OPERATOR’S MANUAL 9 in. (229 mm) BAND SAW BS903 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.
TABLE OF CONTENTS � � � � � � � � � � � � � � Introduction ..................................................................................................................................................................... 2 Warranty .......................................................................................................................................................................... 2 General Safety Rules .................................................
GENERAL SAFETY RULES 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 UNINTENTIONAL STARTING. Be sure switch is off when plugging in any tool.
SPECIFIC SAFETY RULES AVOID AWKWARD OPERATIONS AND HAND POSITIONS where a sudden slip could cause your hand to move into the blade. ALWAYS make sure you have good balance. 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.
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.
SYMBOLS The following signal words and meanings are intended to explain the levels of risk associated with this product. SYMBOL SIGNAL 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.
ELECTRICAL SPEED AND WIRING 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.
GLOSSARY OF TERMS Non-Through Cuts Any cutting operation where the blade does not extend completely through the thickness of the workpiece. Pilot Hole (drill presses) A small hole drilled in a workpiece that serves as a guide for drilling large holes accurately. 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.
FEATURES PRODUCT SPECIFICATIONS Table Size (with extension) ............... 11-3/4 in. x 14-3/4 in. Blade Width ................................................1/8 in. to 3/8 in. Input ................................ 120 V, 60 Hz, AC only, 2.5 Amps Blade Length ..........................................59-1/4 - 59-1/2 in. No Load Speed ............................ 3,000 FPM (1,524 cm/s) Frame to Blade Capacity.............................................. 9 in. Dust Port ............................
FEATURES SAW BLADE KNOW YOUR BAND SAW Saw comes with a standard 1/4 in. blade. The safe use of this product requires an understanding of the information on the tool and in this operator’s manual as well as a knowledge of the project you are attempting. Before use of this product, familiarize yourself with all operating features and safety rules. SAW TABLE WITH THROAT PLATE Your band saw has a saw table with tilt control for maximum accuracy.
TOOLS NEEDED The following tools (not included) are needed for making adjustments or installing the blade: FLATHEAD SCREWDRIVER PHILLIPS SCREWDRIVER HEX KEY, 4 mm SMALL COMBINATION SQUARE ADJUSTABLE WRENCH Fig. 3 LOOSE PARTS The following items are included with the tool: Flat Head Screw ............................................................ 3 Worklight ....................................................................... 1 Switch Key ...........................................................
ASSEMBLY Insert bolts (not included) and tighten securely with lock washers and hex nuts (not included). UNPACKING This product requires assembly. Carefully remove the tool and any accessories from the box. Place it on a level work surface. NOTE: This tool is heavy. To avoid back injury, lift with your legs, not your back, and get help when needed. Inspect the tool carefully to make sure no breakage or damage occurred during shipping.
ASSEMBLY If lag bolts are used, make sure they are long enough to go through holes in the saw base and material the saw is being mounted to. If machine bolts are being used, make sure bolts are long enough to go through holes in the saw base, the material being mounted to, and the lock washers and hex nuts. NOTE: It may be necessary to countersink hex nuts and washers on bottom side of mounting board. TABLE EXTENSION KNOBS MOUNTING THE SAW TABLE See Figures 6 and 7.
ASSEMBLY SQUARING THE SAW TABLE TO THE BLADE See Figure 8. Turn the lock knob counterclockwise to unlock the blade guide assembly. Turning the blade guide knob clockwise, raise the blade guide assembly as far as it will go. Turn the lock knob clockwise to retighten. Place a small combination square on the saw table beside the blade. Loosen the table lock knob and rotate the angle adjustment knob to tilt the saw table up or down to align table 90° to blade (0° position). Retighten the table lock knob.
ASSEMBLY TRACKING THE BLADE BLADE TENSION KNOB See Figure 10. NOTE: Adjust blade tension properly before making tracking adjustments. Check that the blade guides are not interfering with the blade. To Adjust: Open the front cover by releasing the upper and lower latches. Watch the blade’s position on the upper tire through the tracking view window as, by hand, you slowly turn the upper wheel clockwise. If the blade moves away from the center of the tire, the tracking must be adjusted.
OPERATION CUTTING PROCEDURES WARNING: Hold the workpiece firmly against the saw table. Use gentle pressure and both hands when feeding the work into the blade. Do not force the work; allow the blade to cut. The smallest diameter circle that can be cut is determined by blade width. A 1/4 in. wide blade will cut a minimum diameter of 1-1/2 in.; a 1/8 in. wide blade will cut a minimum diameter of 1/2 in. Keep your hands away from the blade.
OPERATION SCROLL CUTTING LOCKING THE SWITCH For general type scroll cutting, follow the pattern lines by pushing and turning the workpiece at the same time. Do not try to turn the workpiece while engaged in the blade without pushing it – the workpiece could bind or twist the blade. See Figure 12. Place the switch in the OFF position. Wait until the saw has come to a full and complete stop, then remove the switch key from the switch assembly. Store key in a safe place.
OPERATION TILTING THE TABLE See Figure 13. Loosen the table lock knob slightly. Turn the angle adjustment knob, tilting the saw table toward the front of the saw housing until it reaches the desired angle. Using the scale indicator, check angle markings. Retighten the table lock knob to hold saw table securely in place. SAW TABLE TABLE LOCK KNOB ANGLE ADJUSTMENT KNOB USING THE MITER GAUGE See Figures 13 and 14. The miter gauge can be turned 60° to the right or left.
ADJUSTMENTS WARNING: Before performing any adjustment, make sure the tool is unplugged from the power supply. Failure to heed this warning could result in serious personal injury. PHILLIPS SCREWS BLADE GUARD INSTALLING AND ADJUSTING THE BLADE See Figures 16 and 17. Loosen and remove the wing nut and table aligning bolt from the saw table. Open the front cover by releasing the upper and lower latches. Turn the lock knob counterclockwise to unlock the blade guide assembly.
ADJUSTMENTS ADJUSTING BLADE GUIDE ASSEMBLY See Figures 18 and 19. BLADE GUIDE KNOB To prevent the blade from twisting or breaking, the blade guide assembly should always be set approximately 1/8 in. (3 mm) above the workpiece. Turn the lock knob counterclockwise to unlock the blade guide assembly. LOCK KNOB As a guide, use a scrap piece of the same wood you are about to cut to set the height of the blade guide assembly. Adjust the blade guide assembly by turning the blade guide knob.
ADJUSTMENTS ADJUSTING BLADE GUIDE SUPPORT, THRUST BEARINGS, AND BLADE GUIDE BEARINGS WARNING: See Figures 20 - 22. NOTE: Tighten the lock knob and refer to “Adjusting Blade Tension” and “Tracking the Blade” procedures explained in the ASSEMBLY section of this operator’s manual prior to making adjustments. Fine tuning of the bearings can be done with a flathead screwdriver. The upper and lower blade guide bearings and thrust bearings support the saw blade during cutting operations.
ADJUSTMENTS To Adjust Blade Guide Bearings: BLADE GUIDE ASSEMBLY The blade guide bearings help keep the blade from twisting and binding. The blade can be ruined if the blade teeth hit the bearings while using the band saw. Remove the blade guard by loosening the two phillips screws. Using a 2.5 mm hex key, loosen the two blade guide screws that lock the upper blade guide bearings. Slide the blade guide bearings to within 1/64 in. (0.4 mm) behind the gullet of the blade.
MAINTENANCE TIRES Remove the nut and washer from the middle of the saw housing. See Figure 24. Pull the lower wheel away from the saw housing. Remove the worn drive belt. Place new drive belt on the pulley. As you slide the wheel shaft back into the hole in the saw housing, place the drive belt over the motor pulley. Replace the nut and washer on the wheel shaft and retighten. Replace saw blade. Check thrust bearings and blade guides.
TROUBLESHOOTING PROBLEM CAUSE SOLUTION Motor will not run. 1. Problem with on/off switch or power cord. 2. Motor defective. 1. Have worn parts replaced before using band saw again. 2. Do not attempt any repair. Have tool repaired by a qualified service technician. Blade does not run in the approximate center of the upper wheel. 1. Not tracking properly. 1. Adjust tracking, See Assembly section, Tracking the Blade. Band Saw slows down when cutting. 1. Cutting too small a radius. 1.
NOTES 25
OPERATOR’S MANUAL 9 in. (229 mm) BAND SAW BS903 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.
