BS902
OPERATOR’S MANUAL
9 in. (229 mm) BAND SAW
BS902
Your band saw has been engineered and manufactured to our high standard for dependability, ease of operation, and
operator safety. When properly cared for, it will give you years of rugged, trouble-free performance.
WARNING: To reduce the risk of injury, the user must read and understand the operator’s manual before using
this product.
Thank you for your purchase.
SAVE THIS MANUAL FOR FUTURE REFERENCE
TABLE OF CONTENTS
Introduction ..................................................................................................................................................................... 2
� Warranty .......................................................................................................................................................................... 2
� General Safety Rules ....................................................................................................................................................... 3
� Specific Safety Rules ....................................................................................................................................................... 4
� Symbols ........................................................................................................................................................................5-6
�� Electrical .......................................................................................................................................................................... 7
�� Glossary of Terms ............................................................................................................................................................ 8
�� Features ...................................................................................................................................................................... 9-10
�� Tools Needed ................................................................................................................................................................. 11
�� Loose Parts ................................................................................................................................................................... 11
�� Assembly ..................................................................................................................................................................12-15
� Operation .................................................................................................................................................................. 16-18
Adjustments .............................................................................................................................................................. 19-22
� Maintenance .............................................................................................................................................................22-23
� Troubleshooting ............................................................................................................................................................. 24
� Parts Ordering / Service ................................................................................................................................................ 26
INTRODUCTION
This tool has many features for making its use more pleasant and enjoyable. Safety, performance, and dependability have
been given top priority in the design of this product making it easy to maintain and operate.
WARRANTY
RYOBI® POWER TOOL - LIMITED TWO YEAR WARRANTY AND 30 DAY EXCHANGE POLICY
One World Technologies, Inc., warrants its RYOBI® power tools with the following conditions:
30-DAY EXCHANGE POLICY: During the first 30 days after date of purchase, you may either request service under this
warranty or you may exchange any RYOBI® power tool which does not work properly due to defective workmanship or
materials by returning the power tool to the dealer from which it was purchased. To receive a replacement power tool
or requested warranty service, you must present proof of purchase and return all original equipment packaged with the
original product. The replacement power tool will be covered by the limited warranty for the balance of the two year period
from the date of the original purchase.
WHAT THIS WARRANTY COVERS: This warranty covers all defects in workmanship or materials in your RYOBI® power
tool for a period of two years from the date of purchase. With the exception of batteries, power tool accessories are
warranted for ninety (90) days. Batteries are warranted for two years.
HOW TO GET SERVICE: Just return the power tool, properly packaged and postage prepaid, to an Authorized Service
Center. You can obtain the location of the Service Center nearest you by contacting a service representative at One
World Technologies, Inc., P.O. Box 1207, Anderson, SC 29622-1207, by calling 1-800-525-2579 or by logging on to www.
ryobitools.com. When you request warranty service, you must also present proof of purchase documentation, which
includes the date of purchase (for example, a bill of sale). We will repair any faulty workmanship, and either repair or replace
any defective part, at our option. We will do so without any charge to you. We will complete the work in a reasonable time,
but, in any case, within ninety (90) days or less.
WHAT’S NOT COVERED: This warranty applies only to the original purchaser at retail and may not be transferred. This
warranty only covers defects arising under normal usage and does not cover any malfunction, failure or defects resulting
from misuse, abuse, neglect, alteration, modification or repairs by other than Authorized Service Centers. One World
Technologies, Inc. makes no warranties, representations or promises as to the quality or performance of its power tools
other than those specifically stated in this warranty.
ADDITIONAL LIMITATIONS: Any implied warranties granted under state law, including warranties of merchantability or
fitness for a particular purpose, are limited to two years from the date of purchase. One World Technologies, Inc. is not
responsible for direct, indirect, or incidental damages, so the above limitations and exclusions may not apply to you. This
warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
2
GENERAL SAFETY RULES
WARNING:
Read and understand all instructions. Failure to follow
all instructions listed below, may result in electric shock,
fire and/or serious personal injury.
READ ALL INSTRUCTIONS
KNOW YOUR POWER TOOL. Read the operator’s manual
carefully. Learn the applications and limitations as well
as the specific potential hazards related to this tool.
GUARD AGAINST ELECTRICAL SHOCK by preventing
body contact with grounded surfaces. For example: pipes,
radiators, ranges, refrigerator enclosures.
KEEP GUARDS IN PLACE and in good working order. Nev-
er operate the tool with any guard or cover removed. Make
sure all guards are operating properly before each use.
REMOVE ADJUSTING KEYS AND WRENCHES. Form
habit of checking to see that keys and adjusting wrenches
are removed from tool before turning it on.
KEEP WORK AREA CLEAN. Cluttered areas and benches
invite accidents.
DO NOT USE IN DANGEROUS ENVIRONMENTS. Do
not use power tools near gasoline or other flammable
liquids, in damp or wet locations or expose them to rain.
Keep the work area well lit.
K E EP CHILDR E N AND V I S I TO RS AWAY. A ll
visitors should wear safety glasses and be kept a safe
distance from work area.
MAKE WORKSHOP CHILDPROOF with padlocks,
master switches, or by removing starter keys.
DON’T FORCE THE TOOL. It will do the job better and
safer at the feed rate for which it was designed.
USE THE RIGHT TOOL. Do not force the tool or attach-
ment to do a job for which it was not designed.
USE THE PROPER EXTENSION CORD. Make sure your
extension cord is in good condition. Use only a cord heavy
enough to carry the current your product will draw. An
undersized cord will cause a drop in line voltage resulting in
loss of power and overheating. A wire gauge size (A.W.G.)
of at least 16 is recommended for an extension cord 25
feet or less in length. If in doubt, use the next heavier
gauge. The smaller the gauge number, the heavier the cord.
WEAR THE PROPER APPAREL. Do not wear loose
clothing, neckties, or jewelry that can get caught in the
tool’s moving parts and cause personal injury. Nonslip
footwear is recommended when working outdoors. Wear
protective hair covering to contain long hair.
ALWAYS WEAR SAFETY GLASSES WITH SIDE
SHIELDS. Everyday eyeglasses have only impact-
resistant lenses, they are NOT safety glasses.
SECURE WORK. Use clamps or a vise to hold work
when practical. It’s is safer than using your hand and frees
both hands to operate the tool.
DO NOT OVERREACH. Keep proper footing and
balance at all times.
MAINTAIN TOOLS WITH CARE. Keep tools sharp
and clean for better and safer performance. Follow
instructions for lubricating and changing accessories.
DISCONNECT TOOLS. When not in use, before
servicing, or when changing attachments, blades, bits,
cutters, etc., all tools should be disconnected from power
source.
REDUCE THE RISK OF UNINTENTIOINAL STARTING.
Be sure switch is off when plugging in any tool.
USE RECOMMENDED ACCESSORIES. Consult the
operator’s manual for recommended accessories. The
use of improper accessories may result in injury.
NEVER STAND ON TOOL. Serious injury could occur if the
tool is tipped or if the blade is unintentionally contacted.
CHECK DAMAGED PARTS. Before further use of the
tool, a guard or other part that is damaged should be
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, mounting and any other conditions that may affect
its operation. A guard or other part that is damaged must
be properly repaired or replaced by an authorized service
center to avoid risk of personal injury.
DIRECTION OF FEED. Feed work into a blade or cutter
against the direction or rotation of the blade or cutter only.
NEVER LEAVE TOOL RUNNING UNATTENDED. TURN
THE POWER OFF. Don't leave tool until it comes to a
complete stop.
DO NOT ABUSE CORD. Never carry tool by the cord or
yank it to disconnect from receptacle. Keep cord from
heat, oil, and sharp edges.
PROTECT YOUR LUNGS. Wear a face or dust mask if
the cutting operation is dusty.
PROTECT YOUR HEARING. Wear hearing protection
during extended periods of operation.
BLADE COASTS AFTER BEING TURNED OFF.
KEEP TOOL DRY, CLEAN, AND FREE FROM OIL AND
GREASE. Always use a clean cloth when cleaning. Never
use brake fluids, gasoline, petroleum-based products, or
any solvents to clean tool.
INSPECT TOOL CORDS AND EXTENSION CORDS
PERIODICALLY and, if damaged, have repaired by a
qualified service technician. Stay constantly aware of cord
location and keep it well away from the rotating wheel.
NEVER USE IN AN EXPLOSIVE ATMOSPHERE.
Normal sparking of the motor could ignite fumes.
USE ONLY OUTDOOR EXTENSION CORDS with ap-
proved ground connection that are intended for use
outdoors and so marked.
BE SURE BLADE PATH IS FREE OF NAILS. Inspect for
and remove all nails from lumber before cutting.
3
SPECIFIC SAFETY RULES
AVOID AWKWARD OP E R AT I O N S AND HAND
POSITIONS where a sudden slip could cause your
hand to move into the blade. ALWAYS make sure you
have good balance. NEVER operate the miter saw
on the floor or in a crouched position.
ALLOW THE MOTOR TO COME UP TO FULL SPEED
before starting a cut to avoid binding or stalling.
DO NOT USE TOOL IF SWITCH DOES NOT TURN IT
ON AND OFF. Have defective switches replaced by an
authorized service center.
REPLACEMENT PARTS. All repairs, whether electrical
or mechanical, should be made by a qualified service
technician at an authorized service center.
WHEN SERVICING use only identical replacement parts.
Use of any other parts may create a hazard or cause
product damage.
KEEP HANDS AWAY FROM CUTTING AREA. Do not
hand hold pieces so small that your fingers go under
the blade guard. Do not reach underneath work or in
blade cutting path with your hands and fingers for any
reason.
NEVER CUT MORE THAN ONE PIECE AT A TIME or
stack more than one workpiece on the saw table at a
time.
FIRMLY CLAMP OR BOLT your saw to a stable, level
workbench or table. The most comfortable table height
is approximately waist height.
DO NOT FEED THE MATERIAL TOO QUICKLY. Do not
force the workpiece against the blade.
USE ONLY CORRECT BLADES. Use the right blade size,
style and cutting speed for the material and the type of
cut. Blade teeth should point down toward the table.
BEFORE MAKING A CUT, BE SURE ALL ADJUST-
MENTS ARE SECURE.
ALWAYS SUPPORT LARGE WORKPIECES while cutting
to minimize risk of blade pinching and kickback. Saw may
slip, walk or slide while cutting large or heavy boards.
DO NOT REMOVE JAMMED CUTOFF PIECES until
blade has stopped.
NEVER START THE TOOL when the blade is in contact
with the workpiece.
NEVER TOUCH BLADE or other moving parts during
use.
BEFORE CHANGING THE SETUP, REMOVING COVERS,
GUARDS OR BLADES, unplug the saw and remove the
switch key.
HOLD THE WORKPIECE firmly against the saw table.
TO AVOID ACCIDENTAL BLADE CONTACT, minimize
blade breakage, and provide maximum blade support,
always adjust the blade guide assembly to just clear the
workpiece.
KEEP BLADES CLEAN, SHARP, AND WITH SUFFICIENT
SET. Sharp blades minimize stalling and kickbacks.
ALWAYS TURN OFF SAW before disconnecting it to
avoid accidental starting when reconnecting to a power
source.
DO NOT OPERATE THIS TOOL WHILE UNDER
THE INFLUENCE OF DRUGS, ALCOHOL OR ANY
MEDICATION.
STAY ALERT AND EXERCISE CONTROL. Watch what
you are doing and use common sense. Do not operate
tool when you are tired. Do not rush.
MAKE SURE WORK AREA HAS AMPLE LIGHTING to
see the work and that no obstructions will interfere with
safe operation BEFORE performing any work using your
saw.
The blade guides have been preset at the factory. These
settings are functional for some applications. We recommend that you check and adjust blade guide settings
before first use of your saw. Refer to “Adjusting thrust
bearings, blade guide support, and blade guides”
procedures explained in the adjustments section of this
operator’s manual.
IF THE POWER SUPPLY CORD IS DAMAGED, it must
be replaced only by the manufacturer or by an authorized
service center to avoid risk.
SAVE THESE INSTRUCTIONS. Refer to them frequently
and use them to instruct other users. If you loan someone
this tool, loan them these instructions also.
WARNING:
Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals
known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:
• lead from lead-based paints,
• crystalline silica from bricks and cement and other masonry products, and
• arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to
these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks
that are specially designed to filter out microscopic particles.
4
SYMBOLS
Some of the following symbols may be used on this tool. Please study them and learn their meaning. Proper
interpretation of these symbols will allow you to operate the tool better and safer.
SYMBOL NAME DESIGNATION/EXPLANATION
V Volts
A Amperes
Hz
W Watt
min Minutes
n
o
.../min
Hertz
Alternating Current
Direct Current
No Load Speed
Class II Construction
Per Minute
Wet Conditions Alert
Voltage
Current
Frequency (cycles per second)
Power
Time
Type of current
Type or a characteristic of current
Rotational speed, at no load
Double-insulated construction
Revolutions, strokes, surface speed, orbits, etc., per minute
Do not expose to rain or use in damp locations.
Read The Operator’s Manual
Eye Protection
Safety Alert
No Hands Symbol
Hot Surface
To reduce the risk of injury, user must read and understand
operator’s manual before using this product.
Always wear safety goggles or safety glasses with side shields and,
as necessary, a full face shield when operating this product.
Precautions that involve your safety.
Failure to keep your hands away from the blade will result in
serious personal injury.
To reduce the risk of injury or damage, avoid contact with any
hot surface.
5
SYMBOLS
The following signal words and meanings are intended to explain the levels of risk associated with this product.
SYMBOL SIGNAL MEANING
DANGER:
WARNING:
CAUTION
CAUTION
Indicates an imminently hazardous situation, which, if not avoided, will result
in death or serious injury.
Indicates a potentially hazardous situation, which, if not avoided, could result
in death or serious injury.
Indicates a potentially hazardous situation, which, if not avoided, may result in
minor or moderate injury.
(Without Safety Alert Symbol) Indicates a situation that may result in property
damage.
SERVICE
Servicing requires extreme care and knowledge and should
be performed only by a qualified service technician. For
service we suggest you return the product to the nearest
AUTHORIZED SERVICE CENTER for repair. When servicing, use only identical replacement parts.
WARNING:
To avoid serious personal injury, do not attempt to use this
product until you read thoroughly and understand completely the operator’s manual. If you do not understand
the warnings and instructions in the operator’s manual,
do not use this product. Call Ryobi customer service for
assistance.
WARNING:
The operation of any power tool can result in foreign objects being thrown into your eyes, which can
result in severe eye damage. Before beginning power tool operation, always wear safety goggles or
safety glasses with side shields and, when needed, a full face shield. We recommend Wide Vision
Safety Mask for use over eyeglasses or standard safety glasses with side shields. Always use eye
protection which is marked to comply with ANSI Z87.1.
SAVE THESE INSTRUCTIONS
6
ELECTRICAL
EXTENSION CORDS
Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the tool’s plug.
When using a power tool at a considerable distance from the
power source, use an extension cord heavy enough to carry
the current that the tool will draw. An undersized extension
cord will cause a drop in line voltage, resulting in a loss of
power and causing the motor to overheat. Use the chart
provided below to determine the minimum wire size required
in an extension cord. Only round jacketed cords listed by
Underwriter’s Laboratories (UL) should be used.
**Ampere rating (on tool data plate)
0-2.0 2.1-3.4 3.5-5.0 5.1-7.0 7.1-12.0 12.1-16.0
Cord Length Wire Size (A.W.G.)
25' 16 16 16 16 14 14
' 16 16 16 14 14 12
50
100' 16 16 14 12 10 —
**Used on 12 gauge - 20 amp circuit.
NOTE: AWG = American Wire Gauge
When working with the tool outdoors, use an extension cord
that is designed for outside use. This is indicated by the
letters “WA” on the cord’s jacket.
Before using an extension cord, inspect it for loose or
exposed wires and cut or worn insulation.
WARNING:
Keep the extension cord clear of the working area.
Position the cord so that it will not get caught on lumber,
tools or other obstructions while you are working with a
power tool. Failure to do so can result in serious personal
injury.
SPEED AND WIRING
The no-load speed of this tool is approximately 3,000
sfpm. This speed is not constant and decreases under
a load or with lower voltage. For voltage, the wiring in a
shop is as important as the motor’s horsepower rating. A
line intended only for lights cannot properly carry a power
tool motor. Wire that is heavy enough for a short distance
will be too light for a greater distance. A line that can
support one power tool may not be able to support two
or three tools.
GROUNDING INSTRUCTIONS
In the event of a malfunction or breakdown, grounding
provides a path of least resistance for electric current to
reduce the risk of electric shock. This tool is equipped with
an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into a
matching outlet that is properly installed and grounded in
accordance with all local codes and ordinances.
Do not modify the plug provided. If it will not fit the outlet,
have the proper outlet installed by a qualified electrician.
Improper connection of the equipment-grounding conductor can result in a risk of electric shock. The conductor with
insulation having an outer surface that is green with or without
yellow stripes is the equipment-grounding conductor. If repair
or replacement of the electric cord or plug is necessary, do
not connect the equipment-grounding conductor to a live
terminal.
Check with a qualified electrician or service personnel if the
grounding instructions are not completely understood, or if
in doubt as to whether the tool is properly grounded.
Repair or replace a damaged or worn cord immediately.
This tool is intended for use on a circuit that has an outlet
like the one shown in figure 1. It also has a grounding pin
like the one shown.
WARNING:
Check extension cords before each use. If damaged
replace immediately. Never use tool with a damaged cord
since touching the damaged area could cause electrical
shock resulting in serious injury.
ELECTRICAL CONNECTION
This tool is powered by a precision built electric motor. It
should be connected to a power supply that is 120 volts,
60 Hz, AC only (normal household current). Do not operate
this tool on direct current (DC). A substantial voltage drop
will cause a loss of power and the motor will overheat. If the
saw does not operate when plugged into an outlet, double
check the power supply.
GROUNDING
PIN
7
120V GROUNDED OUTLET
Fig. 1
GLOSSARY OF TERMS
Anti-Kickback Pawls (radial arm and table saws)
A devise which, when properly installed and maintained,
is designed to stop the workpiece from being kicked back
toward the front of the saw during a ripping operation.
Arbor
The shaft on which a blade or cutting tool is mounted.
Bevel Cut
A cutting operation made with the blade at any angle other
than 90° to the table surface.
Chamfer
A cut removing a wedge from a block so the end (or part of
the end) is angled rather than at 90°.
Compound Cut
A cross cut made with both a miter and a bevel angle.
Crosscut
A cutting or shaping operation made across the grain or the
width of the workpiece.
Cutterhead (planers and jointer planers)
A rotating cutterhead with adjustable blades or knives. The
blades or knives remove material from the workpiece.
Dado Cut
A non-through cut which produces a square-sided notch or
trough in the workpiece (requires a special blade).
Featherboard
A device used to help control the workpiece by guiding
it securely against the table or fence during any ripping
operation.
FPM or SPM
Feet per minute (or strokes per minute), used in reference
to blade movement.
Freehand
Performing a cut without the workpiece being guided by a
fence, miter gauge, or other aids.
Gum
A sticky, sap-based residue from wood products.
Heel
Alignment of the blade to the fence.
Kerf
The material removed by the blade in a through cut or the
slot produced by the blade in a non-through or partial cut.
Kickback
A hazard that can occur when the blade binds or stalls,
throwing the workpiece back toward operator.
Leading End
The end of the workpiece pushed into the tool first.
Miter Cut
A cutting operation made with the workpiece at any angle
to the blade other than 90°.
Non-Through Cuts
Any cutting operation where the blade does not extend
completely through the thickness of the workpiece.
Push Blocks (for jointer planers)
Device used to feed the workpiece over the jointer planer
cutterhead during any operation. This aid helps keep the
operator's hands well away from the cutterhead.
Push Blocks and Push Sticks (for table saws)
Devices used to feed the workpiece through the saw blade
during cutting operations. A push stick (not a push block)
should be used for narrow ripping operations. These aids
help keep the operator's hands well away from the blade.
Pilot Hole (drill presses)
A small hole drilled in a workpiece that serves as a guide for
drilling large holes accurately.
Resaw
A cutting operation to reduce the thickness of the workpiece
to make thinner pieces.
Resin
A sticky, sap-based substance that has hardened.
Revolutions Per Minute (RPM)
The number of turns completed by a spinning object in one
minute.
Ripping or Rip Cut
A cutting operation along the length of the workpiece.
Riving Knife/Spreader/Splitter (table saws)
A metal piece, slightly thinner than the blade, which helps
keep the kerf open and also helps to prevent kickback.
Saw Blade Path
The area over, under, behind, or in front of the blade. As it
applies to the workpiece, that area which will be or has been
cut by the blade.
Set
The distance that the tip of the saw blade tooth is bent (or
set) outward from the face of the blade.
Snipe (planers)
Depression made at either end of a workpiece by cutter
blades when the workpiece is not properly supported.
Through Sawing
Any cutting operation where the blade extends completely
through the thickness of the workpiece.
Throw-Back
The throwing back of a workpiece usually caused by the
workpiece being dropped into the blade or being placed
inadvertently in contact with the blade.
Workpiece or Material
The item on which the operation is being done.
Worktable
Surface where the workpiece rests while performing a
cutting, drilling, planing, or sanding operation.
8
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