General 90-040 User Manual

SETUP & OPERATION MANUAL

FEATURES

Sturdy welded steel frame & precision balanced wheels with replaceable tires.

Easy-to-assemble open-base steel stand.

Precision easy-adjust European style blade guide bearings included.

Two cutting speeds for excellent results in either hard or soft woods.

Miter gauge with aluminum crosscut fence included.

Deluxe dual-position rip fence system.

Hinged doors and easily accessible blade tension knob, for fast blade changes and adjustments.

Extra-large 21 ½ x 15 ¾ cast-iron table.

Smooth running heavy-duty 2/3 HP motor.

Safety lock-out switch with removable key to prevent unauthorized use.

Multi-size dust port ﬁts 4”, 3”, or 2” hose.

SPECIFICATIONS

• Wheel size 12” (305 mm)

• Wheel speeds (2) 445 & 970 rpm

• Blade speeds (2) 1444 & 3150 lin. fpm

• Maximum blade width 3/4” (20 mm)

• Minimum blade width 1⁄8” (3 mm)

• Blade length 88” (2240 mm)

• Table size 21 ½” x 15 ¾” (548 x 400 mm)

• Table tilt 0° to 45° (right)

• Table height 37 3/8” (950 mm)

• Maximum width of cut 12” (305 mm)

• Maximum depth of cut 6 1/2” (165 mm)

• Dust port 4”, 3” and 2” (102, 76 or 51mm)

• Base dimensions (l x w) 18 1/4” x 15 3/4” (465 x 400 mm)

• Motor 2/3 HP, 120 V, 6,4 A

• Weight 165 lbs (75 kg)

Version #1_Revision #2 - December 2014

12” WOOD CUTTING BANDSAW

MODEL

90-040

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 90-040 12” Wood Cutting Bandsaw. This bandsaw 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 bandsaw as well as the set-up, maintenance and identification of its parts and components. This manual is not intended as a substitute for formal woodworking instruction, nor to offer the user instruction in the craft of woodworking. 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 wood cutting Bandsaw 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 ................................................................................................................... 9

Cleaning............................................................................................................................. 9

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

Assembly instructions ................................................................................................. 10-13

Assembling the stand ....................................................................................................................................... 10

Attaching the bandsaw to the stand ............................................................................................................. 11

Installing the work table and the 90° stop ................................................................................................ 11-12

Installing the rip fence system .................................................................................................................... 12-13

Installing the push stick holder ........................................................................................................................ 13

Basic adjustments and controls ................................................................................. 14-20

Connecting to a power source .......................................................................................................................14

On/Off power switch .........................................................................................................................................14

Choosing and changing blades ............................................................................................................... 14-16

Adjusting blade tension ................................................................................................................................... 16

Blade tracking adjustment .............................................................................................................................. 17

Adjusting the upper and lower blade guides ............................................................................................... 18

Adjusting the upper and lower thrust guides ................................................................................................ 19

Selecting and changing the blade speed .............................................................................................. 19-20

Adjusting the upper blade guard .................................................................................................................. 20

Operating Instructions ................................................................................................ 20-22

Checklist before starting .................................................................................................................................. 20

Connecting to a dust collector ....................................................................................................................... 21

Cutting curves ................................................................................................................................................... 21

Cutting circles .................................................................................................................................................... 21

Using the miter gauge ..........................................................................................................................................

Maintenance ............................................................................................................... 22-23

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

Changing the belt and aligning the pulleys ................................................................................................. 22

Wheel tires .......................................................................................................................................................... 23

Motor .................................................................................................................................................................. 23

Lubrication ......................................................................................................................................................... 23

Parts list & diagram .................................................................................................... 24-29

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 bandsaw when tired, distracted or under the effects of drugs, alcohol or any medI cation 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 bandsaw is in operation; do not permit them to operate the bandsaw.

4. Childproof and tamper proof your shop and all machinery 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. Wear face, eye, ear, respiratory and body protection devices.

7. Do not wear loose clothing, gloves, bracelets, necklaces or other jewelry while the bandsaw is in operation.

8. Be sure that adjusting wrenches, 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. Adjust and position the blade guard as close as possible to the workpiece.

11. Adjust blade tension and tracking before starting to cut.

12. Blade teeth must point down toward the table.

13. Be sure that the blade has gained full operating speed before starting to cut.

14. Always use a clean, properly sharpened blade. Dirty or dull blades are unsafe and can lead to accidents.

International disclaims any real or implied warranty and hold itself

15. Use suitable workpiece support if the workpiece does not have a ﬂat surface.

16. Do not work on long stock without adequate support on the out feed end of the table.

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

18. Avoid working from awkward or off balance posi tions. Do not overreach and keep both feet on ﬂoor.

19. Keep guards in place and in working order. If a guard must be removed for maintenance or clean ing be sure it is properly re-attached before using the saw again.

20. Never leave the machine unattended while it is run- ning or with the power on.

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

22. Never stand on machinery. Serious injury could re sult if the tool is tipped over or if the blade is unintentionally contacted.

23. Always disconnect the saw from the power source before servicing or changing accessories such as blades, or before performing any mainte nance or cleaning, or if the machine will be left unattended.

24. Make sure that the switch is in the “OFF” position before plugging in the power cord.

25. Make sure the machine is properly grounded. If equipped with a 3-prong plug it should be used with a three-pole receptacle. Never remove the third prong.

26. Do not use this bandsaw for other than its intended use. If used for other purposes, General® International disclaims any real or implied warranty andholds itself harmless for any in jury, which may resultfrom that use.

International may result in equipment

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.

GROUNDING INSTRUCTIONS

In the event of an electrical malfunction or short circuit, grounding reduces the risk of electric shock. The motor of this machine is wired for 120 V single phase operation and is equipped with a 3-conductor cord and a 3-prong grounding plug A to fit a grounded type receptacle B.

Do not remove the 3rd prong (grounding pin) to make it fit into an old 2-hole wall socket or extension cord. If an adaptor plug is used C, it must be attached to the metal screw of the receptacle.

Note: The use of an adaptor plug is illegal in some areas. Check your local codes. If you have any doubts or if the supplied plug does not correspond to your electrical outlet, consult a qualified electrician before proceeding.

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

If you find it necessary to use an extension cord with your machine, 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. The smaller the number, the heavier the 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. STAND

B. RIP FENCE

C. ON/OFF SWITCH WITH REMOVABLE KEY

D. UPPER WHEEL DOOR

E. BLADE TENSION KNOB

F. UPPER DOOR LOCK KNOB

G. BLADE GUARD LOCK KNOB

H. BLADE

I. MITER GAUGE

J. LOWER DOOR LOCK KNOB

K. BELT TENSION KNOB

L. LOWER WHEEL DOOR

M. DUST TRAY

N. TABLE TILT SCALE

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. WORK TABLE ............................................................................ 1

B. PUSH STICK ............................................................................... 1

C. FRONT FENCE RAIL ................................................................. 1

D. RIP FENCE ................................................................................ 1

E. CROSS BRACE (LONG) ........................................................... 2

F. CROSS BRACE (SHORT) ........................................................... 2

G. SUPPORT LEG ........................................................................... 4

H. MITER GAUGE .......................................................................... 1

I. RIP FENCE HANDLE .................................................................. 1

J. TABLE INSERT ............................................................................ 1

K. LOCK KNOB ............................................................................. 4

L. KNURLED NUT .......................................................................... 1

M. FLAT WASHER (LARGE)............................................................. 4

N. FLAT WASHER (SMALL) ........................................................... 33

O. NUT ......................................................................................... 28

P. TABLE STOP BOLT ...................................................................... 1

Q. BOLT ........................................................................................ 5

R. CAP SCREW ............................................................................. 4

S. CARRIAGE BOLT ..................................................................... 23

T. CAP SCREW W/NUT ................................................................. 1

U. CARRIAGE BOLT ....................................................................... 1

V. RIP FENCE GUIDE HOOK ......................................................... 1

W. 10 - 13 MM COMBINATION WRENCH .................................... 1

ADDITIONAL REQUIREMENTS FOR SET UP

A. 2 EXTRA PEOPLE FOR HELP WITH LIFTING B. 14 MM WRENCH C. 3 & 5 MM ALLEN KEYS D. SQUARE

BASIC FUNCTIONS

This 12” Wood Cutting Bandsaw is supplied with a 1/2” general purpose blade and is designed to accommodate blade widths from 1/8” to 3/4”. Ideal blade length for this model 90-040 is 88” (2240 mm).

Note: Generally speaking, because the upper wheel height is somewhat adjustable (to allow for blade tensioning), a blade length variation of plus or minus 1/2” from the “ideal blade length” can be accommodated.

Maximum inboard width of cut is 12”. For cutting thicker stock or for resawing, the maximum depth of cut (or max. workpiece height) is 6 1/2”. An adjustable rip fence is supplied to serve as a straightedge to guide the workpiece for longer rip cuts. The fence can easily be removed and set aside when not required, for example when making curved cuts.

CLEANING

The protective coating on the saw table prevents rust from forming during shipping and storage. Remove it by rubbing with a rag dipped in kerosene, mineral spirits or paint thinner. (Dispose of potentially ﬂammable solvent-soaked rags according to manufacturer’s safety recommendations).

A putty knife, held ﬂat to avoid scratching the surface, may also be used to scrape off the coating followed by clean-up with solvent. Avoid rubbing the saw’s painted surfaces, as many solvent-based products will remove paint.

To prevent rust, apply a light coating of paste wax or use regular applications of any after-market surface protectant or rust inhibitor.

TIP: WITH A SCREW DRIVER, PUSH A SOLVENT-SATURATED RAG INTO THE T-SLOTS TO REMOVE THE GREASE.

PLACEMENT WITHIN THE SHOP / SAFETY ZONE

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 (165 lbs - 75 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.

65"

27"

25"

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