 1/4 in. (6 mm) blade.  
The safe use of this product requires an understanding of  
the information on the tool and in this operator’s manual as  
wellasaknowledgeoftheprojectyouareattempting.Before  
use of this product, familiarize yourself with all operating  
features and safety rules.  
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.  
SCALE AND SCALE INDICATOR  
The scale and scale indicator show the angle or degree the  
saw table is tilted for bevel cutting.  
BLADE GUARD  
Protects the operator from coming in contact with the  
blade.  
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.  
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 break-  
ing. Always lock the blade guide assembly in place before  
turning on the band saw.  
TABLE LOCK KNOB  
Loosening the table lock knob allows the saw table to be  
tiltedatdifferentangles. Tighteningthetablelockknoblocks  
the saw table in place.  
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.  
TRACKING KNOB  
Adjusts tracking to keep blade centered on the wheels.  
LATCH  
TRACKING VIEW WINDOW  
The tracking view window makes tracking adjustments  
easier to see.  
Easy open latches allow front cover to be opened for mak-  
ing adjustments.  
TRACKLOCK® BLADE GUIDES  
MITER GAUGE  
Upper and lower TrackLock® blade guides helps keep the  
blade from twisting during operation.  
This gauge aligns the wood for a crosscut. The easy-to-read  
indicator shows the exact angle for a miter cut, with positive  
stops at 90° and 45°.  
WORKLIGHT  
Your band saw comes equipped with a worklight that lights  
the work area for safer, more accurate cuts.  
RAPIDSET™ BLADE TENSION LEVER  
Controls blade tension when changing blades and making  
adjustments for various sawing applications.  
RIP FENCE  
A sturdy metal fence guides the workpiece and is secured  
with the rip fence handle.  
10  
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TOOLS NEEDED  
The following tools (not included) are needed for making adjustments or installing the blade:  
COMBINATION  
SQUARE  
PHILLIPS SCREWDRIVER  
Fig. 5  
LOOSE PARTS LIST  
The following items are included with the tool:  
Table Aligning Bolt......................................................... 1  
Hex Key, 4 mm.............................................................. 1  
Rip Fence ...................................................................... 1  
Miter Gauge................................................................... 1  
Saw Table...................................................................... 1  
Wing Screw ................................................................... 1  
Wing Nut........................................................................ 1  
Flat Head Screw............................................................ 3  
Worklight ....................................................................... 1  
Washer .......................................................................... 1  
Switch Key .................................................................... 1  
Operator’s Manual (not shown) ..................................... 1  
WORKLIGHT  
SWITCH  
KEY  
MITER GAUGE  
SAW TABLE  
RIP FENCE  
WING NUT  
FLAT HEAD SCREW  
WASHER  
WING SCREW  
4 mm HEX KEY  
TABLE ALIGNING  
BOLT  
Fig. 4  
WARNING:  
The use of attachments or accessories not listed might be hazardous and could cause serious personal injury.  
11  
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ASSEMBLY  
washers and hex nuts (not included).  
UNPACKING  
NOTE: All bolts should be inserted from the top. Install  
the lock washers and hex nuts from the underside of the  
bench.  
This product requires assembly.  
Carefully remove the tool and any accessories from the  
box. Place it on a level work surface.  
Supporting surface where band saw is mounted should be  
examined carefully after mounting to insure that no move-  
ment during use can result. If any tipping or walking is noted,  
secure workbench or support surface before beginning  
cutting operation.  
NOTE: This tool is heavy. To avoid back injury, lift with  
your legs, not your back, and get help when needed.  
Inspect the tool carefully to make sure no breakage or  
damage occurred during shipping.  
Do not discard the packing material until you have care-  
fully inspected and satisfactorily operated the tool.  
If any parts are damaged or missing, please call 1-800-  
525-2579 for assistance.  
CLAMPING BAND SAW TO WORKBENCH  
See Figure 5.  
If the band saw is to be used as a portable tool, it is recom-  
mended that you fasten it permanently to a mounting board  
thatcaneasilybeclampedtoaworkbenchorothersupporting  
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.  
WARNING:  
If any parts are damaged or missing, do not operate this  
tool until the missing parts are replaced. Failure to do so  
could result in possible serious personal injury.  
Mountsawtoboardusingholesinsawbaseasatemplate  
for hole pattern. Locate and mark the holes where the  
band saw is to be mounted.  
WARNING:  
Follow the last three steps in the section Mounting Band  
Do not attempt to modify this tool or create accesso-  
ries 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.  
Saw to Workbench, shown above.  
If lag bolts are used, make sure they are long enough to  
WARNING:  
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, 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.  
HOLES IN  
SAW BASE  
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  
Fig. 5  
saw base with the holes drilled in the workbench.  
Insert bolts (not included) and tighten securely with lock  
12  
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ASSEMBLY  
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.  
SCREW  
NOTE: It may be necessary to countersink hex nuts and  
washers on bottom side of mounting board.  
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.  
Align the screw holes in the saw table with the holes in  
the saw table bracket.  
SAW  
TABLE  
Using the phillips screws, attach the saw table to the saw  
table bracket. Tighten phillips screws securely.  
SAW TABLE  
BRACKET  
Attach the table aligning bolt, washer, and wing nut to  
the saw table.  
NOTE: The wing nut goes below the saw table.  
Fig. 6  
LOCK  
KNOB  
TABLE  
ALIGNING  
BOLT  
BLADE GUIDE  
KNOB  
WASHER  
WING  
NUT  
Fig. 7  
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ASSEMBLY  
SQUARING THE SAW TABLE TO THE BLADE  
See Figure 8.  
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.  
BLADE  
GUARD  
ZERO STOP  
SET SCREW  
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.  
SAW  
BLADE  
SMALL  
COMBINATION  
SQUARE  
ADJUSTING BLADE TENSION  
See Figures 9 and 10.  
Turn off and unplug the saw. Remove the switch key.  
Before using the band saw, turn the blade tension knob  
Fig. 8  
on the top of the saw clockwise to engage tension.  
TO DECREASE  
TENSION  
TO INCREASE  
TENSION  
NOTE: Adjustments of blade tension can be made at  
anytime.  
Anothermethodofcheckingbladetensionhastodowiththe  
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 devel-  
oped with practice.  
BLADE TENSION KNOB  
Fig. 9  
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.  
14  
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ASSEMBLY  
TRACKING THE BLADE  
See Figure 10.  
BLADE  
TENSION  
KNOB  
NOTE:Adjustbladetensionproperlybeforemakingtracking  
adjustments. Check that the blade guides are not interfering  
with the blade.  
To Adjust:  
Open the front cover by releasing the upper and lower  
latches. Watch the blade’s 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.  
BLADE ON  
WHEEL  
TRACKING  
VIEW  
WINDOW  
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.  
BLADE  
TRACKING  
KNOB  
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.  
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.  
Fig. 10  
NOTE: The 1/8 in. 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.  
WORKLIGHT  
BRACKET  
ATTACHING THE WORKLIGHT  
See Figure 11.  
Open the cover of the saw housing.  
Slide the worklight bracket into the slot at the back of the  
band saw housing and into the slots on the inside of the  
band saw.  
Securely tighten the wing screw clockwise to hold the  
worklight firmly in place.  
Close the saw housing cover.  
IMPORTANT SAFETY INSTRUCTIONS  
This worklight has a polarized plug (one blade wider than  
the other) as a feature to reduce the risk of electric shock.  
This plug will fit in a polarized outlet onlly one way. If the  
plug does not fit fully in the outlet, reverse the plug. If it still  
does not fit, contact a qualified electrician. Never use with  
an extension cord unless the plug can be fully inserted. Do  
not alter the plug.  
Fig. 11  
15  
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OPERATION  
CUTTING PROCEDURES  
Hold the workpiece firmly against the saw table.  
WARNING:  
Do not allow familiarity with tools to make you care-  
less. Remember that a careless fraction of a second is  
sufficient to inflict serious injury.  
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.  
WARNING:  
Always wear safety goggles or safety glasses with side  
shields when operating power tools. Failure to do so  
could result in objects being thrown into your eyes  
resulting in possible serious injury.  
WARNING:  
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.  
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:  
WARNING:  
To avoid blade contact, adjust the blade guide assembly  
to just clear the workpiece. Failure to do so could result  
in serious personal injury.  
APPLICATIONS  
You may use this tool for the purposes listed below:  
Wait until the saw has come to a full and complete  
stop.  
Scroll cutting and circle cutting of wood and wood  
composition products  
Relief cutting of wood and wood composition products  
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  
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.  
wedge.  
Open front cover and turn the upper wheel by hand while  
backing up the workpiece.  
RELIEF CUTS  
This band saw is designed to cut wood and wood composi-  
tion products only.  
Relief cuts are made when an intricate curve (too small  
a radius for the blade) is to be cut. Cut through a scrap  
sectionoftheworkpiecetocurveinpatternlinethencarefully  
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 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.  
16  
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OPERATION  
SCROLL CUTTING  
For general type scroll cutting, follow the pattern lines by  
LOCKING THE SWITCH  
See Figure 12.  
pushing and turning the workpiece at the same time. Do not Wait until the saw has come to a full and complete  
try to turn the workpiece while engaged in the blade without  
pushing it – the workpiece could bind or twist the blade.  
stop.  
Place the switch in the OFF position, remove the switch  
key from the switch assembly. Store key in a safe  
REMOVING JAMMED MATERIAL  
Neverremovejammedcutoffpiecesuntilthebladehascome  
to a full and complete stop.  
place.  
BEFORE LEAVING THE SAW  
See Figure 12.  
Place the switch in the OFF position, remove the switch  
key from the switch assembly.  
Unplug the saw from the power source before removing  
Wait until the saw has come to a full and complete  
stop.  
jammed material.  
Place the switch in the OFF position, remove the switch  
key from the switch assembly. Store key in a safe  
place.  
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.  
Unplug the saw from the power source.  
Make workshop childproof.  
Lock the shop.  
Turn saw off, remove switch key, and unplug cord from  
ON  
OFF  
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.  
SWITCH  
KEY  
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.  
Fig. 12  
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.  
17  
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OPERATION  
TILTING THE TABLE  
See Figure 13.  
Loosen the table lock handle slightly.  
SAW  
TABLE  
Turn the angle adjustment knob, tilting the saw table  
toward the front of the saw housing until it reaches the  
desired angle.  
Using the scale indicator, check angle markings.  
Retighten the table lock handle to hold saw table securely  
in place.  
TABLE LOCK  
KNOB  
USING THE MITER GAUGE  
See Figures 13 and 14.  
SCALE  
INDICATOR  
Fig. 13  
The miter gauge can be turned 60° to the right or left.  
Loose 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.  
Retighten the lock knob.  
MITER  
GAUGE  
SLOT  
NOTE: For convenience, store the miter gauge in the slot  
provide on the back of the band saw.  
LOCK  
KNOB  
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.  
MITER  
GAUGE  
WARNING:  
To reduce the risk of injury, always make sure the rip fence  
is parallel to the blade before beginning any operation.  
Fig. 14  
RIP FENCE  
Fig. 15  
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ADJUSTMENTS  
INSTALLING AND ADJUSTING THE BLADE  
See Figures 16 and 17.  
Loosen and remove the wing nut and table aligning bolt  
from the saw table.  
SET SCREWS  
BLADE  
GUARD  
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.  
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.  
SAW  
TABLE  
WING  
NUT  
TABLE ALIGNING  
BOLT  
Fig. 16  
Release blade tension by pushing the RapidSet™blade  
tension lever to the left.  
RAPIDSET™ BLADE  
TENSION LEVER  
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.  
BLADE  
TENSION  
KNOB  
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  
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 track-  
ing and re-engage the RapidSet™blade tension lever.  
Adjust both upper and lower blade guides and thrust  
bearings.  
BLADE GUIDE  
ASSEMBLY  
Reattach the aligning bolt, washer, and wing nut. Tighten  
securely.  
SAW BLADE  
Reattach the blade guard.  
Close front cover.  
LOWER  
BLADE  
GUIDES  
LOWER  
WHEELS  
Fig. 17  
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ADJUSTMENTS  
ADJUSTING BLADE GUIDE ASSEMBLY  
See Figures 18 and 19.  
BLADE GUIDE  
KNOB  
WARNING:  
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 operator’s manual.  
BLADE GUIDE  
ASSEMBLY  
LOCK  
KNOB  
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  
abouttocuttosettheheightofthebladeguideassembly.  
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  
WARNING:  
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).  
LOCK  
UNLOCK  
Fig. 19  
20  
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ADJUSTMENTS  
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.  
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.  
WARNING:  
Never operate saw without blade guard secured in  
place. To do so could result in possible serious personal  
injury.  
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.  
BLADE  
GUIDE  
ASSEMBLY  
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 20  
and 21.  
THRUST  
BEARING  
UPPER BLADE  
GUIDE SUPPORT  
THRUST  
BEARING  
SCREW  
Remove the blade guard by loosening the two phillips  
screws.  
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.  
BLADE GUIDE  
SUPPORT SCREW  
BLADE GUIDE  
SCREWS  
Adjust the thrust bearings first. Using the 4 mm hex key,  
loosen the thrust bearing screw.  
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.  
BLADE GUARD REMOVED  
FOR CLARIFICATION ONLY  
Fig. 20  
Replace the blade guard if no additional adjustments are  
to be made.  
To Adjust Blade Guide Support:  
Remove the blade guard by loosening the two phillips  
screws.  
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.  
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.  
BLADE GUIDE  
SUPPORT SCREW  
THRUST  
BEARING  
SCREW  
BLADE GUIDE  
SCREWS  
LOWER BLADE  
GUIDE SUPPORT  
Replace the blade guard if no additional adjustments are  
to be made.  
THRUST BEARING  
Fig. 21  
21  
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ADJUSTMENTS  
To Adjust Blade Guides:  
BLADE GUIDE  
ASSEMBLY  
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.  
UPPER BLADE  
GUIDE  
SUPPORT  
THRUST  
BEARING  
Remove the blade guard by loosening the two phillips  
screws.  
THRUST  
BEARING  
SCREW  
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.  
Replace the blade guard if no additional adjustments are  
to be made.  
Repeat this procedure on the lower blade guides located  
under the saw table. See Figure 21.  
BLADE GUIDES  
BLADE GUIDE  
SUPPORT SCREW  
BLADE GUARD REMOVED  
FOR CLARIFICATION ONLY  
Fig. 22  
MAINTENANCE  
Keep your band saw clean.  
WARNING:  
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.  
When servicing, use only identical replacement parts.  
Use of any other parts may create a hazard or cause  
product damage.  
WARNING:  
WARNING:  
Always wear safety goggles or safety glasses with side  
shields during power tool operation or when blowing  
dust. If operation is dusty, also wear a dust mask.  
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.  
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.  
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 lubrica-  
tion is required.  
WARNING:  
Do not at any time let brake fluids, gasoline, petroleum-  
based products, penetrating oils, etc., come in contact  
with plastic parts. Chemicals can damage, weaken or  
destroy plastic which may result in serious personal  
injury.  
MOTOR/ELECTRICAL  
Frequently vacuum or blow out sawdust from the motor.  
BLADE GUIDES  
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.  
22  
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MAINTENANCE  
Remove the nut and washer from the middle of the saw  
TIRES  
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 pul-  
ley 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 re-  
tighten.  
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 saw blade.  
Check thrust bearings and blade guides.  
Replace the saw blade and close the front cover.  
BRUSHES  
See Figure 23.  
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.  
Remove the screw then pull the brush off.  
Place the new brush in the groove.  
Retighten using the screw.  
DRIVE BELT  
See Figures 24 and 25.  
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.  
NUT  
AND  
WASHER  
Remove the saw blade and set it aside. See section on  
Installing and Adjusting the Blade, page 17.  
TIRE  
LOWER  
WHEEL  
SCREW  
BRUSH  
Fig. 24  
PULLEY  
SHAFT  
DRIVE BELT  
Fig. 23  
MOTOR PULLEY  
LOWER  
WHEEL  
Fig. 25  
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TROUBLESHOOTING  
PROBLEM  
CAUSE  
SOLUTION  
Motor will not run.  
1. Problem with On-Off switch or  
power cord.  
1. Have worn parts replaced before  
using band saw again.  
2. Motor defective.  
2. Do not attempt any repair. Have  
tool repaired by a qualified  
service technician.  
Blade does not run in the approxi-  
mate center of the upper wheel.  
1. Not tracking properly.  
1. Adjust tracking, See Adjustments  
section, Tracking the Blade.  
Band Saw slows down when  
1. Cutting too small a radius.  
material slightly until the band  
1. Stop feeding and back up the cutting.  
saw speeds up.  
2. Dull blade.  
2. Replace blade.  
Blade breaking.  
1. Too much blade tension.  
1. Adjust tension. See Adjustments  
section, Adjusting Blade Tension.  
2. Kink in blade caused by cutting  
too small radius or turning the  
material too fast when cutting.  
2. Use correct cutting technique.  
See section, Operation.  
3. Thrust bearings scarred or not  
rotating.  
3. Replace the thrust bearings.  
Saw is noisy when running.  
1. Too much blade tension.  
1. Adjust tension. See Adjustments  
section, Adjusting Blade Tension.  
2. Blade guides and bearings  
are in contact with the blade.  
2. Adjust upper and lower blade  
guides and bearings. See Adjustments  
sections, Adjusting Thrust Bearings,  
Blade Guide Support, and Blade  
Guides.  
Blade will not cut straight.  
1. Blade guides and bearings not  
properly adjusted.  
1. Adjust upper and lower blade  
guides and bearings. See Adjust-  
ments sections, Adjusting Thrust  
Bearings, Blade Guide Support,  
and Blade Guides.  
2. Worn or defective blade.  
2. Replace blade.  
Blade guides will not stay in position. 1. Blade guide screws have  
loosened.  
1. Tighten blade guide screws  
securely.  
24  
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NOTES  
25  
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OPERATOR’S MANUAL  
9 in. (229 mm) BAND SAW  
BS902  
• SERVICE  
Now that you have purchased your tool, should a need ever exist for repair parts or service,  
simply contact your nearest Authorized Service Center. Be sure to provide all pertinent  
facts when you call or visit. Please call 1-800-525-2579 for your nearest Authorized  
list of Authorized Service Centers.  
• MODEL NO. AND SERIAL NO.  
The model number of this tool will be found on a plate attached to the motor housing.  
Please record the model number and serial number in the space provided below.  
• HOW TO ORDER REPAIR PARTS  
When ordering repair parts, always give the following information:  
BS902  
• MODEL NUMBER  
• SERIAL NUMBER  
Ryobi® is a registered trademark of Ryobi® Limited used under license.  
ONE WORLD TECHNOLOGIES, INC.  
1428 Pearman Dairy Road, Anderson, SC 29625  
Phone 1-800-525-2579  
983000-267  
4-20-06 (REV:02)  
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