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: 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. 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. 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 MEANING · Do not expose to rain or use in damp locations. NO HANDS SYMBOL · Failure to keep your hands away from the blade will result in serious personal injury. 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. 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. 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 impactresistant 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. Page 4 RULES FOR SAFE OPERATION 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. 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 ADJUSTMENTS 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 ...