Ryobi SAW BS902 User Manual
OPERATOR'S MANUAL
9 in. (229 mm) BAND SAW
BS902
Your new Band Saw has been engineered and manufactured to Ryobi's high standards for dependability, ease of
operation, and operator safety. 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 buying a Ryobi tool.
SAVE THIS MANUAL FOR FUTURE REFERENCE
TABLE OF CONTENTS
Introduction ...................................................................................................................................................................... 2
Rules for Safe Operation ............................................................................................................................................. 3-5
Electrical...........................................................................................................................................................................6
Glossary of Terms ............................................................................................................................................................ 7
Features ....................................................................................................................................................................... 7-9
Unpacking ........................................................................................................................................................................9
Tools Needed .................................................................................................................................................................10
Loose Parts List ............................................................................................................................................................. 10
Assembly................................................................................................................................................................... 11-14
Operation ................................................................................................................................................................. 14-16
Adjustments ............................................................................................................................................................. 17-20
Maintenance ............................................................................................................................................................ 20-21
Troubleshooting ............................................................................................................................................................. 22
Parts Ordering / Service .................................................................................................................................................24
INTRODUCTION
IMPORTANT
Servicing requires extreme care and knowledge and should
be performed only by a qualified service technician. For
service we suggest you return the tool to your nearest RYOBI
AUTHORIZED SERVICE CENTER for repair. When servicing, use only identical Ryobi replacement parts.
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 tool operation, always wear safety goggles or safety
glasses with side shields and a full face shield when needed. We recommend Wide Vision Safety
Mask for use over eyeglasses or standard safety glasses with side shields. Always wear eye
protection which is marked to comply with ANSI Z87.1.
Look for this symbol to point out important safety precautions. It
means attention!!! Your safety is involved.
WARNING:
Do not attempt to use the tool until you read thoroughly
and understand completely the operator’s manual. Pay
close attention to the safety rules, including Dangers,
Warnings, and Cautions. If you use this tool properly
and only for what it is intended, you will enjoy years of
safe, reliable service.
Page 2
RULES FOR SAFE OPERATION
The purpose of safety symbols is to attract your attention to possible dangers. 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.
Symbol Meaning
DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. It may also be used to alert against unsafe practices that may cause property damage.
NOTE: Advises you of information or instructions vital to the operation or maintenance of the equipment.
SAFETY AND INTERNATIONAL SYMBOLS
This operator's manual describes safety and international symbols and pictographs that may appear on this product.
Read the operator's manual for complete safety, assembly, operating and maintenance, and repair information.
SYMBOL
• Do not expose to rain or use in damp locations.
• Failure to keep your hands away from the blade
will result in serious personal injury.
MEANING
NO HANDS SYMBOL
Page 3
RULES FOR SAFE OPERATION
Safe operation of this power tool requires that you read and
understand this operator's manual and all labels affixed to
the tool. Safety is a combination of common sense, staying
alert, and knowing how your band saw works.
READ ALL INSTRUCTIONS
KNOW YOUR POWER TOOL. Read the operator's
manual carefully. Learn the applications and limitations
as well as 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 working order. Never
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 keys and adjusting wrenches
are removed from tool before turning it on.
KEEP THE WORK AREA CLEAN. Cluttered work areas
and work benches invite accidents.
DON’T 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
work area well lighted.
KEEP CHILDREN AND VISITORS AWAY. All 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 rate for which it was designed.
USE THE RIGHT TOOL. Do not force the tool or
attachment to do a job for which it was not designed.
USE THE PROPER EXTENSION CORD. Make sure your
extension cord is in good condition. When using an
extension cord, be sure to use one 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 gage 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 gage. The smaller
the gage number, the heavier the cord.
WEAR 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 safer than using your hand and it frees both
hands to operate tool.
DO NOT OVERREACH. Keep proper footing and balance
at all times.
MAINTAIN TOOLS WITH CARE. Keep tools sharp and
clean for best and safest performance. Follow instructions
for lubricating and changing accessories.
DISCONNECT ALL 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 UNINTENTIONAL STARTING.
Be sure switch is off when plugging in.
USE RECOMMENDED ACCESSORIES. Consult the
operator’s manual for recommended accessories. The use
of improper accessories may cause risk of 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 POWER OFF. Don’t leave tool until it comes to a
complete stop.
DON’T 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 TURN 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
approved ground connection that are intended for use
outdoors and so marked.
BE SURE THE BLADE PATH IS FREE OF NAILS.
Inspect for and remove nails from lumber before cutting.
Page 4
RULES FOR SAFE OPERATION
AVOID AWKWARD OPERATIONS AND HAND POSI-
TIONS where a sudden slip could cause your hand to
move into the blade. ALWAYS make sure you have good
balance.
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 Ryobi 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 cut-
ting 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 SUFFI-
CIENT SET. Sharp blades minimize stalling and kick-
backs.
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 bear-
ings, blade guide support, and blade guides” procedures explained in the
operator’s manual.
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.
adjustments
section of this
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.
SAVE THESE INSTRUCTIONS
Page 5
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.
Length of Extension Cord Wire Size (A.W.G.)
Up to 25 feet 16
26-50 feet 16
51-100 feet 16
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.
GROUNDING
PIN
COVER OF GROUNDED
OUTLET BOX
Fig. 1
ELECTRICAL CONNECTION
Your band saw is powered by a precision built electric motor.
It should be connected to a power supply that is 120 volts,
60Hz, 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
machine does not operate when plugged into an outlet,
double check the power supply.
CAUTION:
Keep the cord away from the cutting area and position
the cord so that it will not be caught on materials, tools,
or other objects during cutting.
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
one shown.
Figure 1.
It also has a grounding pin like the
Page 6
GLOSSARY OF TERMS FOR WOODWORKING
Bevel Cut
A cutting operation made with the saw table at any angle
other than 90° to the blade.
Compound Cut
A compound cut is a cut made using a miter angle and a
bevel angle at the same time.
Crosscut
A cutting or shaping operation made across the grain or the
width of the workpiece.
Freehand (for band saw)
Performing a cut without the workpiece properly supported
on the saw table.
Gum
A sticky, sap-based residue from wood products.
Kerf
The material removed by the blade in a through cut or the slot
produced by the blade in a non-through cut 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 cutting tool first.
Miter Cut
A cutting operation made with the workpiece at any angle to
the blade other than 90°.
Push Stick
A device used to feed the workpiece through the saw blade
during narrow cutting operations. It helps keep the operator's
hands well away from the blade.
Resaw
A cutting operation to reduce the thickness of the workpiece
to make thinner pieces.
Resin
A sticky, sap-based substance that has hardened.
Ripping
A cutting operation along the length of the workpiece.
Saw Blade Path
The area directly in line — 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.
SFPM
3,000 surface feet per minute, used in reference to surface
speed of blade.
Throw-Back
Saw throwing back a workpiece in a manner similar to a
kickback. Usually associated with a cause other than the kerf
closing, such as a workpiece being dropped into the blade or
being placed inadvertently in contact with the blade.
Through Sawing
Any cutting operation where the blade extends completely
through the thickness of the workpiece.
Workpiece
The item on which the cutting operation is being done. The
surfaces of a workpiece are commonly referred to as faces,
ends, and edges.
Worktable
The surface on which the workpiece rests while performing
a cutting or sanding operation.
FEATURES
PRODUCT SPECIFICATIONS:
Blade Width 1/8 in. to 3/8 in.
(3 mm to 10 mm)
Blade Length 59-1/4 - 59-1/2 in.
(1505mm - 1511mm)
Frame to Blade Capacity 9 in.
(229 mm)
Cutting Thickness Capacity 3-5/8 in.
(92.07 mm)
Table Size 11-13/16 in. x 11-13/16 in.
(30 cm x 30 cm)
Input 2.5 Amperes
Rating 120 Volt, 60Hz
AC Only
No Load Speed 3,000 SFPM
Net Weight 37 lbs.
(17.8 kg)
Dust Port 2-1/4 in.
(57.15 mm)
Page 7
FEATURES
WORKLIGHT
LOCK KNOB
TABLE LOCK
KNOB
SCALE
ANGLE
ADJUSTMENT
KNOB
RAPIDSET™ BLADE
TENSION LEVER
TRACKING
KNOB
DUST EXHAUST
PORT
BLADE TENSION
KNOB
LATCH
TRACKING
VIEW WINDOW
SCALE
INDICATOR
TRACKLOCK
BLADE GUIDE
SWITCH
AND
SWITCH KEY
FENCE
®
RIP
BLADE
GUARD
SAW BLADE
MITER
GAUGE
SAW TABLE
LATCH
Page 8
Fig. 2
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