General 60-250 User Manual

Download

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.

INSTALLING THE MACHINE HEAD ON THE STAND

3. Hold the head above the stand and align the

mounting bolts as shown C.

4. Place the supplied shock absorbers in the loca-

tions shown D and lower the head on its stand with the four mounting bolts in the mounting holes on the stand E.

5. Secure the head to the stand from below using two

12 mm nuts with two lock washers at the rear F and two 17 mm nuts with two ﬂat washers at the front G.

INSTALLING THE COOLANT PUMP

1. Install the pump support plate A inside the stand as

shown.

3. Install the pump in the coolant tank opening with the outlet ﬁtting C to the left as shown.

2. Align the mounting holes with the corresponding

holes on the stand, and attach it using two bolts and ﬂat washers B with a 13 mm wrench.

4. Align the mounting holes with the corresponding

holes on the tank, then attach the pump using four bolts and ﬂat washers D with a 10 mm wrench.

5. Slide the hose clamp onto the end of the coolant hose.

6. Fit the end of the hose onto the pump outlet ﬁtting,

then tighten the hose clamp using a screwdriver.

Tip: Pull on the hose to verify that is fastened securely.

INSTALLING THE COOLANT PUMP (CONTINUED)

7. Install the pump and the tank on the support plate

as shown.

9. Attach the plate to the stand using four bolts and

ﬂat washers with a 13 mm wrench.

8. Align the mounting holes on the second support

plate with the corresponding holes on the stand.

10. Slide the second hose clamp onto the other end of

the coolant hose.

11. Slide the coolant hose onto the ﬁtting on the ma-

chine head, then secure it by using a screwdriver.

Tip: Pull on the hose to verify that is fastened securely.

12. Place the supplied gasket B on the drain hose ﬁt- ting A as shown.

INSTALLING THE COOLANT PUMP (CONTINUED)

13. With a 6 mm Allen key attach the drain hose ﬁtting

hose under the recovery tray at the rear of the machine using two screws and ﬂat washers.

INSTALLING THE DOWNFEED HANDLE

1. Remove plug A using a wrench.

14. Hang the end of the drain hose in the recovery

tank ﬁlter.

Note: Cut the hose with a knife to shorten it if necessary.

2. Screw the downfeed handle into the gear box in

place of the plug and secure it by tightening two jam nuts B with a wrench C.

3. Turn the handle so that the trigger points up and secure by tightening jam nut D.

4. Connect the trigger control cable to the electrical

box on the motor as shown.

INSTALLING A BLADE

There are a variety of different types of blades on the market to suit various cutting applications. Your results may vary based on usage, experience and personal preference. Ask your local tool dealer for suggestions for 12“ x 1 1/4" (305 X 32 mm) cold cut blades. Please note that General International offers an optional a 12” hi-speed steel general purpose blade (#60-255).

1. Remove the blade guard screw A using a 4 mm

Allen key.

3. Remove the blade ﬂange screw using a 10 mm Al-

len wrench. Turn clockwise as shown.

2. Detach the blade guard arm and slide open the

guard.

4. Remove the blade ﬂange from the blade holder.

5. Install the blade on the blade holder, making sure

that the blade is installed with the teeth pointing down as shown B.

6. Hold the blade against the blade holder making

sure it sits ﬂush, then align the two mounting holes C with the corresponding holes of blade holder.

INSTALLING A BLADE (CONTINUED)

7. Re-install the blade ﬂange and thread the mount-

ing screws on 2-3 turns only.

8. Align the two pins on the blade ﬂange with the corresponding holes in the blade and the blade holder A.

9. Push on the ﬂange to seat it ﬂush against the blade. 10. Tighten the mounting screw counterclockwise to

secure the ﬂange and the blade to the holder.

11. Lower the blade guard and re-install the blade guard arm on its pivot B as shown.

12. Secure the arm to the blade guard using a 4 mm

Allen key.

INSTALLING THE SPLASH GUARDS

1. Loosen the two screws already installed on the

back of the machine with a 6 mm Allen key.

INSTALLING THE SUPPORT ROLLER

1. Remove the two screws and ﬂat washers on the left

side of the machine with a 6 mm Allen key.

INSTALLING THE FRONT PLATE

2. Slide a splash guard onto the two screws and be-

hind the ﬂat washers. Retighten the two screws, then repeat with the other splash guard on the front of the machine.

2. Align the roller slots with the holes in the machine

and secure it in place with screws and washers.

Note: To adjust the support roller height as needed along the slotted mounting holes.

1. Remove the four screws installed at the bottom

front of the stand using a 3 mm Allen key.

2. Align the plate mounting holes with the holes in the

base, then attach it with the four screws.

INSTALLING THE WORKPIECE STOP

1. Screw the graduated bar A into the mounting hole

located on the swivel base, and then secure it by tightening its jam nut with a 14 mm open wrench.

Tip: The workpiece stop has two adjustment points: Position the main adjustment block B that slides on the graduated bar using lock knob C. The smaller ﬁne-tuning adjustment bar D can be set using lock knob E.

BASIC ADJUSTMENTS & CONTROLS

TO REDUCE THE RISK OF SHOCK OR FIRE DO NOT OPERATE THE UNIT WITH A DAMAGED POWER CORD OR PLUG. REPLACE DAMAGED CORD OR PLUG IMMEDIATELY. TO AVOID UNEXPECTED OR UNINTENTIONAL START-UP, MAKE SURE THE POWER SWITCH IS IN THE OFF POSITION BEFORE CONNECTING TO A POWER SOURCE.

CONNECTING TO A POWER SOURCE

Once the assembly steps have been completed, plug the power cord into an appropriate outlet.

Refer back to the section entitled “Electrical Require ments” and make sure all requirements and grounding instructions are followed.

When operations have been completed, unplug the saw from the power source.

SWITCH OFF

TO AVOID UNEXPECTED OR UNINTENTIONAL START-UP, MAKE SURE THAT THE POWER SWITCH IS IN THE OFF POSITION BEFORE CONNECTING TO A POWER SOURCE.

MAGNETIC SWITCH

This machine is equipped with a magnetic safety switch designed to protect the unit and the user from power surges, power outages or unintentional start-up.

The switch assembly is equipped with a green “start” button F, a red “stop” button G and a emergency stop button with twist lock-out device H. Once this button has been pressed, the machine can only be started by turning the button to the right to release the stop button, J.

The coolant system pump is controlled using switch I. To start the pump, turn the switch I to the right. To stop the pump, turn the switch I to the left.

MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORMING ANY MAINTENANCE OR ADJUSTMENTS.

OVERLOAD PROTECTION

The magnetic safety switch on this machine is equipped with an overload protection feature. To prevent an electrical overload from damaging the motor, in the event of a spike in line voltage or amperage draw, the internal overload protector will automatically be tripped, thereby cutting off power to the motor.

Common causes of such overloads:

• Overworking the motor by forcing the saw, particularly with thicker denser material, thereby causing an increase in power consumption and a spike in amperage draw.

• An electrical extension cord that is too long or not the correct gauge of wire, which can also cause an increase in amperage draw. If an electric extension cord must be used, follow the instructions and refer to the chart in the electrical requirements section at the beginning of this manual.

• Overworked circuit caused by operating on a circuit that is close to its amperage draw capacity. Make sure thecircuit being used is capable of handling the amperage draw from this machine as well as any other electrical devices operating on the same circuit. If you are unsure, consult a qualiﬁed electrician.

To reset the overload protection switch after it has been tripped proceed as follows:

1. Remove the four screws A located on the back of

the electrical box using a 3 mm Allen key, then remove the cover.

ADJUSTING THE SWIVEL BASE

2. Press on the button B to reset the overload protec-

tion switch. Re-install the box cover before to restart the machine.

Note: If after resetting the overload protector the machine still does not work, check all three fuses C located inside the electrical box and replace them if needed with the same amperage.

1. To unlock the swivel base push the lever D to the left

as shown.

2. Refer to the graduated scale E at the base of the

saw head to set the blade to the required angle.

MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORMING ANY MAINTENANCE OR ADJUSTMENTS.

ADJUSTING THE SWIVEL BASE (CONTINUED)

3. If the lever does not lock the base properly, loosen

the screw A with a 6 mm Allen key while holding the lever in place on its shaft.

5. Make sure the pointer is aligned with the 45° marker

when the saw head is turned all the way to the right or left. To re-align the pointer, go to the next step.

ADJUSTING AND USING THE VISE

4. Turn the lever to the right, and then retighten the

screw A. Make sure the lever locks the swivel base. If not, repeat steps 3 & 4.

LEFT STOP RIGHT STOP

6. Loosen the left stop with a 5 mm Allen key, then ad-

just the stop along its slotted hole until the pointer is aligned with the 45° mark. Repeat with the right stop.

1. Position the workpiece in the vise and secure it in place using vise handwheel D.

2. Lock the workpiece in place turning the quick lock-

ing lever to the left as shown.

MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORMING ANY MAINTENANCE OR ADJUSTMENTS.

ADJUSTING AND USING THE VISE (CONTINUED)

3. To adjust the vise jaw, loosen screw A with a 10 mm

Allen key.

ADJUSTING THE SAW HEAD STOPS

1. If the downfeed handle B is difﬁcult to reach in the

up position, loosen jam nut C with a 19 mm wrench, then loosen bolt D until the desired handle height is reached. Retighten jam nut C.

4. Slide the jaw right or left to the desired position, then retighten screw A.

2. To adjust the saw head in the down position, loos- en jam nut E with a 19 mm wrench, then turn bolt F clockwise or counterclockwise as per the adjust- ment desired. Retighten jam nut E.

IMMOBILIZING THE MACHINE

Machine vibration during operation may cause the machine to move, particularly when installed on uneven surfaces.

The bolt-down tabs and anchor bolts G can be used to help keep the machine immobilized by either lowering the bolts against the ﬂoor to act as another point of contact with the ﬂoor, or for permanent installations, by drilling into the ﬂoor and bolting the machine in place.

OPERATING INSTRUCTIONS

CHECKLIST BEFORE STARTING

VERIFY ALL CHECK POINTS BEFORE STARTING. FAILURE TO COMPLY CAN RESULT IN SERIOUS INJURIES.

1. Make sure you and any assistants are wearing safe and appropriate workshop attire.

2. To reduce the risk of damage to the machine, as well as potential for personal injury, after initial set-up as well

as before each use, make sure that everything is securely installed and that all fasteners and moving parts on this machine are locked in place before starting the machine.

3. Make sure to have on safety glasses as well as hearing or/and respiratory protection at all times when using the

machine.

4. Check the level of coolant in the tank and ﬁll it as necessary. The maximum level is 5 liters.

5. Use only recommended parts and accessories. The use of parts or accessories NOT recommended by

GENERAL® INTERNATIONAL may result in a risk of injury or damage to the machine.

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

OPERATIONS STEP-BY-STEP

NEVER USE THE SAW WITHOUT ALL GUARDS AND COVERS IN PLACE. BEFORE STARTING THE SAW BE SURE THAT THE BLADE IS NOT ALREADY IN CONTACT WITH THE WORKPIECE.

1. Trace the cutting line on your workpiece with a pen-

cil and clamp the material ﬁrmly in the vise jaws. Make sure the workpiece is properly secured in the vise.

Note: Use the work stop to quickly and accu-

rately cut multiple pieces of stock to the same length.

2. Press the “ON” button to start the machine.

3. Turn on the coolant pump by turning the switch A to the right and opening the coolant valve as shown B.

4. Press on the trigger of the downfeed handle while

smoothly lowering the saw head.

5. Once the cut is completed, raise the head and release the trigger. Turn OFF the pump by turning the switch A to the left.

6. Press the button OFF to turn off the machine.

7. Carefully remove the workpiece from the vise.

BURN DANGER: DO NOT USE BARE HANDS TO TOUCH THE WORKPIECE AT THE CUT LOCATION UNTIL IT HAS COOLED.

OPENED

CLOSED

Note: Before operation, see the chart below regarding the cutting capacity of your machine based on the size and shape of the workpiece.

CUTTING CAPACITY

WORKPIECE

Straight cut 60 mm 100 mm 82 x 82 mm

Cut at 45° 50 mm 90 mm 75 x 75 mm

MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORMING ANY MAINTENANCE OR ADJUSTMENTS.

MAINTENANCE

CLEANING

For optimum performance from your machine, follow this maintenance schedule and refer to any speciﬁc instructions given in this section. After using your machine, sweep up and discard any excess chips amd debris.

REGULAR MAINTENANCE TASK FREQUENCY

DAILY WEEKLY MONTHLY 2 x YEAR

• Basic cleaning of the machine

• Fill the coolant tank if necessary

• Inspect the blade

• Leave the saw head in the “up” position to reduce stress on the return spring

• Check the splash guards and verify that the emergency stop works properly

CHANGING THE GEAR BOX OIL

• Thoroughly clean the

• Clean and grease the

•

machine thoroughly, including the tank and ﬁlter

vise screw and the slides

Clean the blade holder

• Make sure all the fastners are tightened

• Inspect the condition of all guards

• Grease the saw head pivot shaft

• Change the gear box oil

1. Position the saw head in the down position. Re-

move oil plug A with a 10 mm Allen Key to drain the gear box. Once the used oil is drained, re-install the plug A.

2. Raise the saw head to the up position. Loosen the

two jam nuts on the downfeed handle using a wrench, then remove the downfeed handle to access the ﬁlling hole.

3. Fill the gear box with 0,25 liter of 460 grade gear oil. The gauge B should be 3/4 full as shown C. When the correct level is reached, re-install the downfeed handle (see section “Installing the downfeed handle”).

DIAGRAM

PARTS LIST

IMPORTANT: When ordering replacement parts, always give the model number, serial number of the machine and part number. Also a brief description of each item and quantity desired.

PART # DESCRIPTION SPECIFICATIONS QTY

60250-A01 LOCK LEVER 1 60250-A02 JAM NUT 1 60250-A03 SHAFT 1 60250-A04 HEAD MACHINE BASE 1 60250-A05 ROLLER STAND BRACKET 1 60250-A06 SHAFT 1 60250-A07 ROLLER 1 60250-A08 RETENTION RING S-12 2 60250-A09 CAP SCREW M8 X 20 1 60250-A10 WASHER 5/16” 1 60250-A11 HANDWHEEL 1 60250-A12 PIN 1 60250-A13 BEARING BUSHING 1 60250-A14 BEARING 1 60250-A15 BUSHING 1 60250-A16 LEAD SCREW 1 60250-A17 LOCK LEVER 1 60250-A18 SLIDING VISE 1 60250-A19 WASHER 1 60250-A20 SPRING 1 60250-A21 PLATE 1 60250-A22 CAP SCREW M12 X 25 3 60250-A23 WASHER 5/16” 2 60250-A24 CAP SCREW M8 X 20 2 60250-A25 SPRING 1 60250-A26 WASHER 5/16” 1 60250-A27 CAP SCREW M8 X 20 1 60250-A28 BLADE GUARD ARM 1 60250-A29 WASHER 1/4” 1 60250-A30 CAP SCREW M6 X 12 1 60250-A31 WASHER 1/4” 1 60250-A32 NUT M8 1 60250-A33 GUARD ARM BRACKET 1 60250-A34 RETENTION RING 1 60250-A35 BLADE GUARD 1 60250-A36 SCREW M5 X 10 7 60250-A37 PLATE 2 60250-A38 BLADE COVER 1 60250-A39 CAP SCREW M12 X 35 1 60250-A40 BLADE FLANGE 1 60250-A41 SAW BLADE (OPTIONAL) 12” X 1-1/4" (305 X 32 MM) 1 60250-A42 BLADE HOLDER 1 60250-A43 WORM GEAR 1 60250-A44 JAM NUT 1 60250-A45 STOP PLATE 1 60250-A46 VISE BODY 1 60250-A47 CAP SCREW M5 X 25 3 60250-A48 SWIVEL BASE 1 60250-A49 SUPPORT ROD 1 60250-A50 SLIDING JAW 1

PARTS LIST

IMPORTANT: When ordering replacement parts, always give the model number, serial number of the machine and part number. Also a brief description of each item and quantity desired.

PART # DESCRIPTION SPECIFICATIONS QTY

60250-A51 FIXED JAW 1 60250-A52 SMALL FIXED JAW 1 60250-A53 TRIGGER SWITCH HANDLE 1 60250-A54 NUT M10 1 60250-A55 CONTROL HANDLE LEVER 1 60250-A56 NUT M20 1 60250-A57 NUT M20 1 60250-A58 MACHINE HEAD 1 60250-A59 BEARING 6205ZZ 1 60250-A60 BEARING 6301ZZ 1 60250-A61 GASKET 1 60250-A62 CAP SCREW M8 X 20 4 60250-A63 WASHER 5/16” 4 60250-A64 FLANGE 1 60250-A65 OIL SEAL 1 60250-A66 WORM SHAFT 1 60250-A67 COUPLING 1 60250-A68 MOTOR 1 60250-A69 STRAIN RELIEF 4 60250-A70 CONTROL WIRE 1 60250-A71 CAP SCREW M8 X 20 4 60250-A72 WASHER 5/16” 4 60250-A73 OIL GAUGE PT1/2” 1 60250-A74 SET SCREW PT1/4” 2 60250-A75 SHAFT 1 60250-A76 BUSHING 1 60250-A77 CAP SCREW M12 X 55 1 60250-A78 NUT M12 1 60250-A79 LOCK KNOB 1 60250-A80 THREADED SHAFT 1 60250-A81 UPPER ROD 1 60250-A82 LOWER ROD 1 60250-A83 NUT 1 60250-A84 LOCK KNOB 1 60250-A85 RECOVERY FILTER 1 60250-A86 HOOK 3 60250-A87 DRAINAGE 1 60250-A88 WASHER 5/16” 2 60250-A89 CAP SCREW M8 X 25 2 60250-A90 CAP SCREW 1 60250-A91 SAW ARM 1 60250-A92 WASHER 5/16” 2 60250-A93 CAP SCREW M8 X 20 2 60250-A94 SCREW M5 4 60250-A95 STOP BUTTON 1 60250-A96 START BUTTON 1 60250-A97 EMERGENCY SWITCH 1 60250-A98 2/4 P SELECTION SWITCH (OPTIONAL) 1 60250-A99 PUMP SELECTION SWITCH 1 60250-A100 CONTROL BOX PANEL 1

PARTS LIST

IMPORTANT: When ordering replacement parts, always give the model number, serial number of the machine and part number. Also a brief description of each item and quantity desired.

PART # DESCRIPTION SPECIFICATIONS QTY

60250-A101 WASHER 5/16” 2 60250-A102 CAP SCREW M8 X 20 2 60250-A103 ELECTRIC CONTROL BOX 1 60250-A104 CONTROL BOX BUTTON PLATE 1 60250-A105 MAGNETIC CONNECTOR 1 60250-A106 FUSE SET 1 60250-A107 COVER PLATE 1 60250-A108 TRANSFORMER 1 60250-A109 RELAY 1 60250-A110 PROTECTION SCREEN 1 60250-A111 SUPPORT PLATE 2 60250-A112 WASHER 5/16” 2 60250-A113 CAP SCREW M8 X 16 2 60250-A114 SCREW M5 2 60250-A117 COVER 2 60250-A118 SCREW 2 60250-A119 OIL SEAL 1 60250-A120 GASKET 1 60250-A121 GASKET 1 60250-A122 PLATE BRACKET 1 60250-A123 SPLASH GUARD 1 60250-A124 SPLASH GUARD 1

BLADE SPECIFICATIONS

• A (blade diameter): 12"/305 mm

• B (distance between pin hole centers): 63 mm

• C (ﬂange diameter): 89 mm

• D (center hole/bore diameter): 32 mm

• E (number of pin holes): can be 2 or 4

• F (hole diameter): 11 mm

B C

B34

DIAGRAM & PARTS LIST

STAND AND PUMP

B33

IMPORTANT: When ordering replacement parts, always give the model number, serial number of the machine and part number. Also a brief description of each item and quantity desired.

PART # DESCRIPTION SPECIFICATIONS QTY

60250-B01 STAND 1 60250-B04 REAR PLATE 1 60250-B05 WASHER 1/4” 4 60250-B06 CAP SCREW M6X15 4 60250-B07 COOLANT TANK 1 60250-B08 HOSE 1 60250-B09 HOSE CLAMP 1 60250-B10 WASHER 1/4” 4 60250-B11 CAP SCREW M6X16 2 60250-B12 COOLANT PUMP 1 60250-B13 CONNECTING BOLT 1 60250-B14 HOSE CLAMP 1 60250-B15 HOSE 1 60250-B16 HOSE CLAMP 1 60250-B17 VALVE 1 60250-B18 WIRE 1 60250-B21 CAP SCREW M6X15 2 60250-B22 WASHER M8 2 60250-B23 SUPPORT PLATE 1 60250-B24 SCREW M5X6 4 60250-B25 FRONT PLATE 1 60250-B27 NUT 4 60250-B28 SCREW 4 60250-B29 SPRING WASHER 2 60250-B30 NUT M8 2 60250-B31 WASHER 2 60250-B32 NUT M10 2 60250-B33 REAR SHOCK ABSORBER 1 60250-B34 FRONT SHOCK ABSORBER 2

WIRING DIAGRAM

NOTES

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

Tel.: (514) 326-1161

Fax: (514) 326-5565 - Parts & Service / (514) 326-5555 - Order Desk

orderdesk@general.ca

www.general.ca

General 60-250 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual