General International 90-040 M1 Use and Care Manual
Contents
1. Aay NS d 2 Sy GENERAL INTERNATIONAL 8360 Champ d Eau Montreal Quebec Canada HIP 1Y3 Telephone 514 326 1161 Fax 514 326 5555 www general ca THANK YOU for choosing this General International model 90 040 12 Wood Cutting Bandsaw This bandsaw has been carefully tested and inspected before shipment and if properly used and maintained will provide you with years of reliable service For your safety as well as fo 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 bandsaw as well as the set up maintenance and identification 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 confirm from knowledgeable and qualified sources that it is safe to do so Once you ve read through these instructions keep this manual handy for future reference DISCLAIMER The information and specifications was supplied However special orders and after factory in this manual pertain to the unit as it was supplied from the factor2. Installing the push stick holder Basic adjustments and controls Connecting to a power source On Off power switch Choosing and changing blades Adjusting blade tension Blade tracking adjustment Adjusting the upper and lower blade guides Adjusting the upper and lower thrust guides Selecting and changing the blade speed Adjusting the upper blade guard Operating Instructions Checklist before starting Connecting to a dust collector Cutting curves Cutting circles Using the miter gauge Maintenance Cleaning Changing the belt and aligning the pulleys Wheel tires Lubrication Parts list amp diagram Contact information RULES FOR SAFE OPERATION To help ensure safe operation please take a moment to learn the machine s applications and limitations as well as potential hazards General International disclaims any real or implied warranty and hold itself harmless for any injury that may result from the improper use of it s equipment Do not operate the bandsaw when tired distracted or under the effects of drugs alcohol or any medl cation that impairs reflexes or alertness The work area should be well lit clean and free of debris Keep children and visitors at a safe distance when the bandsaw is in operation do not permit them to operate the bandsaw Childproof and tamper proof your shop and all machinery with locks master electrical switches and switch keys to prevent unauthorized or unsupervised use
3. STAY ALERT Give your work your undivided attention Even a momentary distraction can lead to serious injury Fine particulate dust is a carcinogen that can be hazardous to health Work in a well ventilated area Wear face eye ear respiratory and body protection devices Do not wear loose clothing gloves bracelets necklaces or other jewelry while the bandsaw is in operation Be sure that adjusting wrenches tools drinks and other clutter are removed from the machine and or the table surface before operating Keep hands well away from the blade and all moving parts Use a brush not hands to clear away chips and dust Adjust and position the blade guard as close as possible to the workpiece Adjust blade tension and tracking before starting to cut Blade teeth must point down toward the table Be sure that the blade has gained full operating speed before starting to cut Always use clean properly sharpened blade Dirty or dull blades are unsafe and can lead to accidents Use suitable workpiece support if the workpiece does not have a flat surface Do not work on long stock without adequate support on the out feed end of the table Do not push or force stock into the blade The band saw will perform better and more safely when work ing at the rate for which it was designed Avoid working from awkward or off balance posi tions Do not overreach and keep both feet on floor Keep
4. 90040 59 CAP SCREW 90040 60 SWITCH 90040 61 WASHER 90040 62 RING 90040 63 BRUSH 90040 64 CARRIAGE BOLT 8 100 90040 65 FLAT WASHER 6 90040 66 HEX HEAD BOLT M6X16 90040 67 SHAFT 90040 68 TENSION ROLLER 90040 69 BEARING 90040 70 RETENTION RING 90040 71 MOTOR PULLEY 90040 72 LOWER WHEEL 90040 73 HEX BOLT M8X35 90040 74 FLAT WASHER 8 90040 75 HEX NUT M20X1 5 90040 76 HEX NUT M5 90040 77 FLAT WASHER 90040 78 BOLT 90040 79 HOOK PLATE 90040 86 KNOB 90040 87 SHAFT 90040 88 GUIDE BRACKET 90040 89 SHAFT 90040 90 GUIDE BRACKET 90040 109 KNOB 90040 111 RETENTION RING 90040 112 SCREW 90040 113 LEAD SCREW 90040 114 FRAME 90040 116 PHILLIPS SCREW 90040 117 MULTIPLE DUST PORT 90040 118 SHAFT 90040 119 LOWER BLADE GUARD 90040 120 FLANGE NUT M8 90040 121 SQUARE NUT 90040 123 SELF TAPPING SCREW 514 2 9 5 90040 124 90040 125 CARRIAGE BOLT M8 90040 126 KNOB COVER 90040 127 MOTOR ef IN 0o ee ef 111 fs fs p JS NS p J J PARTS LIST BANDSAW IMPORTANT When ordering replacement parts always give the model number serial number of the m
5. collector not in cluded Be sure to use appropriate sized hose and fittings not included Check that all connections are sealed tightly to help minimize airborne dust If you do not already own a dust collection system consider contacting your General amp International distributor for information on our com plete line of dust collection systems and accessories or visit our Web Site at www general ca CUTTING CURVES e When cutting curves carefully turn the workpiece so the blade follows without twisting If the curve is so sharp that you repeatedly back up and cut new kerf use a narrower blade or a blade with more set teeth further apart When a blade has more set the workpiece turns easier but the cut is rougher When changing a cut do not withdraw the workpiece from the blade The blade may get drawn off the wheels To change a cut turn the workpiece and cut your way out through the waste material area When cutting long curves make relief cuts as you go along CUTTING CIRCLES e Adjust the blade guard assembly to 1 8 above the workpiece Use both hands while feeding the work into the blade Hold the workpiece firmly against the ta ble Use gentle pressure Do not force the work Al Min circle diameter low the blade to cut 2D The smallest diameter circle that can be cut is de 3 8 termined by the width of the blade For example a 1 4 wide blade will cut a minimum diameter of Blade width approximately 1
6. en thumbscrew C or out until the bearing is 1 64 behind the blade Retighten the thumbscrew C SELECTING AND CHANGING THE BLADE SPEED This bandsaw is equipped with 2 speed settings High 3150 Feet Per Minute fpm and Low 1444 fpm allowing you to achieve better results by selecting the appropriate speed based on the type of cut Some general guidelines to consider for selecting blade speed Thick Material Slower Speed Thin Material 2 Faster Speed Harder or Denser Material Slower Speed Soft Material Faster Speed Blades with Fine Tooth Pitch 2 Slower Speed Blades with Few Teeth per inch Faster Speed i Open the lower door and remove the dust tray 2 Loosen the belt by turning the knob counterclock wise E MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORM ING ANY MAINTENANCE OR ADJUSTMENTS SELECTING AND CHANGING THE BLADE SPEED CONTINUED 3 Place the belt on the motor pulley and onthe wheel 4 Turn the tension knob clockwise until the desired pulley as per the desired speed See the diagram tension is achieved Re install the dust tray and below then close the wheel cover Note check the sion by pushing on the belt with your finger The belt should not move more than 1 2 A 3150 pm mp MOTOR PULLEYS WHEEL PULLEYS ADJUSTING THE UPPER BLADE GUARD The upper blade guard should be adjusted based on the height of the workpiece To re
7. life of the tool However the Limited Lifetime Warranty does not cover any product used for professional or commercial production purposes nor for industrial or educational applications Such cases are covered by our Standard 2 year Limited Warranty only The Limited Lifetime Warranty is also subject to the Conditions and Exceptions as listed below Standard 2 Year Limited Warranty All products not covered by our lifetime warranty including products used in commercial industrial and educational applications 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 To file a Claim To file a claim under our Standard 2 year Limited Warranty or under our Limited Lifetime Warranty all defective parts components or machinery must be returned freight or postage prepaid to General amp 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 or your local distributor for assistance when filing your claim Along with the return ofthe product being claimed for warranty a copy of the original proof of purchase and a letter of claim
8. 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 Warranty does not include failures breakage or defects deemed inspection by General International have been directly indirectly caused by 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 TABLE OF CONTENTS Rules for safe operation Electrical requirements Identification of main parts and components Unpacking Basic functions Cleaning Placement within the shop Assembly instructions Assembling the stand Attaching the bandsaw to the stand Installing the work table and the 90 stop Installing the rip fence system
9. or perimeter of each machines safety zone Take steps to ensure that all operators and shop visi tors are aware that these areas are off limits whenever a machine is running for everyone but the individual operating the unit ASSEMBLY INSTRUCTIONS BEFORE ASSEMBLING MAKE SURE THAT THE SWITCH IS IN THE OFF POSITION AND THAT THE POWER CORD IS UNPLUGGED DO NOT PLUG IN OR TURN ON THE MACHINE UNTIL YOU HAVE COMPLETED THE ASSEMBLY AND INSTALLATION STEPS DESCRIBED IN THIS SECTION OF THE MANUAL ASSEMBLING THE STAND 1 Attach two stand legs and a small cross brace us 2 Repeat with the two longer cross braces as shown ing the carriage bolts flat washers and nuts Note Note Tighten the nuts by hand only Tighten the nuts by hand only 3 Attach a third stand leg using the carriage bolts 4 Repeat with the last leg flat washers and nuts Note Tighten the nuts by hand only 5 Secure the four cross braces tightening the bolts 6 Place the assembled stand upright on a flat surface flat washers and the nuts with a 13 mm wrench BEFORE ASSEMBLING MAKE SURE THAT THE SWITCH IS IN THE OFF POSITION AND THAT THE POWER CORD IS UNPLUGGED DO NOT PLUG IN OR TURN ON THE MACHINE UNTIL YOU HAVE COMPLETED THE ASSEMBLY AND INSTALLATION STEPS DESCRIBED IN THIS SECTION OF THE MANUAL ATTACHING THE MACHINE TO STAND THE BANDSAW IS HEAVY DO NOT OVER EXERT THE HELP OF ASSISTANTS WILL BE NEEDED FOR THE FOLLOWING STEP DO NOT GRIP TH
10. turned to sharply Narrower thinner blades with finer teeth will cut more slowly but can turn much tighter corners for cutting more intricate work TO AVOID UNEXPECTED OR UNINTENTIONAL START UP MAKE SURE THAT THE POWER SWITCH IS IN THE OFF POSITION BEFORE CONNECTING TO A POWER SOURCE LOCK OUT KEY PREVENTS START UP WHEN REMOVED BLADE SELECTION CHOOSING AND CHANGING THE BLADE CONTINUED Common causes of blade breakage Poor blade guide alignment and adjustment Forcing or twisting a wide blade around a short ra dius Feeding the workpiece too quickly Too much blade tension Setting the blade guard too high above the work piece Lumpy or improperly finished braze or weld on the blade Continuous running blade when not cutting Dull teeth MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORM ING ANY MAINTENANCE OR ADJUSTMENTS 2 Lower the blade guard halfway by turning the knob A clockwise Loosen the four lock knobs and remove the fence 4 Remove the insert from the table using a screw rail driver 5 Open the upper door by turning the knob B clock 6 Open the lower door by turning the knob C clock wise wise MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORM ING ANY MAINTENANCE OR ADJUSTMENTS CHOOSING AND CHANGING THE BLADE CONTINUED X 9 Release the blade tension by turning the tension
11. 0 93 CARRIAGE BOLT M6X20 90040 94 END CAP 90040 95 SELF TAPPING SCREW 514 2 13 90040 96 SUPPORT 90040 97 HANDLE MIO 90040 98 NUT M6 90040 99 FENCE CLAMP FLAP 90040 100 PHILLIPS SCREW M3X6 90040 101 SHAFT 90040 102 ECCENTRIC BLOCK 90040 103 LOCK WASHER 90040 104 FENCE POINTER 90040 105 RIVET 90040 106 THUMBSCREW 90040 107 GUIDE HOOK 90040 108 END CAP ff 1 S BANDSAW PARTS LIST BANDSAW IMPORTANT When ordering replacement parts always give the model number serial number of the machine and part number Also a brief description of each item and quantity desired PART DESCRIPTION SPECIFICATIONS 90040 1 WHEEL COVER DOOR 90040 2 CAP SCREW M6X16 90040 3 RING 90040 4 LOCK WASHER 6 90040 5 CARRIAGE BOLT 6 90040 6 SPRING 90040 7 RIVET 90040 8 DUST TRAY 90040 9 ROLLER GUIDE SHAFT 90040 10 KNURLED NUT 90040 11 THUMBSCREW 90040 12 ROLLER 90040 13 THRUST BEARING SHAFT 90040 14 UPPER GUIDE ASSEMBLY 90040 15 SELF TAPPING SCREW ST4 8X22 90040 16 SET SCREW M6X10 90040 17 GUIDE BRACKET 90040 18 FIXED LINK 90040 19 ROLLER GUIDE SHAFT 90040 20 PIN 90040 21 UPPER BLADE GUARD 9
12. 0040 22 RACK 90040 23 FIXED PLATE 90040 24 STEEL COVER PLATE 90040 25 SELF TAPPING SCREW ST4 8X22 90040 26 GEAR SHAFT 90040 27 BLADE 2240 12 5 0 5 4 90040 28 RETENTION RING 90040 29 BEARING 80203 90040 30 TIRE 90040 31 UPPER WHEEL 90040 32 SHAFT 90040 33 FIXED BLOCK 90040 34 FIXED BLOCK 90040 35 CYLINDRICAL PIN 8 H8X24 90040 36 RING 90040 38 ECCENTRIC BLOCK 90040 39 SET SCREW 90040 40 LEFT GUIDE PLATE 90040 41 HEX BOLT 90040 42 FLAT WASHER 90040 43 HEX NUT 90040 44 RING 90040 45 SQUARE TUBE 90040 46 RING 90040 47 RIGHT GUIDE PLATE 90040 48 HEX BOLT 90040 49 SCREW 90040 50 GRADUATED TENSION SCALE LI ao 1 1 1 1 1 PARTS LIST BANDSAW IMPORTANT When ordering replacement paris always give the model number serial number of the machine and part number Also a brief description of each item and quantity desired PART DESCRIPTION SPECIFICATIONS o 4 90040 51 SPRING 90040 52 POINTER 90040 53 SQUARE NUT 90040 54 FLANGE NUT 90040 55 ADJUSTING POLE 90040 56 HEX NUT 90040 57 TENSION KNOB 90040 58 TENSION KNOB COVER
13. 1 2 MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORM ING ANY MAINTENANCE OR ADJUSTMENTS A r Insert the miter gauge into the T slot of the table as 2 Lift tab as shown to slide the miter gauge on the shown table Loosen knurled nut A to adjust face fence 4 Loosen handle B and lift tab to adjust the face an then retighten it to secure the face in place gle with the graduated scale Tighten the handle Note to use preset stops of the guide let the tabs down MAINTENANCE CLEANING Keep your band saw clean Sawdust will accumulate under the table base and in the wheel housings This could cause difficulty tilting the table Frequently blow out or vacuum up the sawdust Do not allow dirt pitch or gum to build up on the table the guard or blade guides Clean as needed with gum and pitch remover Note Do not immerse the bearings in the gum and pitch remover Put a thin coat of paste wax on the table so that the wood slides easily while cutting WHEEL TIRES Pitch and sawdust that build up on the tires should be removed with a stiff brush or scraped off with a piece of wood Note To avoid damaging the tires do not use a sharp knife or any kind of solvent When the tires be come worn they should be replaced When replacing the tires stretch them around the wheels but do not glue on MOTOR Frequently blow or vacuum out any sawdust
14. E lever E to the right Remove the blade carefully start ing on the right as shown ADJUSTING THE BLADE TENSION RIGHT SIDE VIEW 10 To install a blade repeat the previous steps in re verse order making sure that the blade is installed with the teeth pointing forward and down as shown Note With the blade installed proceed fo the ten sioning and tracking instructions A properly tensioned blade is critical to obtaining maximum performance from any bandsaw A properly ten sioned blade will last longer and be much less likely to break prematurely If the blade tension is too loose you will notice that the blade will have a tendency to drift or slip off line when cutting and you will have more difficulty controlling your cuts A blade that is tensioned too tightly will break prematurely This bandsaw is equipped with a blade tension scale which can be used as a reference for the ideal setting with various blade widths Turn the blade tension knob A clockwise raising the upper wheel to tighten the blade Turn the knob counter clockwise to lower the upper wheel loos ening the blade Note Changes in blade width and the type of material being cut will have an effect on the blade tension Note The tension indicator B at the rear of the up per wheel housing indicates the proper tension for the various blade widths Set the tension indicator to correspond with the width of the blade in use MAKE SURE THE MACHINE HAS BEEN TURN
15. E BANDSAW BY THE LOWER WHEEL COVER DOOR WHEN LIFTING KEEP HANDS AWAY FROM BLADE AT ALL TIMES 1 Place the machine on the stand with the hel 2 Secure the machine to the stand using carriage two assistants bolts flat washers nuts and a 13 mm wrench and tighten all the stand mounting nuts A INSTALLING THE TABLE AND THE 90 STOP 1 2 Using a 5 mm Allen key secure the table to its base by tightening the four supplied cap screws and four flat washers Es 5 4 3 Loosen the table by turning the lock lever A coun 4 Tilt the table by turning the knob B terclockwise BEFORE ASSEMBLING MAKE SURE THAT THE SWITCH IS IN THE OFF POSITION AND THAT THE POWER CORD IS UNPLUGGED DO NOT PLUG IN OR TURN ON THE MACHINE UNTIL YOU HAVE COMPLETED THE ASSEMBLY AND INSTALLATION STEPS DESCRIBED IN THIS SECTION OF THE MANUAL INSTALLING THE TABLE AND THE 90 STOP CONTINUED 5 Screw the table stop bolt with j jam nutin the mount 6 Place a combination square on the table against ing hole C under the table and then set the table the blade D and adjust the table until threre is no in the horizontal position by hand space between the square and the blade Tighten the lock lever A Loosen the table bolt until its head touches the machine E and then tighten the jam nut F INSTALLING THE RIP FENCE Slide a flat washer onto each ofthe fourlock knobs 2 Loosely screw the four lock knobs in the mounting holes in the u
16. ED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORM ING ANY MAINTENANCE OR ADJUSTMENTS ADJUSTING BLADE TRACKING Blade tracking means centering the blade on the wheels A Ideally the blade should stay relatively cen tered on both the upper and lower wheels Due to natural variations in castings blade thickness or density and tire wear absolute perfect centering align ment is rarely attainable A slight misalignment of the blade on the wheels is inevitable and as long as it is kept to a minimum following the steps listed below will not hinder the performance of the saw This misalignment is controlled and kept to a minimum by adjusting the tilt angle of the upper wheel When adjusting blade tracking to center the blade on the wheels and assuming that perfect centering is not attainable it is preferable to have the blade slightly off center towards the front of the wheels rather than towards the rear because the teeth on most bandsaw blades have al ternating hook one inner one outer therefore if the blade is centered too far back on the wheel or if the blade tension is too tight inner hooked teeth will dig into the wheel tire and cause premature wear of the tire Nonethe less to avoid having the blade come off of the wheels on it s own during operation the front edge of the blades teeth should never be any closer than 3 mm 1 8 from the front edge of the wheel B To adjust the blade tracking Open the upper wh
17. NCH FRONT FENCE RAIL RIP FENCE CROSS BRACE LONG CROSS BRACE SHORT SUPPORT LEG MITER GAUGE 2 EXTRA PEOPLE FOR HELP WITH LIFTING RIP FENCE HANDLE B 14 MM WRENCH TABLE INSERT 3 amp 5 MM ALLEN KEYS LOCK KNOB D SQUARE KNURLED NUT FLAT WASHER LARGE FLAT WASHER SMALL ADDITIONAL REQUIREMENTS FOR SET UP CARRIAGE BOLT CAP SCREW W NUT A B C D E F G H J K L M N S T BASIC FUNCTIONS This 12 Wood Cutting Bandsaw is supplied with a 1 2 general purpose blade and is designed to accommodate blade widths from 1 8 to 3 4 Ideal blade length for this model 90 040 is 88 2240 mm Note Generally speaking because the upper wheel height is somewhat adjustable to allow for blade tensioning a blade length variation of plus or minus 1 2 from the ideal blade length be accom modated Maximum inboard width of cut is 12 For cutting thicker stock or for resawing the maximum depth of cut or max workpiece height is 6 1 2 An adjustable rip fence is supplied to serve as a straightedge to guide the workpiece for longer rip cuts The fence can easily be removed and set aside when not required for example when making curved cuts The protective coating on the saw table prevents rust from forming during shipping and storage Remove it by rubbing with a rag dipped in kerosene mineral spir its or paint thinner Dispose of potentially flammable solve
18. RY TO THE USER AS WELL AS DAMAGE TO THE MACHINE IF IN DOUBT CONTACT A QUALIFIED ELECTRICIAN BEFORE CONNECTING TO THE POWER SOURCE THIS TOOL IS FOR INDOOR USE ONLY DO NOT EXPOSE RAIN OR USE WET OR DAMP LOCATIONS 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 A to fit a grounded type receptacle B Do not remove the 3rd prong grounding pin to make it fit into an old 2 hole wall socket or extension cord If an adaptor plug is used C it must be attached to the metal screw of the receptacle Note The use of an adaptor plug is illegal in some areas Check your local codes If you have any doubts or if the supplied plug does not correspond fo your electrical outlet consult a qualified electrician before proceeding CIRCUIT CAPACITY Make sure that the wires in your circuit are capable of handling the amperage draw from your machine as well as any other machines that could be operating on the same circuit If you are unsure consult a qualified electrician If the circuit breaker trips or the fuse blows regularly your machine may be operating on a circuit that is close to its amperage draw capacity However if an unusual amperage draw does not exist and a power failure still occurs contact a qualified te
19. SETUP amp OPERATION MANUAL 12 WOOD CUTTING BANDSAW FEATURES Sturdy welded steel frame amp precision balanced wheels with replaceable tires Easy to assemble open base steel stand Precision easy adjust European style blade guide bearings included Two cutting speeds for excellent results in either hard or soft woods Miter gauge with aluminum crosscut fence included Deluxe dual position rip fence system Hinged doors and easily accessible blade tension knob for fast blade changes and adjust ments Extra large 21 x 15 cast iron table Smooth running heavy duty 2 3 HP motor Safety lock out switch with removable key to prevent unauthorized use Multi size dust port fits 4 3 or 2 hose SPECIFICATIONS Wheel size 12 305 mm Wheel speeds 2 445 amp 970 rpm Blade speeds 2 1444 amp 3150 lin fpm Maximum blade width 3 4 20 mm Minimum blade width 1 8 3 mm Blade length 88 2240 mm Table size 21 0 x 15 34 548 x 400 mm Table tilt 0 to 45 right Table height 37 3 8 950 mm Maximum width of cut 12 305 mm Maximum depth of cut 6 1 2 165 mm Dust port 4 3 and 2 102 76 or 51mm Base dimensions I x 18 1 4 x 15 3 4 465 x 400 mm Motor 2 3 HP 120 V 64 A Weight 165 Ibs 75 kg Version 1_Revision 2 December 2014 Copyright General International N AIAX NN aeneae NEI GENERALY N GENERAL Wy
20. STING THE UPPER AND LOWER BLADE GUIDES Loosen the two knurled nuts A Adjust the guides us ing the knobs B so that the space between each guide and the blade is 0 02 Note Use a feeler gauge Ce 3 To access the lower guide assembly unlock and tilt the table as shown Loosen the two set screws I using a 3 mm Allen key and then adjust the lower guides so that the space between each guide and the blade is 0 02 Retight en the two set screws I Note Use a feeler gauge 4 6 RIGHT SIDE VIEW Loosen the thumbscrew E and adjust the bracket F so that the blade guides are at least 1 32 behind the teeth of the blade to avoid damage during cut ting Retighten the thumbscrew E Pivot the lower guard G under the table to the left to access the lower blade guides H 1 32 Loosen bolt J and adjust the bracket along the slot ted hole so that the guides are at least 1 32 behind the teeth of the blade to avoid damage during cut ting K Retighten the bolt J MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORM ING ANY MAINTENANCE OR ADJUSTMENTS RIGHT SIDE VIEW 1 For the upper thrust bearing loosen thumbscrew A 2 Then manually adjust the thrust bearing shaft B in or out until the bearing is 1 64 behind the blade Retighten the thumbscrew A un For the lower thrust bearing under the table loos 4 Then manually adjust the thrust bearing shaft D in
21. achine and part number Also a brief description of each item and quantity desired PART DESCRIPTION SPECIFICATIONS 90040 128 SCREW M6X25 90040 129 KNOB 90040 130 CARRIAGE BOLT M6 90040 131 RING 90040 132 NUT M8 90040 133 KNOB 90040 134 WASHER 8 90040 135 HEX BOLT 90040 136 NUT 90040 137 HANDLE SEAT 90040 138 HANDLE LEVER 90040 139 KNOB BALL 90040 141 END CAP 90040 142 PUSHING STICK 90040 145 COVER 90040 146 SLIDE RAIL 90040 147 SELF TAPPING SCREW ST3 5X9 5 90040 148 RIGHT COVER 90040 149 THUMBSCREW 90040 150 TABLE 90040 151 TABLE INSERTION 90040 152 GUIDE PLATE 90040 153 SWINGING STRUT 90040 154 KNOB 90040 155 LOCK KNOB 90040 156 WASHER 90040 157 SHAFT 90040 158 GEAR 90040 159 SUPPORT 90040 160 KNOB 90040 161 MITER GAUGE FACE BODY 90040 162 CARRIAGE BOLT 90040 163 PIN 90040 164 WASHER 90040 165 TAB 90040 166 GUIDE BAR 90040 167 ANGLE POINTER 90040 168 SCREW 90040 169 SCREW 90040 170 KNURLED NUT 90040 171 NUT 90040 172 SCALE 90040 173 RIBBED BELT 90040 174 NUT 90040 175 HEX NUT 2 lt ee met es fe es es es fe es ef eS J eS fe es fe J eS J eS J Be fe J es J eS J es J es fe J es eS S OO OS 4 A EXPN GENERA o INTE NATIONAL 8360 Champ d Eau Montreal Quebec Canada 1Y3 Tel 514 326 1161 Fax 514 326 5565 Parts amp Service 514 326 5555 Order Desk orderdeskGgeneral ca www general ca Follow us
22. chnician or our service department EXTENSION CORDS If you find 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 dam aged extension cord or plug immediately Make sure the cord rating is suitable for the amperage listed on the motor 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 If in doubt use the next heavier gauge The smaller the number the heavier the gauge TABLE MINIMUM GAUGE FOR CORD EXTENSION CORD LENGTH NR Not Recommended IDENTIFICATION OF MAIN PARTS AND COMPONENTS STAND BLADE RIP FENCE MITER GAUGE ON OFF SWITCH WITH REMOVABLE KEY LOWER DOOR LOCK KNOB UPPER WHEEL DOOR BELT TENSION KNOB BLADE TENSION KNOB LOWER WHEEL DOOR UPPER DOOR LOCK KNOB DUST TRAY BLADE GUARD LOCK KNOB TABLE TILT SCALE Carefully unpack and remove the unit and its components from the box and check for missing or damaged items as per the list of contents below NOTE PLEASE REPORT ANY DAMAGED OR MISSING ITEMS TO YOUR GENERAL INTERNATIONAL DISTRIBUTOR IMMEDIATELY LIST OF CONTENTS U CARRIAGE BOLT WORK TABLE V RIPFENCE GUIDE HOOK PUSH STICK W 10 13 MM COMBINATION WRE
23. duce risks of injuries a minimum amount of blade should be exposed 1 Loosen lock knob B and turn knob C to raise or low er the guard and set it 1 8 1 4 above the work piece Re tighten the lock knob B before turning on the saw OPERATING INSTRUCTIONS CHECKLIST BEFORE STARTING VERIFY ALL CHECK POINTS BEFORE STARTING FAILURE TO COMPLY CAN RESULT IN SERIOUS INJURIES Make sure you and any assistants are wearing safe and appropriate workshop attire To reduce the risk of damage to the machine as well as potential for personal injury after initial set up as well as before each use make sure that everything is securely installed and that all fasteners and moving parts on this machine are locked in place before starting the machine Make sure to have on safety glasses as well as hearing or and respiratory protection at all times when using the machine Use only recommended parts and accessories The use of parts or accessories NOT recommended by GENERAL INTERNATIONAL may result in a risk of injury or damage to the machine Be sure that adjusting wrenches tools drinks and other clutter are removed from the machine and or the table surface before operating MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORM ING ANY MAINTENANCE OR ADJUSTMENTS CONNECTING TO A DUST COLLECTOR A multi size dust port fits 4 3 or 2 hose is provided to accommodate connection to a dust
24. eel cover door then rotate the wheel slowly forward by hand C and check the po sition of the blade on the wheel The blade should remain as centered as possible on the wheel as it turns A If the blade tracking must be adjusted loosen the wing nut D on the tracking adjustment knob E then turn the knob Clockwise if the blade moves toward the front of the wheel This tilts the top of the wheel to the back and moves the blade toward the center Counterclockwise if the blade moves toward the back edge This tilts the top of the wheel to the front and moves the blade toward the center Note Turn the tracking knobs in 1 2 turn increments re check and adjust again as needed With the tracking set retighten the wing nut D Note The upper and lower wheels are factory set to allow for easy and optimal blade tracking adjust ments using the primary blade tracking adjustment knob which adjusts the angle of tilt of the upper wheel In extremely rare cases if acceptable blade track ing cannot be attained through the primary adjust ment it may eventually become necessary 1o make minor adjustments to the angle of tilt of the lower wheel The four bolts F may be adjusted in or out to tilt the lower wheel up down or left right as needed Once the adjustment is finished retighten the the jam nuts MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORM ING ANY MAINTENANCE OR ADJUSTMENTS AJU
25. from the motor Follow lubrication instruction on the motor label LUBRICATION All of the bearings are sealed and permanently lubricated They require no further lubrication MAKE SURE THE MACHINE HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORM ING ANY MAINTENANCE OR ADJUSTMENTS CHANGING THE BELT AND ALIGNING THE PULLEYS 1 Open the lower wheel cover and then remove the dust tray Release blade tension by turning the tension lever A to the right then loosen the belt by turning the knob B counterclockwise Remove the blade from the lower wheel only Remove the retention ring C and remove the wheel and the belt Install the new belt on the motor pulley and re in stall the blade wheel with its retention ring C Install the belt on the blade wheel and the motor pulley D Make sure the two pulleys are well aligned by plac ing a straight edge in the front groove of both pul leys and behind the blade wheel To re adjust the alignment loosen the set screw E with a 3 mm Allen key to move the pulley on the shaft Adjust the pulley in or out on the shaft to align the edge of the two pulleys When aligned retighten the set screw E Retension the belt Note the pulley belt is prop erly tensioned when there is 1 2 deflection if pressed in the center between the pulleys F Re Install the blade Re install the dust tray and close the wheel cover Adjust the blade tension tracking a
26. g the power cord into an appropriate outlet Refer back to the section entitled Electrical Require ments and make sure all requirements and grounding instructions are followed When operations have been completed unplug the saw from the power source ON OFF POWER SWITCH The bandsaw is equipped with a rocker type ON OFF switch A that is equipped with a lock out key To prevent unwanted or unauthorized start up or usage remove the lock out key D and store it in a safe place To start the bandsaw insert the lock out key and pull up the switch B To stop the bandsaw push down on the power switch C When the saw comes to a complete stop remove the lock out key D by gently pulling it outward POWER OFF CHOOSING AND CHANGING THE BLADE There are a variety of different types of bandsaw blades on the market to suit various cutting applications The accompanying Blade Selection chart provides a general reference tool your re sults may vary based on usage experience and personal prefer ence Ask your local tool dealer for suggestions for 88 bandsaw blades in 1 8 to 3 4 widths based on what is available in your area Some general guidelines to consider when choosing bandsaw blades Wider blades with coarse teeth are best suited to cutting straight lines re sawing and for sweeping curves but will not turn tight corners They will cut quickly and aggressively but do have a ten dency to bind get stuck in the cut if
27. guards in place and in working order If a guard must be removed for maintenance or clean ing be sure it is properly re attached before using the saw again Never leave the machine unattended while it is run ning or with the power on Use of parts and accessories NOT recommended by General International may result in equipment malfunction or risk of injury Never stand on machinery Serious injury could re sult if the tool is tipped over or if the blade is unintentionally contacted Always disconnect the saw from the power source before servicing or changing accessories such as blades or before performing any mainte nance or cleaning or if the machine will be left unattended Make sure that the switch is in the OFF position before plugging in the power cord Make sure the machine is properly grounded If equipped with a 3 prong plug it should be used with a three pole receptacle Never remove the third prong Do not use this bandsaw for other than its intended use If used for other purposes General International disclaims any real or implied warranty andholds itself harmless for any in jury which may resultfrom that use ELECTRICAL REQUIREMENTS BEFORE CONNECTING THE MACHINE TO THE POWER SOURCE VERIFY THAT THE VOLTAGE OF YOUR POWER SUP PLY CORRESPONDS WITH THE VOLTAGE SPECIFIED ON THE MOTOR I D NAMEPLATE A POWER SOURCE WITH GREATER VOLTAGE THAN NEEDED CAN RESULT IN SERIOUS INJU
28. nd the upper and lower guides and the thrust bearings before operating the bandsaw STAND amp MITER GAUGE IMPORTANT When ordering replacement parts always give the model number serial number of the machine and part number Also a brief description of each item and quantity desired PART DESCRIPTION DESCRIPTION 90040 200 LEG 90040 204 WASHER 90040 201 LONG CROSS BRACE 90040 205 NUT 90040 202 SHORT CROSS BRACE 90040 206 CARRIAGE BOLT 90040 203 HEX HEAD BOLT M8 X 16 MITER GAUGE IMPORTANT When ordering replacement parts always give the model number serial number of the machine and part number Also a brief description of each item and quantity desired PART DESCRIPTION SPEC PART DESCRIPTION 90040 65 FLAT WASHER 6 90040 166 GUIDE BAR 90040 83 SELF TAPPING SCREW ST3 5X9 5 90040 167 ANGLE POINTER 90040 160 KNOB 90040 168 SCREW 90040 161 MITER GAUGE FENCE 90040 169 SCREW 90040 162 CARRIAGE BOLT 90040 170 KNURLED NUT 90040 163 PIN 90040 171 NUT 90040 164 WASHER 90040 172 MITER GAUGE BODY 90040 165 TAB IMPORTANT When ordering replacement parts always give the model number serial number of the machine and part number Also a brief description of each item and quantity desired PART st DESCRIPTION SPECIFICATIONS 90040 37 HEX NUT M10 90040 65 FLAT WASHER 6 90040 77 FLAT WASHER 5 90040 84 FLAT WASHER 3 90040 91 90040 92 GUIDE RAIL 9004
29. nderside of the table as shown 3 Fit the rail onto the lock knobs as shown 4 Secure the rail in place by tightening the lock knobs BEFORE ASSEMBLING MAKE SURE THAT THE SWITCH IS IN THE OFF POSITION AND THAT THE POWER CORD IS UNPLUGGED DO NOT PLUG IN OR TURN ON THE MACHINE UNTIL YOU HAVE COMPLETED THE ASSEMBLY AND INSTALLATION STEPS DESCRIBED IN THIS SECTION OF THE MANUAL INSTALLING THE RIP FENCE CONTINUED 5 Thread the lock knob of the fence handle ee 7 Pull the handle back towards you and place the 8 Insert the small carriage bolt into the guide hook fence on the Note the screw A serves as a and then slide a flat washer onto it B Screw on the stop for the fence knurled nut C and slide the bolt head into the slot under the guide until the stop is against the table edge Tighten the knurled nut to hold the guide in INSTALLATING THE PUSH STICK HOLDER Thread the cap screw A in the mounting hole 2 Hang the push stick to keep it handy the left side of the machine and tighten the jam nut to secure it in place BASIC ADJUSTMENTS amp CONTROLS TO REDUCE THE RISK OF SHOCK OR FIRE DO NOT OPERATE THE UNIT WITH A DAMAGED POWER CORD OR PLUG RE PLACE DAMAGED CORD PLUG IMMEDIATELY TO AVOID UNEXPECTED UNINTENTIONAL START UP MAKE SURE THE POWER SWITCH IS IN THE OFF POSITION BEFORE CONNECTING TO A POWER SOURCE CONNECTING TO A POWER SOURCE Once the assembly steps have been completed plu
30. nt soaked rags according to manufacturer s safe ty recommendations A putty knife held flat to avoid scratching the surface may also be used to scrape off the coating followed by clean up with solvent Avoid rubbing the saw s painted surfaces as many solvent based products will remove paint To prevent rust apply a light coating of paste wax or use regular applications of any aftermarket surface protectant or rust inhibitor TIP WITH A SCREW DRIVER PUSH A SOLVENT SATURATED RAG INTO THE T SLOTS TO REMOVE THE GREASE PLACEMENT WITHIN THE SHOP SAFETY ZONE PLACEMENT WITHIN THE SHOP This machine should be installed and operated only on a solid flat and stable floor that is able to support the weight of the machine 165 Ibs 75 kg and the operator Using the dimensions shown as a guideline plan for placement within your shop that will allow the operator to work unencumbered and unobstructed by foot traf fic either passing shop visitors or other shop workers or other tools or machinery ESTABLISHING A SAFETY ZONE For shops with frequent visitors or multiple operators it is advisable to establish a safety zone around shop machinery A clearly defined no go zone on the floor around each machine can help avoid accidents that could cause injury to either the operator or the shop visitor It is advisable to take a few moments to either paint using non slip paint or using tape define on the floor the limits
31. y 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 specifications and information in this manual corresponds with that of the unit with which it modifications may render some or all information in this manual inapplicable to your machine Further as several generations of this model of wood cutting Bandsaw 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 unit 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 clarification GENERAL INTERNATIONAL WARRANTY All component parts of General International and Excalibur by General International products are carefully inspected during all stages of production and each unit is thoroughly inspected upon completion of assembly Limited Lifetime Warranty Because of our commitment to quality and customer satisfaction 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 for the
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