Ryobi BS903 User Manual

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Ryobi BS903 User Manual

OPERATOR’S MANUAL

9 in. (229 mm) BAND SAW

BS903

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

 

TABLE OF CONTENTS

Introduction .....................................................................................................................................................................

2

Warranty ..........................................................................................................................................................................

2

General Safety Rules.......................................................................................................................................................

3

Specific Safety Rules.......................................................................................................................................................

4

Symbols........................................................................................................................................................................

5-6

Electrical..........................................................................................................................................................................

7

Glossary of Terms............................................................................................................................................................

8

Features......................................................................................................................................................................

9-10

Tools Needed.................................................................................................................................................................

11

Loose Parts ...................................................................................................................................................................

11

Assembly..................................................................................................................................................................

12-15

Operation..................................................................................................................................................................

16-18

Adjustments..............................................................................................................................................................

19-22

Maintenance.............................................................................................................................................................

22-23

Troubleshooting.............................................................................................................................................................

24

Parts Ordering / Service................................................................................................................................................

26

 

INTRODUCTION

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

WARRANTY

RYOBI® POWER TOOL - LIMITED TWO YEAR WARRANTY AND 30 DAY EXCHANGE POLICY

One World Technologies, Inc., warrants its RYOBI® power tools with the following conditions:

30-DAY EXCHANGE POLICY: During the first 30 days after date of purchase, you may either request service under this warranty or you may exchange any RYOBI® power tool which does not work properly due to defective workmanship or materials by returning the power tool to the dealer from which it was purchased. To receive a replacement power tool or requested warranty service, you must present proof of purchase and return all original equipment packaged with the original product. The replacement power tool will be covered by the limited warranty for the balance of the two year period from the date of the original purchase.

WHAT THIS WARRANTY COVERS: This warranty covers all defects in workmanship or materials in your RYOBI® power tool for a period of two years from the date of purchase. With the exception of batteries, power tool accessories are warranted for ninety (90) days. Batteries are warranted for two years.

HOW TO GET SERVICE: Just return the power tool, properly packaged and postage prepaid, to an Authorized Service Center. You can obtain the location of the Service Center nearest you by contacting a service representative at One World Technologies, Inc., P.O. Box 1207, Anderson, SC 29622-1207, by calling 1-800-525-2579 or by logging on to www. ryobitools.com. When you request warranty service, you must also present proof of purchase documentation, which includes the date of purchase (for example, a bill of sale). We will repair any faulty workmanship, and either repair or replace any defective part, at our option. We will do so without any charge to you. We will complete the work in a reasonable time, but, in any case, within ninety (90) days or less.

WHAT’S NOT COVERED: This warranty applies only to the original purchaser at retail and may not be transferred. This warranty only covers defects arising under normal usage and does not cover any malfunction, failure or defects resulting from misuse, abuse, neglect, alteration, modification or repairs by other than Authorized Service Centers. One World Technologies, Inc. makes no warranties, representations or promises as to the quality or performance of its power tools other than those specifically stated in this warranty.

ADDITIONAL LIMITATIONS: Any implied warranties granted under state law, including warranties of merchantability or fitness for a particular purpose, are limited to two years from the date of purchase. One World Technologies, Inc. is not responsible for direct, indirect, or incidental damages, so the above limitations and exclusions may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

2

GENERAL SAFETY RULES

WARNING:

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

READ ALL INSTRUCTIONS

KNOWYOURPOWERTOOL.Readtheoperator’smanual carefully. Learn the applications and limitations as well as the specific potential hazards related to this tool.

GUARD AGAINST ELECTRICAL SHOCK by preventing bodycontactwithgroundedsurfaces.Forexample:pipes, radiators, ranges, refrigerator enclosures.

KEEPGUARDSINPLACEandingoodworkingorder.Neveroperatethetoolwithanyguardorcoverremoved.Make sure all guards are operating properly before each use.

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.

KEEP CHILDREN AND VISITORS AWAY. All visitors should wear safety glasses and be kept a safe distance from work area.

MAKE WORKSHOP CHILDPROOF with padlocks, master switches, or by removing starter keys.

DON’T FORCE THE TOOL. It will do the job better and safer at the feed rate for which it was designed.

USE THE RIGHT TOOL. Do not force the tool or attachment to do a job for which it was not designed.

USETHEPROPEREXTENSIONCORD.Makesureyour extensioncordisingoodcondition.Useonlyacordheavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. A wire gauge size (A.W.G.) of at least 16 is recommended for an extension cord 25 feet or less in length. If in doubt, use the next heaviergauge.Thesmallerthegaugenumber,theheavier the cord.

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.

ALWAYS WEAR SAFETY GLASSES WITH SIDE SHIELDS. Everyday eyeglasses have only impactresistant lenses, they are NOT safety glasses.

SECURE WORK. Use clamps or a vise to hold work whenpractical.It’sissaferthanusingyourhandandfrees both hands to operate the tool.

DO NOT OVERREACH. Keep proper footing and balance at all times.

MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for better and safer performance. Follow instructions for lubricating and changing accessories.

DISCONNECT TOOLS. When not in use, before servicing, or when changing attachments, blades, bits, cutters,etc.,alltoolsshouldbedisconnectedfrompower source.

REDUCE THE RISK OF UNINTENTIONAL STARTING.

Be sure switch is off when plugging in any tool.

USE RECOMMENDED ACCESSORIES. Consult the operator’s manual for recommended accessories. The use of improper accessories may result in injury.

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.

DIRECTION OF FEED. Feed work into a blade or cutter againstthedirectionorrotationofthebladeorcutteronly.

NEVERLEAVETOOLRUNNINGUNATTENDED.TURN THE POWER OFF. Don't leave tool until it comes to a complete stop.

DO NOT ABUSE CORD. Never carry tool by the cord or yank it to disconnect from receptacle. Keep cord from heat, oil, and sharp edges.

PROTECT YOUR LUNGS. Wear a face or dust mask if the cutting operation is dusty.

PROTECT YOUR HEARING. Wear hearing protection during extended periods of operation.

BLADE COASTS AFTER BEING TURNED OFF.

KEEP TOOL DRY, CLEAN, AND FREE FROM OIL AND GREASE.Alwaysuseacleanclothwhencleaning.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.

NEVER USE IN AN EXPLOSIVE ATMOSPHERE.

Normal sparking of the motor could ignite fumes.

USE ONLY OUTDOOR EXTENSION CORDS with approved ground connection that are intended for use outdoors and so marked.

BE SURE BLADE PATH IS FREE OF NAILS. Inspect for and remove all nails from lumber before cutting.

3

SPECIFIC SAFETY RULES

AVOID AWKWARD OPERATIONS AND HAND POSITIONS where a sudden slip could cause your hand to move into the blade. ALWAYS make sure you have good balance.

ALLOW THE MOTOR TO COME UP TO FULL SPEED before starting a cut to avoid binding or stalling.

DO NOT USE TOOL IF SWITCH DOES NOT TURN IT ON AND OFF. Have defective switches replaced by an authorized service center.

REPLACEMENT PARTS. All repairs, whether electrical or mechanical, should be made by a qualified service technician at an authorized service center.

WHENSERVICINGuseonlyidenticalreplacementparts. Use of any other parts may create a hazard or cause product damage.

KEEP HANDS AWAY FROM CUTTING AREA. Do not hand hold pieces so small that your fingers go under the blade guard. Do not reach underneath work or in blade cutting path with your hands and fingers for any reason.

NEVER CUT MORE THAN ONE PIECE AT A TIME or stack more than one workpiece on the saw table at a time.

FIRMLY CLAMP OR BOLT your saw to a stable, level workbench or table. The most comfortable table height is approximately waist height.

DO NOT FEED THE MATERIAL TOO QUICKLY. Do not force the workpiece against the blade.

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 ADJUSTMENTS ARE SECURE.

ALWAYSSUPPORTLARGEWORKPIECESwhilecutting tominimizeriskofbladepinchingandkickback.Sawmay slip, walk or slide while cutting large or heavy boards.

DO NOT REMOVE JAMMED CUTOFF PIECES until blade has stopped.

NEVER START THE TOOL when the blade is in contact with the workpiece.

NEVER TOUCH BLADE or other moving parts during use.

BEFORE CHANGING THE SETUP, REMOVING COVERS, GUARDS OR BLADES, unplug the saw and remove the switch key.

HOLD THE WORKPIECE firmly against the saw table.

TO AVOID ACCIDENTAL BLADE CONTACT, minimize blade breakage, and provide maximum blade support, always adjust the blade guide assembly to just clear the workpiece.

KEEPBLADESCLEAN,SHARP,ANDWITHSUFFICIENT SET. Sharp blades minimize stalling and kickbacks.

ALWAYS TURN OFF SAW before disconnecting it to avoid accidental starting when reconnecting to a power source.

DO NOT OPERATE THIS TOOL WHILE UNDER THE INFLUENCE OF DRUGS, ALCOHOL OR ANY MEDICATION.

STAY ALERT AND EXERCISE CONTROL. Watch what you are doing and use common sense. Do not operate tool when you are tired. Do not rush.

MAKE SURE WORK AREA HAS AMPLE LIGHTING to see the work and that no obstructions will interfere with safe operation BEFORE performing any work using your saw.

THE BLADE GUIDES HAVE BEEN PRESET AT THE FACTORY. These settings are functional for some applications. We recommend that you check and adjust blade guide settings before first use of your saw. Refer to

“Adjusting thrust bearings, blade guide support, and blade guides” procedures explained in the adjustments section of this 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.

SAVETHESEINSTRUCTIONS.Refer to them frequently and use them to instruct other users. If you loan someone this tool, loan them these instructions also.

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

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

A

Amperes

Current

Hz

Hertz

Frequency (cycles per second)

W

Watt

Power

min

Minutes

Time

 

Alternating Current

Type of current

 

Direct Current

Type or a characteristic of current

no

No Load Speed

Rotational speed, at no load

 

Class II Construction

Double-insulated construction

.../min

Per Minute

Revolutions, strokes, surface speed, orbits, etc., per minute

 

Wet Conditions Alert

Do not expose to rain or use in damp locations.

 

Read The Operator’s Manual

To reduce the risk of injury, user must read and understand

 

operator’s manual before using this product.

 

 

 

Eye Protection

Always wear safety goggles or safety glasses with side shields and,

 

as necessary, a full face shield when operating this product.

 

 

 

Safety Alert

Precautions that involve your safety.

 

No Hands Symbol

Failure to keep your hands away from the blade will result in

 

serious personal injury.

 

 

 

Hot Surface

To reduce the risk of injury or damage, avoid contact with any

 

hot surface.

 

 

5

SYMBOLS

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

SYMBOL

SIGNAL

MEANING

 

 

 

 

DANGER:

Indicates an imminently hazardous situation, which, if not avoided, will result

 

in death or serious injury.

 

 

 

 

 

 

WARNING:

Indicates a potentially hazardous situation, which, if not avoided, could result

 

in death or serious injury.

 

 

 

 

 

 

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, may result in

 

minor or moderate injury.

 

 

 

 

 

 

CAUTION

(Without Safety Alert Symbol) Indicates a situation that may result in property

 

damage.

 

 

SERVICE

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 servicing, use only identical replacement parts.

WARNING:

To avoid serious personal injury, do not attempt to use this product until you read thoroughly and understand completely 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

6

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. Whenusingapowertoolataconsiderabledistancefromthe 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 providedbelowtodeterminetheminimumwiresizerequired in an extension cord. Only round jacketed cords listed by Underwriter’s Laboratories (UL) should be used.

**Ampere rating (on tool data plate)

 

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'

16

16

16

16

14

14

50'

16

16

16

14

14

12

 

 

 

 

 

 

 

100'

16

16

14

12

10

**Used on 12 gauge - 20 amp circuit. NOTE: AWG = American Wire Gauge

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.

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.

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.

SPEED AND WIRING

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

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 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.

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.

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.

GROUNDING

 

PIN

120 V GROUNDED OUTLET

 

 

Fig. 1

7

GLOSSARY OF TERMS

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.

Arbor

The shaft on which a blade or cutting tool is mounted.

Bevel Cut

A cutting operation made with the blade at any angle other 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°.

Compound Cut

A cross cut made with both a miter and a bevel angle.

Crosscut

A cutting or shaping operation made across the grain or the width of the workpiece.

Cutterhead (planers and jointer planers)

A rotating cutterhead with adjustable blades or knives. The blades or knives remove material from the workpiece.

Dado Cut

A non-through cut which produces a square-sided notch or trough in the workpiece (requires a special blade).

Featherboard

A device used to help control the workpiece by guiding it securely against the table or fence during any ripping operation.

FPM or SPM

Feet per minute (or strokes per minute), used in reference to blade movement.

Freehand

Performing a cut without the workpiece being guided by a fence, miter gauge, or other aids.

Gum

A sticky, sap-based residue from wood products.

Heel

Alignment of the blade to the fence.

Kerf

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

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 tool first.

Miter Cut

A cutting operation made with the workpiece at any angle to the blade other than 90°.

Non-Through Cuts

Any cutting operation where the blade does not extend completely through the thickness of the workpiece.

Pilot Hole (drill presses)

A small hole drilled in a workpiece that serves as a guide for drilling large holes accurately.

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.

Push Blocks and Push Sticks (for table saws)

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.

Resaw

Acuttingoperationtoreducethethicknessoftheworkpiece to make thinner pieces.

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.

Ripping or Rip Cut

A cutting operation along the length of the workpiece.

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.

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.

Set

The distance that the tip of the saw blade tooth is bent (or set) outward from the face of the blade.

Snipe (planers)

Depression made at either end of a workpiece by cutter blades when the workpiece is not properly supported.

Through Sawing

Any cutting operation where the blade extends completely through the thickness of the workpiece.

Throw-Back

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.

Workpiece or Material

The item on which the operation is being done.

Worktable

Surface where the workpiece rests while performing a cutting, drilling, planing, or sanding operation.

8

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