General 60-250 User Manual

SETUP & OPERATION MANUAL

FEATURES

52 rpm blade speed - ideal for cutting ferrous materials.

Mitering capabilities - stops at 90°, 45° left and 45° right.

Heavy-duty design spindle and worm gear box.

Quick clamp vise for easy workpiece loading.

Control handle with safety trigger switch.

Coolant pump system with high volume tank.

Specially designed water channel for better cooling effect.

Shock-proof control panel.

Magnetic switch with overload protection.

12” SLOW SPEED COLD CUT SAW

SPECIFICATIONS

• Cutting capacity at 90º & 45° 2 3/8” (60 mm) 2" (50 mm)

• Cutting capacity at 90º & 45° 4” (100 mm) 3 1/2” (90 mm)

• Cutting capacity at 90º & 45° 3 1/4” x 3 1/4” (82 x 82 mm) 3" x 3" (75 x 75 mm)

• Blade 12” x 1 1/4" (305 x 32 mm) - optional

• Spindle speed 52 rpm

• Maximum vise opening 4 3/4” (120 mm)

• Coolant pump 1/8 HP

• Coolant tank 5 liters

• Overall dimensions 40” x 39” x 72” (1020 x 990 x 1830 mm)

• Motor 2 1/2 HP, 220 V, 16 A

• Weight 418 LB (190 kg)

Version #1_Revision #3 - January 2015

MODEL

60-250

GENERAL® INTERNATIONAL

8360 Champ-d’Eau, Montreal (Quebec) Canada H1P 1Y3

Telephone (514) 326-1161 • Fax (514) 326-5555 • www.general.ca

THANK YOU

for choosing this General® International model 60-250 12” slow speed cold cut saw. This cold cut saw has been carefully tested and inspected before shipment and if properly used and maintained, will provide you with years of reliable service. For your safety, as well as to ensure optimum performance and trouble-free operation, and to get the most from your investment, please take the time to read this manual before assembling, installing and operating the unit.

The manual’s purpose is to familiarize you with the safe operation, basic function, and features of this cold cut saw as well as the set-up, maintenance and identification of its parts and components. This manual is not intended as a substitute for formal metalworking instruction, nor to offer the user instruction in the craft of metalworking. If you are not sure about the safety of performing a certain operation or procedure, do not proceed until you can confirm, from knowledgeable and qualified sources, that it is safe to do so.

Once you’ve read through these instructions, keep this manual handy for future reference.

DISCLAIMER: The information and specifications

in this manual pertain to the unit as it was supplied from the factory at the time of printing. Because we are committed to making constant improvements, General® International reserves the right to make changes to components, parts or features of this unit as deemed necessary, without prior notice and without obligation to install any such changes on previously delivered units. Reasonable care is taken at the factory to ensure that the specifications and information in this manual corresponds with that of the unit with which it

was supplied. However, special orders and “after factory” modifications may render some or all information in this manual inapplicable to your machine. Further, as several generations of this model of cold cut saw and several versions of this manual may be in circulation, if you own an earlier or later version of this unit, this manual may not depict your unit exactly. If you have any doubts or questions contact your retailer or our support line with the model and serial number of your unit for clarification.

GENERAL® INTERNATIONAL WARRANTY

All component parts of General® International and Excalibur by General International® products are carefully inspected during all stages of production and each unit is thoroughly inspected upon completion of assembly.

Limited Lifetime Warranty

Because of our commitment to quality and customer satisfaction, General® International agrees to repair or replace any part or component which upon examination, proves to be defective in either workmanship or material to the original purchaser for the life of the tool. However, the Limited Lifetime Warranty does not cover any product used for professional or commercial production purposes nor for industrial or educational applications. Such cases are covered by our Standard 2-year Limited Warranty only. The Limited Lifetime Warranty is also subject to the “Conditions and Exceptions” as listed below.

Standard 2-Year Limited Warranty

All products not covered by our lifetime warranty including products used in commercial, industrial and educational applications are warranted for a period of 2 years (24 months) from the date of purchase. General® International agrees to repair or replace any part or component which upon examination, proves to be defective in either workmanship or material to the original purchaser during this 2-year warranty period, subject to the “conditions and exceptions” as listed below.

To file a Claim

To file a claim under our Standard 2-year Limited Warranty or under our Limited Lifetime Warranty, all defective parts, components or machinery must be returned freight or postage prepaid to General® International, or to a nearby distributor, repair center or other location designated by General® International. For further details call our service department at 1-888-949-1161 or your local distributor for assistance when filing your claim.

Along with the return of the product being claimed for warranty, a copy of the original proof of purchase and a “letter of claim” must be included (a warranty claim form can also be used and can be obtained, upon request, from General® International or an authorized distributor) clearly stating the model and serial number of the unit (if applicable) and including an explanation of the complaint or presumed defect in material or workmanship.

CONDITIONS AND EXCEPTIONS:

This coverage is extended to the original purchaser only. Prior warranty registration is not required but documented proof of purchase i.e. a copy of original sales invoice or receipt showing the date and location of the purchase as well as the purchase price paid, must be provided at the time of claim.

Warranty does not include failures, breakage or defects deemed after inspection by General® International to have been directly or indirectly caused by or resulting from; improper use, or lack of or improper maintenance, misuse or abuse, negligence, accidents, damage in handling or transport, or normal wear and tear of any generally considered consumable parts or components.

Repairs made without the written consent of General® International will void all warranty.

TABLE OF CONTENTS

Rules for safe operation ..................................................................................................... 5

Electrical requirements ...................................................................................................... 6

Identiﬁcation of main parts and components .................................................................. 7

Unpacking .......................................................................................................................... 8

Basic functions ................................................................................................................... 8

Placement within the shop ................................................................................................ 9

Assembly instructions ................................................................................................... 9-17

Installing the saw on its stand ....................................................................................................................... 9-10

Installing the coolant pump ....................................................................................................................... 11-13

Installing the downfeed handle ...................................................................................................................... 13

Installing a blade ......................................................................................................................................... 14-15

Installing the splash guards ............................................................................................................................. 16

Installing the support roller .............................................................................................................................. 16

Installing the work stop .................................................................................................................................... 17

Basic adjustments and controls ................................................................................. 17-20

Connecting to a power source .......................................................................................................................17

Main On/Off switch ........................................................................................................................................... 17

Magnetic switch ................................................................................................................................................ 17

Overload protection ......................................................................................................................................... 18

Adjusting the swivel base............................................................................................................................ 18-19

Adjusting and using the vise ...................................................................................................................... 19-20

Adjusting the machine head stops ................................................................................................................ 20

Immobilizing the machine .............................................................................................................................. 20

Operating Instructions ..................................................................................................... 21

Checklist before starting .................................................................................................................................. 21

Operations step-by-step ................................................................................................................................... 21

Maintenance .................................................................................................................... 22

Cleaning ............................................................................................................................................................ 22

Changing the gear box oil .............................................................................................................................. 22

Parts list & diagrams ................................................................................................... 23-28

Contact information ........................................................................................................ 30

RULES FOR SAFE OPERATION

To help ensure safe operation, please take a moment to learn the machine’s applications and limitations, as well as potential hazards. General harmless for any injury that may result from the improper use of it’s equipment.

1. Do not operate the saw when tired, distracted, or un der the effects of drugs, alcohol or any medication that impairs reﬂexes or alertness.

2. The work area should be well lit, clean and free of debris.

3. Keep children and visitors at a safe distance when the saw is in operation; do not permit them to ope rate the saw.

4. Childproof and tamper proof your shop and all ma chinery with locks, master electrical switches and switch keys, to prevent unauthorized or unsupervised use.

5. STAY ALERT! Give your work your undivided attention. Even a momentary distraction can lead to serious injury.

6. Fine particulate dust is a carcinogen that can be hazardous to health. Work in a well-ventilated area and whenever possible use a dust collector and wear eye, ear and respiratory protection devices.

International disclaims any real or implied warranty and hold itself

13. Do not push or force stock into the blade. The saw will perform better and more safely when working at the rate for which it was designed.

14. To minimize risk of injury in the event of workpiece kickback, never stand directly in-line with the blade or in the potential kickback path of the work piece.

15. Avoid working from awkward or off balance posi tions. Do not overreach while cutting; keep both feet on ﬂoor. Use out feed support or have an assistant help when cutting long material.

16. Keep blade guards in place and in working or der. If a guard must be removed for maintenance or cleaning, be sure it is properly reattached before using the tool again.

17. Never leave the machine running with the power on when not in operation.

18. Use of parts and accessories NOT recommended by General malfunction or risk of injury.

International may result in equipment

7. Do not wear loose clothing, gloves, bracelets, neck laces or other jewelry while the saw is in operation. Wear protective hair covering to contain long hair and wear non-slip footwear.

8. Be sure that adjusting wren ches, tools, drinks and other clutter are removed from the machine and/or the table surface before operating.

9. Keep hands well away from the blade and all moving parts. Use a brush, not hands, to clear away chips and dust.

10. Be sure that the blade is securely installed and in- proper cutting direction before operation.

11. Be sure the blade has gained full operating speed before beginning to cut.

12. Always use a clean, properly sharpened blade. Dir ty or dull blades are unsafe and can lead to accidents.

19. Never stand on machinery. Serious injury could result if the tool is tipped over or if the blade is unin tentionally contacted.

20. Always disconnect tool from power before servicing or changing accessories such as blades, or before performing any maintenance, cleaning or adjust ments, or if the machine will be left unattended.

21. Make sure that switch is in “OFF” position before plug ging in the power cord.

22. Make sure the tool is properly grounded. If equip ped with a 3-prong plug it should be used with a

three-pole receptacle. Never remove the third prong.

23. Do not use this saw for any purpose other than its intended use. If used for other purposes, General® International disclaims any real or im plied warranty and holds itself harmless for any in jury, which may result from that use.

ELECTRICAL REQUIREMENTS

BEFORE CONNECTING THE MACHINE TO THE POWER SOURCE, VERIFY THAT THE VOLTAGE OF YOUR POWER SUPPLY CORRESPONDS WITH THE VOLTAGE SPECIFIED ON THE MOTOR I.D. NAMEPLATE. A POWER SOURCE WITH GREATER VOLTAGE THAN NEEDED CAN RESULT IN SERIOUS INJURY TO THE USER AS WELL AS DAMAGE TO THE MACHINE. IF IN DOUBT, CONTACT A QUALIFIED ELECTRICIAN BEFORE CONNECTING TO THE POWER SOURCE.

THIS TOOL IS FOR INDOOR USE ONLY. DO NOT EXPOSE TO RAIN OR USE IN WET OR DAMP LOCATIONS.

ELECTRICAL CONNECTIONS

Both a manual circuit breaker (or similar device) as well as an electrical plug (similar to the one shown) are recommended and SHOULD BE INSTALLED BY A QUALIFIED ELECTRICIAN.

Use locally approved wire A that includes a separate grounding wire and a 3 prong grounding type plug B with a matching receptacle C.

GROUNDING INSTRUCTIONS

In the event of an electrical malfunction or short circuit, grounding reduces the risk of electric shock to the operator. The motor of the “M1” model of this machine is wired for 220 V single phase operation. As with many stationary industrial type machines, because each installation situation is unique, this machine is supplied without a power cord or plug. The installation of an appropriate power cord and plug must be performed by a qualiﬁed electrician. The machine must be connected to an electrical source using a power cord that has a grounding wire, which must also be properly connected to the grounding prong on the plug. The outlet must be properly installed and grounded and all electrical connections must be made in accordance with all local codes and regulations.

CIRCUIT CAPACITY

Make sure that the wires in your circuit are capable of handling the amperage draw from your machine, as well as any other machines that could be operating on the same circuit. If you are unsure, consult a qualiﬁed electrician. If the circuit breaker trips or the fuse blows regularly, your machine may be operating on a circuit that is close to its amperage draw capacity. However, if an unusual amperage draw does not exist and a power failure still occurs, contact a qualiﬁed technician or our service department.

EXTENSION CORDS

The use of an extension cord is not generally recommended for 220 V equipment. If you ﬁnd it necessary, use only 3-wire extension cords that have 3-prong grounding plug and a matching 3-pole receptacle that accepts the tool’s plug. Repair or replace a damaged extension cord or plug immediately. Make sure the cord rating is suitable for the amperage listed on the motor I.D. plate. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. The accompanying chart shows the correct size extension cord to be used based on cord length and motor I.D. plate amp rating. If in doubt, use the next heavier gauge.

TABLE - MINIMUM GAUGE FOR CORD

EXTENSION CORD LENGTH

AMPERES 50 feet 100 feet 200 feet 300 feet

< 5

6 to 10

10 to 12

12 to 16

*NR = Not Recommended

18 16 16 14

18 16 14 12

16 16 14 12

14 12 *NR *NR

IDENTIFICATION OF MAIN PARTS AND COMPONENTS

A. LEVELING FEET (4)

B. WORKPIECE STOP

C. MOTOR

D. EMERGENCY STOP BUTTON

E. COOLANT PUMP ON/OFF SWITCH

F. STOP BUTTON

G. START BUTTON

H. DOWNFEED HANDLE

I. BLADE GUARD

J. VISE

K. VISE HANDLE

L. FLUID RECOVERY TRAY

M. BASE LOCK LEVER

N. MITER SCALE

O. DEPTH STOP

P. STAND

Q. QUICK LOCK LEVER

UNPACKING

Carefully unpack and remove the unit and its components from the box and check for missing or damaged items as per the list of contents below.

NOTE: PLEASE REPORT ANY DAMAGED OR MISSING ITEMS TO YOUR GENERAL® INTERNATIONAL DISTRIBUTOR IMMEDIATELY.

LIST OF CONTENTS QTY

A. COOLANT TANK ....................................................................... 1

B. ROLLER STAND ......................................................................... 1

C. TANK SUPPORT PLATE .............................................................. 1

D. WORKPIECE STOP .................................................................... 1

E. REAR PANEL.............................................................................. 1

F. FRONT PANEL .......................................................................... 1

G. RECOVERY TRAY DRAIN HOSE ................................................ 1

H. HOSE ........................................................................................ 2

I. SPLASH SCREEN ....................................................................... 2

J. FRONT SHOCK ABSORBER .................................................... 2

K. REAR SHOCK ABSORBER ....................................................... 1

L. DOWNFEED HANDLE ............................................................... 1

M. FLAT WASHER (LARGE)............................................................. 2

N. FLAT WASHER (MEDIUM) ....................................................... 10

O. FLAT WASHER (SMALL) ............................................................. 4

P. LOCK WASHER ......................................................................... 2

Q. NUT (LARGE) ............................................................................ 2

R. NUT ........................................................................................... 2

S. CAP SCREW ............................................................................. 2

T. HEX HEAD BOLT (MEDIUM) ..................................................... 8

U. HEX HEAD BOLT (SMALL)......................................................... 2

V. HOSE CLAMP ........................................................................... 2

W. GASKET ..................................................................................... 1

ADDITIONAL REQUIREMENTS FOR SET UP

A. FORKLIFT B. EXTRA PERSON FOR HELP WITH LIFTING C. 10, 6, 5, 4 & 3 MM ALLEN KEYS D. SCREWDRIVER E. 10, 12,13, 17 &19 MM WRENCHES

M N O P Q R S T U

BASIC FUNCTIONS

This General International model 60-250 12" slow speed cold cut saw is designed for multipurpose cutting applications in all types of metal fabrication shop.

With the correct carbide or hi-speed steel blade, the built-in coolant system, and its low rpm blade speed this unit is designed to produce cleaner more accurate cuts, as compared to abrasive wheels, on a variety of materials including, aluminum, steel, brass and other work pieces of various sizes and proﬁles.

PLACEMENT WITHIN THE SHOP / SAFETY ZONE

THIS COLD CUT SAW MODEL 60-250 IS HEAVY. DO NOT OVER-EXERT. A HOIST OR FORKLIFT WITH STRAPS SHOULD BE USED TO LIFT THIS MACHINE. TO LIMIT THE RISK OF SERIOUS INJURY OR DAMAGE TO THE MACHINE, ANY EQUIPMENT USED TO LIFT THIS MACHINE SHOULD HAVE A RATED CAPACITY IN EXCESS OF 418 LBS (190 KG).

PLACEMENT WITHIN THE SHOP

This machine should be installed and operated only on a solid, ﬂat and stable ﬂoor that is able to support the weight of the machine (418 lbs - 190 kg) and the operator. Using the dimensions shown as a guideline, plan for placement within your shop that will allow the operator to work unencumbered and unobstructed by foot trafﬁc (either passing shop visitors or other shop workers) or other tools or machinery.

ESTABLISHING A SAFETY ZONE

For shops with frequent visitors or multiple operators, it is advisable to establish a safety zone around shop machinery. A clearly deﬁned “no-go” zone on the ﬂoor around each machine can help avoid accidents that could cause injury to either the operator or the shop visitor.

It is advisable to take a few moments to either paint (using non-slip paint) or using tape, deﬁne on the ﬂoor the limits or perimeter of each machines safety zone. Take steps to ensure that all operators and shop visitors are aware that these areas are off limits whenever a machine is running for everyone but the individual operating the unit.

72"

40"

39"

ASSEMBLY INSTRUCTIONS

BEFORE ASSEMBLING, MAKE SURE THAT THE SWITCH IS IN THE “OFF” POSITION AND THAT THE POWER CORD IS UNPLUGGED. DO NOT PLUG IN OR TURN ON THE MACHINE UNTIL YOU HAVE COMPLETED THE ASSEMBLY AND INSTALLATION STEPS DESCRIBED IN THIS SECTION OF THE MANUAL.

TIP: TO ASSEMBLE THIS UNIT, YOU WILL NEED TO LIFT THE HEAD OF THE MACHINE. DUE TO THE WEIGHT OF THE MACHINE, ADEQUATE LIFTING EQUIPMENT SUCH AS A JACK, HOIST, OR FORKLIFT WITH STRAPS IS REQUIRED. ANY EQUIPMENT USED TO LIFT THE MACHINE MUST HAVE A MINIMUM WEIGHT CAPACITY OF 418 LBS (190 KG).

INSTALLING THE MACHINE HEAD ON THE STAND

1. Remove the bolts holding the machine head to the

shipping pallet and install appropriate lifting straps around the head A.

Note: Verify the load capacity of the straps.

2. Lift the machine head using appropriate lifting

equipment.

Note: Hold the pump to prevent damage to its power cord B.

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