General International BS5205 User Manual
BS5205 man v.141110
Model #
SETUP & OPERATION MANUAL
FEATURES
● Heavy duty steel base
with wheels
● Strong cast iron
head frame
● Cast iron vise opens to
6 in. (150 mm):
● Three speeds help to cut
ferrous and non-ferrous
metals
● Miter gauge allows 90º to 45º
cuts
● Adjustable blade guide
● Converts to vertical cutting
4-1/2 inch
Metal Cutting
Band Saw
SPECIFICATIONS
● 120 V ~ 60 Hz 550 W
motor:
● Blade included:
64-1/2 in.
(1638 mm)
● Max. cutting capacity
(round):
4-1/8 in. (105 mm)
● Max. cutting capacity
(square): 4 x 6 in.
(102 x 150 mm)
● Blade speeds:
80 / 120 / 180 ft/min
(24 / 36.5 / 55 m/
min)
● CSA certication
● Net weight: 134 lb. (61
kg)
BS5205
ENGLISH
THANK YOU
for choosing this General International machine. This tool has been
carefully tested and inspected before shipment and if properly used and
maintained, will provide you with years of reliable service. 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 tool as well as the set-up, maintenance and
identication 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 conrm, from knowledgeable and qualied sources, that it is safe to do so.
Once you’ve read through these instructions, keep this manual handy for
future reference.
GENERAL® INTERNATIONAL
WARRANTY
All component parts of General® International products are carefully
inspected during all stages of production and each unit is thoroughly
inspected upon completion of assembly.
2-YEAR LIMITED WARRANTY
All products 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.
Repairs made without the written consent of General International will void
the warranty.
DISCLAIMER
The information and specications 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 specications and information in
this manual corresponds with that of the unit with which it was supplied.
However, special orders and “after factory” modications may render some
or all information in this manual inapplicable to your machine. Further, as
several generations of this model of dust collector 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 machine 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 clarication.
TO FILE A CLAIM
To le a claim under our Standard 2-year Limited 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.
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.
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141110
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.
READ ALL INSTRUCTIONS
BEFORE OPERATING
SAVE THESE INSTRUCTIONS
Before attempting to operate your new tool, please read these instructions
thoroughly. You will need these instructions for the safety warnings,
precautions, assembly, operation, maintenance procedures, parts list and
diagrams. Keep your invoice with these instructions. Write the invoice
number on the inside of front cover. Keep the instructions and invoice in a
safe, dry place for future reference.
THE WARNINGS, CAUTIONS AND INSTRUCTIONS discussed
in this instruction manual cannot cover all possible conditions or
situations that could occur. It must be understood by the operator that
common sense and caution are factors which cannot be built into this
product, but must be supplied by the operator.
IMPORTANT SAFETY
INSTRUCTIONS
The purpose of safety symbols is to attract your attention to possible
hazards. The safety symbols, and the explanations with them, deserve
your careful attention and understanding. The safety warnings do not, by
themselves, eliminate any danger. The instructions or warnings they give
are not substitutes for proper accident prevention measures.
DANGER! Indicates an imminently hazardous situation which, if not
avoided, will result in serious injury or death.
WARNING! Indicates an imminently hazardous situation which, if not
avoided, could result in serious injury or death.
CAUTION: Indicates an imminently risky situation which, if not avoided,
could result in minor injuries or slight injury. It may also be used to notify
the user to remain alert regarding unsafe practises which may cause
property damage.
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WARNINGS AND CAUTIONS
WEAR YOUR
FORESIGHT IS
BETTER THAN
NO SIGHT
Be sure to read, understand and follow all safety warnings and instructions
in the supplied operator’s manual.
WORK AREA
1. KEEP CHILDREN AND BYSTANDERS AWAY.
All children should be kept away from the work area. Don’t let them
handle machines, tools or extension cords. Visitors can be a distraction
and are difcult to protect from injury.
2. KEEP WORKING AREA CLEAN
and be sure adequate lighting is available. Cluttered areas invite
injuries.
3. AVOID DANGEROUS ENVIRONMENTS
Don’t use power tools in damp or wet locations. Keep work area
well lit. Do not expose power tools to rain. Do not use the tool in the
presence of ammable liquids or gases.
4. STORE IDLE EQUIPMENT.
Store equipment in a dry area to inhibit rust. Equipment also should
be in a high location or locked up to keep out of reach of children and
untrained persons.
PERSONAL SAFETY
1. LEARN THE MACHINE’S APPLICATIONS AND LIMITATIONS,
as well as the specic potential hazards particular to this machine.
Follow available safety instructions and safety rules carefully.
2. DON’T OVERREACH.
Keep proper footing and balance at all times. Do not reach over or
across machines that are running.
3. STAY ALERT
Avoid distractions while operating this tool. Watch what you are doing.
Use common sense. Do not operate tool when you are tired. Do not
operate while under medication or while using alcohol or other drugs.
4. WEAR APPROPRIATE APPAREL
Do not wear loose clothing, gloves, bracelets, necklaces,or jewellery
while operating the tool. Wear face, eye, ear, respiratory and body
protection devices, as indicated for the operation or environment.
5. ALWAYS WEAR SAFETY GLASSES
Use ANSI approved safety glasses (in accordance with ANSI Z87.1-
2003.) Also use face or dust mask if cutting operation is dusty, and ear
plugs during extended periods of operation. Everyday eyeglasses have
only impact resistant lenses, they are NOT safety glasses.
6. WEAR BREATHING PROTECTION.
Use of this tool can generate and/or disperse dust, which may cause
serious and permanent respiratory or other injury. Many types of wood
are naturally toxic, especially in dust form. Wear a clean dust mask
if the work involves creating a lot of ne or coarse dust. Always use
NIOSH/OSHA-approved respiratory protection appropriate for the dust
exposure. Direct particles away from face and body.
7. WEAR HEARING PROTECTION,
especially from repeated exposure. This tool is loud. Proper hearing
protection should be worn (in accordance with ANSI S12.6-1997
R2002).
8. GUARD AGAINST ELECTRIC SHOCK
Prevent body contact with grounded surfaces. For example: pipes,
radiators, ranges, refrigerator enclosures. When your body is grounded
the risk of electric shock increases. When working wherever “live”
electrical wires may be encountered, try to ascertain whether there is
a danger of shock. Even so, DO NOT TOUCH ANY METAL PARTS
OF THE TOOL while using it. Hold the tool only by the plastic grip to
prevent electric shock if you contact a live wire.
9. ALWAYS DISCONNECT TOOL BEFORE SERVICING
and when changing accessories such as the blade.
10. ENSURE KEYS AND ADJUSTING WRENCHES ARE REMOVED
before turning power on. Left attached, these parts can y off a rotating
part and result in personal injury.
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141110
11. MAKE SURE THAT SWITCH IS IN “OFF” POSITION
before plugging in cord to reduce the risk of unintentional starts.
12. NEVER STAND ON TOOL
Serious injury could occur if the tool is tipped or if the cutting tool is
unintentionally contacted.
13. KEEP HANDS WELL AWAY FROM CUTTING SURFACES
and all moving parts. Do not clear chips and sawdust away with
hands. Use a brush.
14. SECURE WORK.
Use clamps or a vise to hold the work. It’s safer than using your hands
and it frees both hands to operate the tool.
15. DISCONNNECT THE PLUG FROM POWER
before making any adjustments. Changing attachments or accessories
can be dangerous if the tool could accidentally start.
TOOL SAFETY
1. MAKE SURE ALL CUTTING TOOLS
are moving at operation speed before feeding.
2. DO NOT FEED THE MATERIAL TOO QUICKLY.
The tool will perform better and be safer working at the rate for which it
was designed.
3. NEVER LEAVE THE MACHINE WITH THE POWER ON.
4. DO NOT FORCE THE MACHINE.
It will do the job better and be safer at a rate for which it was designed.
Don’t force a small tool or attachment to do the work of a larger
industrial tool. Don’t use a tool for a purpose for which it was not
intended.
5. MAINTAIN TOOLS WITH CARE.
Keep tools sharp and clean for better and safer performance. Follow
instructions for lubricating and safe performance. Follow instructions
for lubricating and changing accessories. Keep handles dry, clean and
free from oil and grease.
6. DISCONNNECT THE PLUG FROM POWER BEFORE MAKING ANY
ADJUSTMENTS.
Changing attachments or accessories can be dangerous if the tool
could accidentally start.
7. AVOID UNINTENTIONAL STARTING.
Be sure the switch is in the OFF position before plugging in. Do not
carry the tool with the power connected and your nger on the trigger.
8. KEEP GUARDS IN PLACE
and in working order. If a guard must be removed for maintenance or
cleaning, make sure it is properly attached before using the tool again.
9. DO NOT USE THE TOOL
if it cannot be switched on or off. Have your tool repaired
before using it.
10. CHECK FOR DAMAGED PARTS.
Before using this tool, any part that is damaged should be carefully
checked to determine that it will operate properly and perform its
intended function. Check for alignment of moving parts, binding of
moving parts, breakage of parts, mountings, and other conditions that
may affect its operation. Inspect screws and tighten any ones that
are loose. Any part that is damaged should be properly repaired or
replaced by an authorized service center unless otherwise indicated
elsewhere in the instruction manual. Have defective switches replaced
by an authorized service center. Don’t use the tool if switch does not
turn it on and off properly.
11. OBTAIN ADVICE
from your supervisor, instructor or another qualied person if you are
not thoroughly familiar with the operation of this machine. Knowledge
is safety.
12. USE ONLY RECOMMENDED ACCESSORIES.
Use of accessories NOT recommended by General International may
result in a risk of injury.
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SERVICE
1. INSPECT AND MAINTAIN THE TOOL REGULARLY.
Have it repaired only by an authorized repair technician.
2. MAINTAIN TOOLS WITH CARE.
Keep tools sharp and clean for better and safer performance. Follow
instructions for lubricating and safe performance. Follow instructions for
lubricating and changing accessories. Keep handles dry, clean and free
from oil and grease.
3. ENSURE THAT THE VENTILATION OPENINGS
are kept clear of debris.
4. IF THE CORDSET IS DAMAGED HAVE IT REPAIRED
only by an authorized service center.
5. SERVICE AND REPAIRS SHOULD BE MADE BY QUALIFIED REPAIR
TECHNICIANS
at an authorized repair center. Improperly repaired tools could cause
serious shock or injury.
6. REPLACEMENT PARTS.
When servicing, use only the manufacturer’s recommended
replacement dentical replacement parts and accessories.
7. THE MANUFACTURER SHALL NOT BE LIABLE
for any changes made to the tool, nor for any damage resulting from
such changes.
SAFETY RULES SPECIFIC TO THIS EQUIPMENT
Because each shop situation is unique, no list of safety guidelines can
ever be complete. The most important safety feature in any shop is the
knowledge and good judgement of the user. Use common sense and
always keep safety considerations, as they apply to your individual shop
situation rst and foremost in mind. If you have any doubts about the
safety of an operation you are about to perform: STOP! Do not perform the
operation until you have validated from qualied individuals if the operation
is safe to perform and what is the safest method to perform it.
WARNING! To avoid mistakes that could cause serious, permanent
injury, do not plug the tool in until the following steps have been
completed:
Assembly and alignment
Learn the use and function of the on/off switch, feed control, depth
stop, belt tension and other adjustments.
Review and understanding of all safety instructions and operating
procedures in this manual.
Review of the maintenance methods for this tool.
1. READ THE WARNING LABELS ON THE TOOL.
2. AVOID UNINTENTIONAL STARTING.
Be sure the switch is in the OFF position before plugging in.
3. ALWAYS CHECK AND MAKE SURE TO REMOVE ANY ADJUSTING
KEYS OR WRENCHES
before turning the tool on. Left attached, these parts can y off a
rotating part and result in personal injury.
4. DO NOT OPERATE THIS MACHINE UNTIL IT IS COMPLETELY
ASSEMBLED
and installed according to the instructions. A machine incorrectly
assembled can cause serious injury.
NOTE: If any parts are damaged or missing, do not attempt to plug in
the power cord and turn the switch on until the damaged or missing parts
are obtained and are installed correctly.
5. NEVER CLIMB OR STAND ON THE TOOL.
Serious injury could occur if the tool tips. Do not store anything above
or near the tool where anyone might stand on the tool to reach them.
6. NEVER TURN THE MACHINE ON BEFORE
clearing the table/work area of all objects (tools, scraps of wood, etc.).
Flying debris is dangerous.
7. USE EXTRA SUPPORTS
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(tables, saw horses, blocks, etc.) for any workpiece large enough to tip
when not held down to the work table.
8. DO NOT LEAVE THE WORK AREA UNTIL ALL MOVING PARTS
HAVE STOPPED.
Shut off the power to master switches. Childproof the workshop!
9. BEFORE STARTING,
be certain the motor, table, attachments and adjustment knobs are
secured.
10. NEVER TURN THE MACHINE ON
with the workpiece contacting the cutting surface. Workpiece may be
thrown and cause injury or damage.
11. PREVENT THE WORKPIECE
from contacting the blade before starting the tool. Loss of control of the
workpiece is dangerous.
12. DISCONNNECT THE PLUG FROM POWER BEFORE MAKING ANY
ADJUSTMENTS.
Changing attachments, making bit changes, adjustments or repairs or
accessories can be dangerous if the tool could accidentally start. Turn
off and unplug the drill press before moving it.
13. TURN THE MACHINE OFF,
disconnect the machine from the power source, when not in operation
and before leaving the machine. Clean the table/work area before
leaving the machine.
14. DO NOT LEAVE THE WORK AREA UNTIL ALL MOVING PARTS
HAVE STOPPED.
Shut off the power to master switches. Childproof the workshop!
15. TO FREE ANY JAMMED MATERIAL, TURN THE SWITCH OFF.
Unplug the tool. Wait for all moving parts to stop before removing the
jammed material.
16. SUPPORT THE WORKPIECE FIRMLY WITH A CLAMP,
vise, or work table when cutting. Hold the workpiece rmly. Loss of
control of the workpiece can result in injury.
17. PROPERLY SUPPORT LONG OR WIDE WORKPIECES.
If a workpiece overhangs the table so that it could fall or tip if not held,
clamp it to the table or provide auxiliary support(s). Loss of control of
the workpiece is dangerous.
18. SUPPORT ROUND WORK PROPERLY
Use V blocks to prevent it from rolling.
19. USE THE RECOMMENDED CUTTING SPEED
for the specic operation and workpiece material — check the label for
information
20. KEEP PULLEY COVER CLOSED
when not making belt adjustments.
21. USE ONLY ACCESSORIES DESIGNED FOR THIS TOOL
to avoid serious injury from thrown, broken parts or work pieces.
22. AVOID AWKWARD OPERATIONS AND HAND POSITIONS.
A sudden slip could cause a hand to move into the blade.
23. NEVER PERFORM LAYOUT, ASSEMBLY, OR SET-UP WORK ON
THE TABLE
/work area when the machine is running. A sudden slip could cause a
hand or hair to move into the blade Severe injury can result.
24. DO NOT GET DISTRACTED AND ALWAYS CONCENTRATE ON
WHAT YOU ARE DOING.
Use common sense. Never operate the machine when you are tired,
sick, or under the inuence of alcohol, or other drugs.
25. LOCK THE SWITCH IN THE “OFF” POSITION TO PREVENT
UNAUTHORIZED USE.
Someone else might accidentally start the machine and cause injury to
themselves.
26. FAILURE TO FOLLOW OPERATING INSTRUCTIONS AND SAFETY
PRECAUTIONS IN THIS INSTRUCTION MANUAL CAN RESULT IN
SERIOUS INJURY.
Read the manual before starting or operating this unit.
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27. KEEP THESE INSTRUCTIONS.
Refer to them frequently and use them to instruct other users. If you
loan someone this unit, also loan them the instructions.
HEALTH NOTICE: Some dust created by power sanding, sawing,
grinding, drilling, and other construction activities contain 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
─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 lter out microscopic
particles.
ELECTRICAL
WARNINGS AND CAUTIONS
1. BEFORE CONNECTING THE MACHINE to the power source, verify
that the voltage of your power supply corresponds with the voltage
specied 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 qualied electrician
before connecting to the power source.
2. MAKE SURE YOUR FINGERS
do not contact the terminals of the power cord plug when plugging in or
unplugging the saw.
3. GROUNDED TOOLS MUST BE PLUGGED INTO AN OUTLET THAT
ITSELF IS PROPERLY INSTALLED AND GROUNDED.
Grounding provides a low-resistance path to carry electricity to ground
away from the operator, should the tool malfunction electrically.
4. DO NOT ABUSE THE CORD.
Never carry your tool by the cord or pull on the cord to unplug it.
Protect the cord from potential sources of damage: heat, oil & solvents,
sharp edges, or moving parts. Replace damaged cords immediately.
5. WHEN WORKING OUTDOORS, USE AN OUTDOOR-RATED
EXTENSION CORD.
An extension cord rated for outdoor use must be marked “W-A” or “W”.
6. THIS TOOL IS FOR INDOOR USE ONLY.
Do not expose electrical power tools to moisture. Rain or wet
conditions can cause water to enter the tool and lead to electric shock.
7. FOLLOW ALL LOCALLY APPLICABLE WIRING CODES
and recommended electrical connections to prevent shock or
electrocution.
POWER
POWER REQUIREMENTS
This tool is designed to operate on a properly grounded 120 volt, 60 Hz,
single phase, alternating current (AC) power source, fused with a 15 amp
time delayed circuit breaker. It is recommended that a qualied electrician
verify the ACTUAL VOLTAGE at the receptacle into which the tool will be
plugged and conrm that the receptacle is properly grounded. The use of
the proper circuit size can eliminate nuisance circuit breaker tripping when
using your tool.
CAUTION: do not operate this tool if the actual power source voltage is
less than 105 volts ac, or greater than 132 volts ac. Contact a qualied
electrician if this problem exists. Improper performance, and/or, damage
to the tool will result if operated on inadequate, or excessive power.
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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 to t a grounded type receptacle (B, g 1). Do not
remove the 3rd prong (grounding pin) to make it t into an obsolete 2-hole
wall socket or extension cord.
WARNING! BANDSAW MUST BE GROUNDED. Use a Ground Fault
Interrupter (GFI). Plug the power cord to a standard 120 volt receptacle
protected by a 20 amp circuit breaker.
If an adaptor plug is used (C, g 1), it must be attached to the metal screw
of the receptacle.
NOTE: The use of an adaptor plug is illegal in some areas, including
Canada. Check your local codes. If you have any doubts or if the
supplied plug does not correspond to your electrical outlet, consult a
qualied electrician before proceeding.
EXTENSION CORDS
If you nd 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.
Total Extension Cord Length
Amp Rating Feet Meters Feet Meters Feet Meters Feet Meters
25 8 50 15 100 30 125 40
3-10 amp 18 ga. 16 ga. 14 ga. 14 ga.
10.1 - 12 amp 16 ga. 16 ga. 14 ga. 14 ga.
12.1 - 16 amp 14 ga. 12 ga. Not Recommended
Use only UL or CSA approved extension cords
WARNING! Do not allow familiarity with your tool to make your
careless. Remember that a careless fraction of a second is sufcient to
inict severe injury.
IMPORTANT: The warnings, cautions and instructions detailed in this
manual cannot cover all possible conditions and situations that occur. It
must be understood by the operator that common sense and caution are
factors that cannot be built into this product, but must be supplied by the
operator.
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FUNCTIONAL DESCRIPTION
GETTING TO KNOW YOUR BAND SAW
WARNING! To avoid injury from accidental start, turn the switch off
and remove the plug from the power source outlet before making any
adjustments
B Leg assembly
C Tool tray
D Wheels
E Wheel frame
F Transport handle
J Pulley cover
K Work stop rod
O Lock chain
P Switch lock screw
Q Switch
R Switch tab
S Saw handle
T Vise handle
U Adjusting rod
V Work stop
W Miter lock handle
X Head support plate
Y Motor
Z Blade tension adjustment knob
AA Sliding vise plate
BB Mitering vise plate
CC Lock tab
DD Upper blade cover
EE Blade guard adjustment
FF Lower blade guard
UNPACKING
WARNING! Do not attempt to assemble the band saw, plug in the
power cord or turn on the switch if any parts are damaged or missing.
Failure to heed this warning could result in serious personal injury.
CONTENTS
Separate all parts from the packing materials and check carefully against
g 2 and the list below.
NOTE: Make certain all parts are accounted for before discarding any
packing material.
1. This tool comes partly assembled. It will be necessary to complete the
assembly.
2. Unpack and layout all the items and identify each one. Some items
listed below may be packed already assembled to each other.
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A Band saw head assembly 1
B Leg assembly 2
C Tool tray 1
D Wheels 2
E Wheel frame 1
F Transport handle 1
G Worm gear pulley 1
H Motor shaft pulley 1
I V-belt 1
J Pulley cover 1
K Work stop rod 1
L Vertical cutting plate 1
M Vertical cutting support 1
N Accessory pack 1
ASSEMBLY PROCEDURE
WARNING! For your own safety, never connect the plug to the power
source outlet or insert the switch insert key until all the assembly steps
are complete and you have read and understood the entire owner's
manual.
STAND
Attach the lower tray, wheels and transport handle in this order:
1. Locate the two 2 leg assemblies (B, g 2 & 3).
2. Locate the tool tray (C, g 2).
3. On both leg assemblies, open the hinged ap 90 degrees. (g 3)
4. Place the two 2 leg assemblies about 18" (45 cm) apart.
5. Place the tool tray with the edges pointing up, between the 2 leg
assembies.
6. At each end, align the holes of the tool tray with the holes in the edge of
the leg assembly.
NOTE: the legs should t equally well either way around.
7. Locate 8 M6 washers, 4 M6 hexagon nuts and 4 M6 x 10 hexagon head
bolts.
8. Place a washer onto each M6 x 10 hexagon head bolt.
9. Fully insert 1 hex head bolt with washer rst, through each of the 4
holes of the tool tray, then the holes of the leg assembly.
10. Slide a washer onto the threaded ends of each hex head bolt.
11. Place a hex nut onto each bolt.
12. Be sure the stand is symetrical and stable.
13. Fully tighten the 4 hexagon nuts and bolts.
BAND SAW CONNECTING PLATES
1. Locate the two connecting plates (GG, g 5) and place one connecting
plate on top of each leg assembly with the tabs inside.
2. Align the 3 bottom holes (b, g 5) of each connecting plate with the 3
holes at the tops of each leg assembly.
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3. Place the 3 bottom tabs of the connecting plates inside the leg
assemblies (b, g 6).
4. Locate 6 M8 washers (d, g 7), and 6 M8 x 16 hexagon head bolts (c,
g 7).
5. Place a washer onto each hexagon head bolt.
6. Hand thread each hex head bolt, rst through the leg assembly, then
into the one of the two connecting plates (g 7).
7. Do not fully tighten any of the 6 hexagon head bolts at this time; this will
be done later.
BAND SAW HEAD MOUNTING
WARNING! This item is very heavy. We strongly suggest that two
people be used to unpack and assemble this band saw. Using proper
lifting methods and the help of another person, lift the band saw head
assembly and place it between the brackets of both connecting plates.
NOTE: The band saw head may be placed with the motor facing either
direction on the stand assembly.
1. Locate the 3 holes at either end of the base of the band saw head
assembly.
2. With the help of another person, adjust the band saw head assemblyso
as to align the 3 holes of the band saw head with the 3 brackets and
holes (t, g 5 & 6) of each connecting plate.
CAUTION: The head assembly is heavy (about 55 lb. / 25 kg) and you
will require assistance from a second person.
3. Locate 6 M8 x 25 hexagon head bolts and 6 M8 washers.
4. Place one washer on each hexagon head bolt.
5. Thread one hexagon head bolt through each hole of the connecting
plate bracket (t, g 8), then into the base of the band saw head head
assembly (e, g 8).
PULLEY SYSTEM ASSEMBLY
1. Locate the complete pulley cover. The complete pulley cover consists of
the pre-assembled lower pulley cover (l, g 9) and the upper pulley
cover (u, g 9).
2. Locate the worm gear shaft (w, g 10) on the band saw head assembly.
3. Locate the M4 x 8 screw (s, g 10), which is already in place near the
worm gear shaft .
4. Un-thread and remove the M4 x 8 screw.
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5. Locate the motor adjusting knob (k, g 11).
6. Loosen, but do not fully unscrew, the motor adjusting knob by rotating it
counter-clockwise.
7. Slide the kidney shaped hole of the lower pulley cover (l, g 12) over the
shaft (y, g 12) of the motor (Y, g 12).
NOTE: The motor rests on a hinge.
8. Raise the motor to allow for the needed slack to place the pulley cover
onto the worm gear shaft.
9. Slide the round hole of lower pulley cover onto the worm gear shaft (g
13).
1. Inside the pulley cover are 2 holes. These holes are used to mount the
pulley cover (g 14)
2. Align hole #1 with the pre-drilled hole on the band saw.
3. Locate and slide an M6 rubber washer under both holes, 1 and 2, of the
pulley cover.
4. Locate 1 M6 x 12 cross head screw.
5. Screw the cross head (Phillips) screw through hole #1 and the rubber
washer, fully securing the pulley cover in place.
6. Re-insert the M4 x 8 screw in hole #2 and through the rubber washer.
This screw was removed in step 4 of this section.
7. Locate the motor pulley and worm gear pulley.
8. Locate the 2 M8 x 12 set screws; 1 in the motor pulley (ss, g 15) and 1
in the worm gear pulley (ss, g 16).
9. Place the motor pulley onto the motor shaft and align the set screw (ss,
g 17) of the motor pulley with the atted surface of the motor shaft (f,
g 17).
10. Place the worm gear pulley onto the worm gear shaft and align the set
screw of the worm gear pulley (ss, g 17) with the atted surface of the
worm gear shaft (f, g 17).
NOTE: In g 17, the pulley cover has been removed for clarity.
11. Raise and lower each pulley until they are visually ush with each other.
12. Fully tighten both of the set screws with the provided hex wrench.
13
ENGLISH
13. Locate the V-Belt.
14. Lift the hinged motor and place the V-belt around the top grooves of
both the motor pulley and the worm gear pulley.
15. Lower the hinged motor.
16. The band saw is now set at a speed of 80 f.p.m. (24 m/min).
17. Fully tighten the motor adjusting knob (k, g 11) by rotating it clockwise.
NOTE: By tightening the adjusting knob, the v-belt is fully tightened on
the pulleys.
18. Tension is correct when the belt deects by about 1/2 an inch (13 mm)
at their center of run when using reasonable thumb pressure.
19. Close band saw upper pulley cover.
TRANSPORT HANDLE
1. Locate the transport handle.
2. Place the ends of the transport handle through the 2 holes of the leg
assembly at the opposite side of the motor (g 18).
3. Locate two 3 x 18 cotter pins.
4. Place a cotter pin through the hole at each end of the oor stand handle;
now located inside the oor stand.
5. Using pliers, wrap 1 leg of each cotter pin around the transport handle
(g 19 shows one side of the handle inside the leg assembly).
6. Wrap the other leg of each cotter pin, in the opposite direction, around
the transport handle.
WHEELS
1. Locate the wheel frame (E, g 2).
2. Place the wheel frame against the bottom of the oor stand.
NOTE: Install the wheel frame on the same end of the band saw as the
motor.
3. Align the holes of the wheel frame with the holes of the oor stand.
When aligning the holes, make sure the wheel frame is level with the
ground.
4. Locate 8 M8 washers, 4 M8 hexagon nuts and 4 M8 x 16 hexagon head
bolts.
5. Place a washer onto each hexagon head bolt.
6. Insert one hexagon head bolt with washer, rst through each hole of the
wheel frame, then into the oor stand, for a total of 4 bolts.
7. Place a washer onto the threaded ends of each inserted bolt.
8. Fully thread and tighten a hexagon nut onto the threaded ends of each
inserted bolt.
9. Locate 2 wheels and two 3 x 18 cotter pins.
10. Slide 1 wheel onto each side of the wheel frame axle.
11. Insert 1 cotter pin into each hole of the wheel frame axle.
12. Using pliers, wrap the 1 leg of the cotter pin around the axle (g 21).
13. Wrap the other leg of the cotter pin, in the opposite direction, around
the axle.
14
ENGLISH
141110
WORK STOP
A work stop can be used to cut multiple work pieces to equal length without
having to re-measure each piece individually.
1. Locate the work stop. This includes the work stop rod (r), the work stop
(s) and the M8 x 10 hexagon socket set screw (see g 22).
2. Locate M8 x 12 set screw, already installed in the band saw base.
3. Push the work stop rod into the hole located below this M8 x 12 set
screw. (See a view looking down at the vise assembly, g 23)
4. Tighten the M8 x 12 set screw (clockwise) to secure the work stop rod in
place.
5. Using the provided hex wrench, loosen, do not remove, the hexagon
socket set screw located in the work stop itself.
6. Swing up and slide the work stop to the desired length to be cut by
measuring the distance from the work stop to the blade.
NOTE: always perform a test cut on a piece of scrap material after
making adjustments to the tool.
7. Using the provided hex wrench, tighten the hexagon socket set screw.
OPERATING INSTRUCTIONS
WARNING! Before using this machine, the operator should carefully
read over this operation manual and acquaint himself with the
construction, controls and drive system of the band saw.
WARNING! Always disconnect the tool from power source before
making any adjustments, storing, servicing, or changing accessories.
Such preventative safety measures reduce the risk of starting the tool
accidentally.
CLAMPING A WORK PIECE
This tool comes with a vise for securing your work piece. For larger work
pieces, seek out additional vises or clamps. The vise is designed to be
used for horizontal cuts only.
SECURE AN ITEM FOR CUTTING
1. Raise and lock the band saw head in the vertical position using the head
support plate (X, g 2).
2. Locate the vise handle (T, g 2 & 24).
3. Rotate the vise handle counter-clockwise until there is enough room
for your work piece between the sliding vise plate (AA, g 25) and the
mitering vise plate (BB, g 25).
4. Locate the M10 x 30 hexagon head bolt (hb. g 25).
5. Loosen the M10 x 30 hexagon head bolt by rotating it counterclockwise. This will allow for a tighter clamp later.
6. Place the work piece between both of the vise plates.
7. Rotate the vise handle clockwise until the sliding vise plate clamps the
work piece against the mitering vise plate.
8. Fully tighten the hexagon head bolt.
15
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