General International 90-125 M1 Use and Care Manual
Contents
1. Q BLADE GUARD ADJUSTMENT KNOB 9 TRACKING ADJUSTMENT KNOB BLADE TENSION INDICATOR Q TENSION LEVER DUST PORT MOTOR Carefully unpack and remove the unit and its components from its shipping container 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 Once the parts have been removed from the packa ging you should have the following items aly mel 2 M A 1 MIEREAUEE 4 _ O BASEGABINATI E S 1 1 HARDWARE BAG INSIDE BASE CABINET DORIA ee eee eee Z DWORBOB BR 1 TABLE amp TRUNNIONS 1 O TABLETILT BRACKET 1 O TENSION LEVER A 1 girik reni A a 1 O HARDWARE BAG POWER CORD HOOK 2 aj M T 2 Z HEAD BOL e GG 4 TELAS ESRA S la e eee eee eee 8 BEM MGS E AA T R 4 K oad A Sr 2 HEX HEAD BOLT LONG 3 SIMN ALIEN KEY ALIEN KEY 2 10 MM COMBINATION WRENCH Note Deluxe Excalibur Universal Bandsaw Rip Fence System is packaged separately Refer to the manual supplied in box with the Excalibuer Rip Fence for c2. ADJUSTING THE BLADE GUARD FOR DEPTH OF CUT The blade guard can be moved up or down to accommodate the height of the work to be cut To prevent the blade which is flexible and which would not otherwise be supported from slipping out of position during cutting and to reduce risks of injuries a minimum amount of blade should be exposed The blade guard should be set 1 8 1 4 above the work piece O 1o prevent the blade from flexing out of position or off line during cutting Adjust the height of the blade guard to suit the thick ness of the workpiece as follows 1 Make sure the bandsaw is turned off and the power cord is disconnected from the power source 2 Loosen the smaller lock knob 3 Move the blade guide assembly up or down by turn ing the adjustment knob Then re tighten the lock knob Q Note The depth gauge O on the front of the blade guard can be used as a reference but it is not intended for high precision measurements ADJUSTING THE UPPER GUIDES AND THRUST BEARING The blade guides keep the blade from moving from side to side during cutting and must be snug but not touching the blade in order to ensure accurate cuts The space between each bearing and the blade must not exceed 0 02 the thickness of a sheet of paper If less space is left the blade will get stuck or jammed between both bearings Too much friction will cause blade to overheat and break Also the guides must remain at least 1
3. Identification of main parts andcomponents 7 Unpacking 8 List of contents 8 Additional requirements for set up 8 Placement within the shop Establishing a safety zone 9 cleanup 9 Assembly Instructions 10 Attaching the door knob 10 Install the bandsaw onto the base cabinet 10 Installing the tension lever handle 11 Attaching the dust port 11 Attaching the table tilt bracket 11 Attaching the table 12 Rip fence and rail 13 Connecting the blower device 13 MHS gauge ead d ad Y arae MA a Chee usus a ows 13 Power cord hooks 13 Basic functions of the unit 14 Basic adjustments and controls 14 Connecting to a power source 14 Power on off switch with safety key 14 Recommended adjustments 15 Adjusting the 90 table stop and re aligning the angle poinfer 15 Tilting the table 15 Removing installing the blade 16 Blade clearance 16 Blade selection 17 Adjusting blade tension 18 Adjusting blade tracking
4. Adjust blade tension and tracking before starting to cut Saw teeth must point down toward the table Be sure that the blade has gained full operating speed before starting to cut Always use a clean properly sharpened blade Dirty or dull blades are unsafe and can lead to accidents 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Use suitable workpiece support if the workpiece does not have a flat surface Hold material firmly against the table Do not work on long stock without adequate sup port on the out feed end of the table If using a power feeder stop the feeder before stop ping the bandsaw 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 guards in place and in working order If a guard must be removed for maintenance or clea ning be sure it is properly re attached before using the tool 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 equip ment malfunciion or risk of injury Never stand on machinery Serious injury could re sult if the tool is tipped over or if the cutting tool is unintentionally contacted Always disconnect
5. 2 Uncoil the power cord O and plug it into an appro priate outlet refer back to section Electrical Re quirements and make sure all requirements and grounding instructions are followed POWER ON OFF SWITCH WITH SAFETY KEY The model 90 125 is equipped with a simple rocker style On Off switch featuring a removable lock out safety key O to prevent unauthorized use or uninten tional start up of the bandsaw Whenever the bandsaw is not in use remove the yellow safety key and store it in a safe place out of the reach of children To START the bandsaw 7 E Insert the safety key and pull the switch toward you SAFETY NG STOE amp PREVENTS START UP WHEN REMOVED Push the red tab down O 14 RECOMMENDED ADJUSTMENTS ADJUSTING THE 90 TABLE STOP AND RE ALIGNING THE ANGLE POINTER To ensure that your 90 cuts are square and that angled cuts are accurate with the angle indicator scale the table default position must be set to 90 to the blade and the angle indicator pointer must be set to read 0 when the table is in the default 90 position To set the table stop bolt 1 Loosen the two lock knobs Fig 20 See Fig 18 2 Place a combination square flat on the table O with heel of the square flat against the saw blade 3 Level the table until it is exactly 90 to the saw blade Tighten the lock knobs See Fig 19 5 Adjust the height of the table stop bolt
6. 20 Adjusting the blade guard for depth of cut 21 Adjusting the upper guides and thrust bearing 21 Positioning the lower blade guides and thrust bearing 7 4 W 2 989 1 I S 22 Changing speed settings 23 Operating instructions 24 Checklist before starting 24 Connecting to a dust collector 24 Operations step by step 25 To stop the machine K 2 25 Installing using the rip fence 25 Using the miter gauge 26 Cutting curves 1 NM LADA 26 Cutting circles S M RR 1421 D 1 26 lubrication 26 Periodic Maintenance 27 Required Maintenance 27 Replacing the bandsaw blade 27 Replacing the upper and lower blade guides and thrust bearings F 9 ABD E 27 Replacing the wheel tire 29 Adjusting replacing the lower wheel brush 29 Replacing lower wheel motor belt 29 Recommended optional accessories 30 Parts list amp diagrams 32 39 Contact information 40 Rules for Safe Operation To help ensure safe operation please take a moment to learn the machine s applications and limita tions as well as potential hazards General amp International disclaims any real or implied warranty and hold itself h
7. 8 5 16 x 23 3 16 x 3 8 1 2 x 28 1 2 x 2 1 2 3 8 x 25 3 8 x 45L 5 x 5 x 30L 50 76 QTY 36 PART REF NO 90125 113 90125 114 90125 115 90125 11 90125 117 90125 118 90125 119 90125 120 90125 121 90125 122 90125 123 90125 124 90125 125 90125 126 90125 127 90125 128A 90125 129 90125 130 90125 131 90125 132 90125 133 90125 134 90125 135A 90125 136A 90125 137A 90125 138A 90125 139 90125 140 90125 141 90125 142 90125 143N 90125 145 90125 146 90125 147 90125 148 90125 149 90125 150 90125 151 90125 152 90125 153 90125 154 90125 155 90125 156 90125 157 90125 158 90125 159 90125 160 90125 161 90125 162 90125 163 90125 164 90125 165 90125 166 90125 167 90125 168 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128A 129 130 13 132 133 134 135A 136A 137A 138A 139 140 14 142 143 145 146 147 148 149 150 15 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 PARTS LIST 90 125 DESCRIPTION SET SCREW NYLON NUT UPPER ARM COVER SWITCH FLANGE SCREW STEEL PLATE FLANGE SCREW STRAIN RELIEF BUSHING POWER CORD W MOTOR POWER CORD W PLUG THUMB SCREW ALLEN KEY SPROCKET WASHER COPPER WASHER FLANGE SCREW MITER GAUGE ALLEN KEY LOCK KNOB HEX HEAD BOLT FLAT WASHER HEX NUT BLADE GUARD SCALE 90 BLOWER ELBOW BLOWER TUBE STRAIN RELIEF FLANGE SCREW BASE CABINET FLANGE SCREW CHAIN LO
8. Loosen the upper thumb screw Q 4 Unscrew the upper Allen bolt with the 3 mm Allen key provided FRONT VIEW 5 Remove the thrust bearing and mounting shaft 6 Use C ring pliers to remove the C ring O and slide bearing off the shaft 7 Install a new bearing on the mounting shaft 8 Re install the C ring 9 Put the bearing and mounting shaft back in place re install the Allen bolt and tighten the upper thumb screw 10 Re install the blade guard Note After the upper blade guides and thrust bearing have been changed always verify the lower blade guides and thrust bearing If needed replace them proceeding in the same way as with upper blade guides and thrust bearing 28 REPLACING THE WHEEL TIRE Wheel tires must be replaced if they get worn out or dam aged If it is worn out the blade will not track straight on the wheels Use a flat screwdriver to remove the tire from the groove on the wheel then install a new fire ADJUSTING REPLACING THE LOWER WHEEL BRUSH The lower wheel is equipped with a cleaning brush that prevents pitch and sawdust build up on the lower fire Any pitch and sawdust that builds up on the upper wheel tire should be removed with a stiff brush or scraped off with a piece of wood Note To avoid damaging the tire do not use a sharp knife or any kind of solvent to remove pitch build up Verify that the brush keeps the lower wheel surface clean at all times With use and nor
9. and accessories We offer a wide selection of dust collectors and accessories to suit virtually all your shop needs Dust collectors contribute to q cleaner healthier workshop environment 5 FRAME ASSEMBLY 26 lt lt 54 S OSG G 143 WHEEL AND TABLE ASSEMBLY 34 124 34 PART REF NO 90125 01A 90125 02 90125 03 90125 04 90125 05 90125 06 90125 07 90125 08 90125 09 90125 10 90125 11 90125 12 90125 13 90125 14 90125 15 90125 16 90125 17 90125 18 90125 19 90125 20 90125 21 90125 22 90125 23 90125 24 90125 25 90125 26 90125 27 90125 28 90125 29 90125 30 90125 31 90125 32 90125 33 90125 34 90125 35 90125 36 90125 37 90125 38 90125 39 90125 40 90125 41 90125 42 90125 43 90125 44 90125 45 90125 46 90125 47 90125 48 90125 49 90125 50 90125 51 90125 52 90125 53 90125 54 2 3 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2 22 23 24 25 26 27 28 29 30 31 32 33 34 35 3 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 PARTS LIST 90 125 DESCRIPTION SAW BASE UPPER ARM STEEL PIN HEX HEAD BOLT FLAT WASHER LOCK WASHER HEX NUT LOWER SHAF
10. 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 Nonetheless 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 Fig 29 BLADE CLEARANCE Note As previously stated when performing blade installation removal tensioning or tracking maximum clearance between the blade and both upper and lower bearing assemblies is required lo minimize friction which would be damaging to the blade Refer back and follow the instructions for blade clearance before performing blade irack ing adjustments To adjust the blade tracking 1 Openthe upper wheel cover door then rotate the wheel slowly forward by hand The blade should remain as cen tered as possible on the wheel as it turns Fig 30 2 If the blade tracking must be adjusted turn the tracking knob on the rear of the bandsaw Fig 31 A Clockwise if the blade moves toward the front of the wheel This tills the top of the wheel to the back and mo ves the blade toward the center B Counterclockwise if the blade moves toward the back edge This tills the top of the wheel to the front and mo ves the blade toward the center Note Turn the tracking knob in 1 2 turn increments re check and adjust again as needed 20
11. o prevent rust and from forming on the unpainted cast iron of the table and so that the wood slides easily while cutting apply a light coating of paste wax or use regular applications of any aftermarket surface protectant or rust inhibitor such as General International Top Saver item GC 010 See Section Recommended optional accessories for your bandsaw REQUIRED MAINTENANCE REPLACING THE BANDSAW BLADE The blade should be replaced when worn out Refer to the following symptoms to determine whether or not it is time to replace the blade It is not cutting as fast It is not able to follow a cutting line as it used to REPLACING THE UPPER AND LOWER BLADE GUIDES AND THRUST BEARINGS Bearings should be verified each time the blade is replaced Check if they turn well If not the blade will get stuck or jammed between them and will wear prematurely To replace the upper blade guides proceed as follows 1 Loosen and remove the two Allen bolts O using the 5 mm Allen key provided Removing the two bolts will free the blade guides Q 2 Replace the two blade guides with new ones and tighten with the two Allen bolts To replace the upper thrust bearing proceed as follows 6 1 Pull the tension lever up to loosen the blade 2 Unscrew the two Phillips head screws and remo ve the blade guard O Note Hold the micro adjust nut while unscrewing the Allen bolt 3
12. the machine 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 un attended Make sure that the switch is in the OFF position be fore plugging in the power cord Make sure the tool is properly grounded If equip ped 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 Interna tional disclaims any real implied warranty and holds itself harmless for any injury which may result from that use ELECTRICAL REQUIREMENTS Before connecting the machine to the power source verify that the voltage of your power supply corresponds with the voltage specified on the 1 D nameplate located on the back of the machine A power source with greater volt age than needed can result in serious injury 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 to rain or use in wet or damp locations GROUNDING INSTRUCTIONS This bandsaw must be grounded to protet the operator from electrical shock in the event of an electrical malfunction or short circuit The sup plied motor for this machine is wired for 110V single phase operation and has a 3 conductor cord and 3 prong g
13. 0125 98 90125 102 90125 103 90125 104 90125 105 90125 106A 90125 107 90125 108 90125 109 90125 110 90125 111 90125 112 55 56 57 58 59N 60N 61N 62 63 64 65 66 67 68 69 70 71 72 74 75 76 77 78 79 80 81 82 83 84 85 8 87 88A 89 90 9 92 93 94 95 96 97 98 102 103 104 105 106A 107 108 109 110 111 112 PARTS LIST 90 125 DESCRIPTION SET SCREW BEARING SHAFT THRUST BEARING C RING BLADE GUIDE MOUNTING BLOCK BUSHING BEARING THUMB SCREW ADJUSTMENT SCREW MICRO ADJUST KNOB BLADE GUARD FLAT WASHER SCREW UPPER WHEEL BLADE SEE 90125 B38 LOWER BLADE GUIDE HOLDER FLAT WASHER HEX HEAD BOLT TABLE TILT BRACKET HEX NUT TABLE STOP BOLT FLAT WASHER HEX BOLT POINTER LOCK WASHER FLAT WASHER SCALE TRUNNION TRUNNION CLAMP SHOE HEX HEAD BOLT LOCK WASHER FLANGE HEAD BOLT TABLE TABLE INSERT TABLE INSERT PIN TABLE ALIGNMENT PIN BRUSH HOLDER BRUSH FLANGE SCREW ARM COVER LOWER FLANGE SCREW LOWER DOOR DOOR HINGE LOWER DOOR CLIP MOUNTING POST BLADE GUARD FLAT WASHER FLAT HEAD SCREW MOTOR FLAT WASHER HEX HEAD BOLT FLAT WASHER RATCHET LEVER KEY MOTOR PULLEY SPECIFICATION M x 10L 620072 9 10 M x 16L M x 45L M 3 16 x 14 3 16 x 3 8 93 1 2 x 3 8 x 0 65 x 6T 1 4 x 16 1 4 x 3 4 5 16 5 16x3 5 16 5 16x 1 1 4 MY 2000P M5 3 8 x 19 x 2T 450 M10 x 50L 9 16 1 4 x 5 8 3 x 1OL 3 16 x 3 8 3 16 x 3
14. 14 326 5555 Order Desk orderdesk general ca www general ca IMPORTANT
15. 32 behind the blade teeth to prevent damage to the blade The thrust bearing keeps the blade from moving back and out of position when the work is being fed into the blade and must be very close to the back of the blade to prevent damage to the blade during cutting Note Before adjusting the upper and lower blade guides and thrust bearings make sure the blade is tensioned and Irack ing properly Adjust the upper and lower blade guides and thrust bearings after each blade tension and tracking adjust ment Whenever fhe upper blade guide and thrust bearing are adjusted the lower blade guide and thrust bearing should also be adjusted Adjust the positioning of the upper blade guides as follows To avoid injury make sure that the switch is in the OFF position and that the power cord is unplugged before performing any adjustments on the bandsaw 1 Loosen the two Allen bolts with the 5 mm Allen key provided and slide the two blade guides along the elongated hole in the mounting bracket 0 toward the blade 2 Place a feeler gauge between one of the bearings and the blade and tighten the Allen bolt until there is a 0 02 gap left between the blade guide and the blade See Fig 32 3 Repeat step 2 for the other guide on the other side of the the blade 4 Loosen the lower thumb screw See Fig 33 5 Turn the micro adjust nut See Fig 32 to move the guide bearing assembly See Fig 33 in or out until the g
16. 6 2011 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 90 125 MI 14 Wood Cutting Bandsaw This bandsaw has been carefully tested and inspected before ship ment and if properly used and maintained will provide you with years of reliable service To 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 opera ting the unit The manual s purpose is fo 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 compo nents 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 in this manual pertain to the unit as it was supplied from the factory at the time of printing Because we commit ted to making constant improvements General International reserves the right
17. CK WASHER BASE CABINET DOOR CAP SCREW FLAT WASHER NYLON HEX NUT GUIDE POST ADJUSTMENT SHAFT GUIDE POST ADJUSTMENT GEAR PAD BLADE GUARD ADJUSTMENT KNOB SET SCREW BRACKET TENSION SHAFT SPRING PIN SEAT SET SCREW CAP SCREW TENSION LEVER ARM TENSION LEVER HANDLE SWITCH BOX FLAT WASHER SCREW POWER CORD HOOK FLANGE SCREW TERMINAL STICKER BEARING SHAFT SPECIFICATION M x 16L 1 2 4P 3 16 x 3 8 3 16 x 3 8 6N 4 M x 10L SMM Mo 5 3 16 x 1 4 3MM M10 9 16 x 2 5 16 x 23 9 16 1 8PT X 480L ACC 2 5 3 16 x 3 8 3 16x 1 A 1 4 1 4x 1 5 16 x 16 x 1 51 1 4 x 5 27 15 x 66 15L 26 x 20T 15 x 34 5L M x 121 33 x 23 5 x 15 15 x 74L M3 x 14L 35 x 40L 5 16 x 3 8 1 4 x 5 8 3 16x 12x 1 3 16 x 2 1 4 3 16x1 2 P3B QTY PARTS LIST 90 125 PART NO REF NO DESCRIPTION SPECIFICATION 90125 169 169 WAVE WASHER 90125 171 171 RIGHT DUST COLLECTOR 90125 172 172 LEFT DUST COLLECTOR 90125 173N 173 DUST CHUTE 4 90125 174 174 FLANGE SCREW 3 16 x 3 8 3 90125 200 200 COMBINATION WRENCH 10 MM NOTES PARTS LIST 90 125 PART N0 REF NO DESCRIPTION 90125 106A 01 1 SHAFT 1 RE 90125 106A 02 2 ROTOR 1 90125 106A 03 3 STATOR 1 e 90125 106A 04 4 COPPER WINDING 90125 106A 05 5 WIRE 6 90125 106A 06 BEARING 90125 106A 07 7 BEARING 90125 106A 08 8 MOTOR COVER FRONT 1 90125 106A 09 9 MOTOR COVER REAR 1 90125 106A 10 10 MOTOR HOUSI
18. E TABLE 1 Remove the red insert O from the center of the table and the table alignment pin from the table slot 2 Turn the table right side up Verify that the long bolts in the center of each trunnion are pointing down See Fig 9 3 Carefully move the table into position over the table tilt bracket guiding the saw blade through the table slot See Fig 7 4 Rotate the table 1 4 turn counter clockwise so that the saw blade is now perpendicular to the table slot See Fig 8 5 Gently lower the table onto the bracket so the long bolts in the center of the trunnions pass through the holes in the table tilt bracket Note If the long bolts have moved out of position have an assistant tap them into place with a screw driver 6 Thread the two lock knobs G onto the long bolts now protruding from the underside of the table tilt brack et and tighten loosely See Fig 9 7 Make sure that the blade is centered in the table open ing If the blade is not centered slide the table back or forward O until the blade is centered in the table opening Then tighten the six combination head bolts and the two hex bolts and See Fig 10 7 Re install the red insert fo the center of the table with the opening in the slot facing the rear of the saw See Fig 11 8 Re install the table alignment pin into the table slot 12 This model 90 125 MI is equipped with an Excalibur T fence and gu
19. Fig 27 4 Make a test cut on a sample piece of wood and if need ed re adjust the blade tension Note To prolong the life of the blade whenever the bandsaw is not in use for prolonged periods more than 24 hours release the blade tension lever to remove tension from the blade Over time maintaining tension on a blade that is not in use will cause the blade to deform by taking the shape of the wheels at both extremities This can weaken the blade and cause premature breakage ADJUSTING BLADE TRACKING 3 mm 1 8 Blade tracking means centering the blade on the wheels _ Ideally the blade should stay relatively centered on both the upper and lower wheels Fig 28 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 hin der 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 attain able 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 alternating hook one inner one outer therefore if the blade
20. Fig 41 This loosens the belt enough to move it between one set of pulleys and the other 4 To set the bandsaw speed to the slower setting 1800 FPM 549 MPM place the belt on the frontmost set of pulleys as in Fig 42 5 To set the bandsaw speed to the faster setting 3000 FPM 915 MPM place the belt on the rearmost set of pulleys as in Fig 43 6 Having repositioned the belt push down firmly on the mo tor capacitor cover to tighten the belt then turn the ratch et lever clockwise until it is tight and the motor does not move OPERATING INSTRUCTIONS CHECKLIST BEFORE STARTING NOTE Now that you have completed the four adjustment steps which are an essential part of safe accurate bandsaw operation it would be a good idea to make yourself a checklist as follows to ensure that each adjustment fo the bandsaw is made in fhe proper order starting with the general safety precaution l Turn off the bandsaw and unplug the power cord Adjust blade tension Adjust blade tracking Adjust upper blade guides and thrust bearing Adjust lower blade guides and thrust bearing These additional safety measures should be be included in your checklist Make sure all the blade guards are in place 7 Make sure the bandsaw table and work area in general are clean and free of sawdust and debris These steps should always be followed when any adjustment is performed the blade is changed or periodically as vib
21. HE UNIT This 14 wood cutting bandsaw is supplied with a 3 8 wide general purpose blade and is designed to accommo date blade widths from 1 8 to 3 4 Ideal blade length for this 90 125 model is 93 1 2 2375 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 can be accommodated Maximum inboard width of cut space between the blade and the body of the saw O is 13 1 2 For cutting thicker stock or for resawing the maximum depth of cut or max workpiece height is up to 12 with optional riser block kit item 490 130 Refer to section Recommended Optional Accessories for your Bandsaw A dual position aluminum rip fence 0 tall for resawing or short for rip cuts is supplied to serve as a straight edge 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 BASIC ADJUSTMENTS AND CONTROLS CONNECTING TO A POWER SOURCE To avoid risk of shock or fire do not operate the unit with a damaged power cord or plug Replace damaged cord or plug immediately 1 Connectthe power cord from the motor to the inlet plug on the switch To avoid unexpected or unintentional start up make sure that the power switch is in the the OFF position before connecting to a power source
22. NG 1 90125 106A 11 11 CAPACITOR 1 90125 106A 12 12 CAPACITOR TUBE 1 90125 106A 13 13 CAPACITOR COVER 1 90125 106A 14 14 CENTRIFUGAL SWITCH SET 90125 106A 15 15 TERMINAL 2 90125 106A 16 16 STRAIN RELIEF 90125 106A 17N 17 TUBE 1 90125 106A 18N 1 8 TUBE T 90125 106A 19 19 COVER LOWER 1 90125 106A 20 20 COVER UPPER 1 90125 106A 21 2 FLANGE SCREW 2 90125 106A 22 22 FLANGE SCREW 6 90125 106A 23 23 FLANGE SCREW 1 90125 106A 24 24 FLANGE SCREW 4 90125 106A 25 25 SPROCKET WASHER 1 90125 106A 26 26 COPPER WASHER 1 90125 106A 27 27 LOCK WASHER 4 90125 106A 28 28 HEX NUT 4 90125 106A 29 29 POWER CORD FEMALE 1 90125 106A 30 30 WIRE 1 38 BLOWER DEVICE ASSEMBLY PART NO 90125 106B 01 90125 106B 02 90125 106B 03 90125 106B 04 90125 106B 05 90125 106B 06 90125 106B 07 90125 106B 08 90125 106B 09 90125 106B 10 90125 106B 11 90125 106B 12 90125 106B 13 90125 106B 14 90125 106B 15 REF NO Co NJOJO ICO IN I o sI PARTS LIST 90 125 DESCRIPTION SPECIFICATION BLOWER FAN HOUSING WASHER BLOWER WHEEL BLOWER PINS BLOWER COVER LOCK WASHER SCREW HOSE BARB BLOWER HOSE SPONGE COVER MOTOR FAN 147 x 13 MOTOR COVER 176 x 88 SCREW 1 4 x 3 8 FLANGE SCREW 3 16 x 3 8 QTY ATSINISSY 301140 41MOT8 W MODEL 90 125 M1 8360 Champ d Eau Montreal Quebec Canada HIP 1Y3 Tel 514 326 1161 Fax 514 326 5565 Parts 8 Service Fax 5
23. Q until it tou ches the underside of the table 6 Turn the jam nut clockwise until it meets the table tilt bracket Q and tighten it 7 Loosen the lock knobs and make sure the table is rest ing on the table stop bolt 8 Checkthe square and make sure the table is still at 90 to the blade If not re adjust the table stop bolt See Fig 20 9 With the table set to 90 and the stop bolt at the cor rect height make sure the table tilt angle indicator pointer is set to read 0 10 If the pointer needs to be adjusted loosen the screw on the pointer O of the front trunnion and adjust the pointer to the O point on the scale Then re tighten the screw to secure the pointer in place You will now be able to accurately return the table to the 90 position automatically without further adjustments and scale reading for any angle other than 0 will also be accurate TILTING THE TABLE The table can be tilted to any angle from 0 to 45 to the right to allow for any type of bevel or angle cutting Refer to the table tilt angle indicator to set the angle of the table to the desired position Never adjust the table angle while the bandsaw is run ning Turn off power first 1 Loosen the two lock knobs 2 Tilt the table until it is at the desired angle Refer to the angle indicator under the bandsaw table 3 Tighten the lock knobs to lock the table in position REMOVING INSTALLING THE BLADE Your bandsaw is design
24. SETUP 6 OPERATION MANUAL FEATURES 14 WOOD CUTTING BANDSAW Cast iron frame precision balanced aluminum wheels with replaceable rubber tires e Closed stand model features a rigid one piece welded stand e Deluxe Excalibur bandsaw rip fence system with curved resaw guide block Precision metal miter gauge with handle Deluxe blade guide bearings included 2 Cutting speeds for excellent results in either hard or soft woods t Hinged door easily accessible blade ten sioning knob for fast blade changes or SPECIFICATIONS WHEEL SIZE 13 78 353 mm WHEEL SPEEDS 2 495 825 RPM MAXIMUM BLADE WIDTH 3 4 19 mm MINIMUM BLADE WIDTH 1 8 3 2 mm BLADE LENGTH 93 1 2 2375 mm BLADE SPEEDS 2 1800 3000 LIN FPM 549 915 LIN MPM TABLE SIZE 16 x 16 406 x 406 mm TABLE TILT 45 RIGHT amp 10 LEFT TABLE HEIGHT 42 3 4 1085 mm MAXIMUM WIDTH OF CUT 13 1 2 343 mm MAXIMUM DEPTH OF CUT 6 150 mm UP TO 12 WITH OPTIONAL RISER KIT DUST COLLECTION PORT 4 102 mm BASE DIMENSIONS L x W 18 5 8 x 15 3 4 460 x 400 mm MOTOR PRE WIRED 120V 1 HP 120 240V 1 Ph 10A 5A WEIGHT 224 LBS 102 kg MODE 90 I25 y ES bik PX YN GEEN GENERAL NY INTERNATIK TLCAN ALY VERSION 5_ REVISION 1 JUNE 1 11 91988411 Copyright General International 0
25. T BEARING KEY PULLEY 2 SLOT V BELT LOWER WHEEL TIRE LOWER WHEEL WASHER HEX HEAD BOLT C RING BEARING COVER TENSIONING COVER TENSIONING CAM UPPER SHAFT SPRING PIN FIXED SHAFT TENSION SPRING SQUARE NUT TENSIONING SHAFT BLADE TENSION ADJUSTMENT KNOB SPRING PIN WING NUT TRACKING ADJUSTMENT KNOB BEARING C RING HEX NUT UPPER WHEEL COVER UPPER DOOR FLAT WASHER FLANGE SCREW MOUNTING POST DOOR CLIP MOUNTING POST DOOR CLIP LOCK WASHER SCREW DOOR HINGE FLANGE SCREW LOCK WASHER HEX NUT DOOR KNOB NAMEPLATE BLADE GUIDE POST UPPER BLADE GUIDE LOCK KNOB STEEL BALL SPRING SET SCREW UPPER BLADE GUIDE HOLDER SPECIFICATION 1 4 x 16mm 3 Ax 2 1 2 3 4 3 4 3 4 620472 5 x 5 x 60L 180 168 26 1 4 x 38 x 3mm 1 4 x 5 8 S 20 3 x 30L 3 8 302L SK 62 x M8 3 x 20L 5 16 5 16 x 2L 620272 R34 1 2 INNER OUTER 3 16 x 14 3 16 x 3 8 3 8 3 8 3 16 3 16 x 1 4 UPPER 3 16 x 1 4 3 16 3 16 3 8 9 16x 1 1 4 1 4 5 16 x 5 16 QTY PART REF NO 90125 55 90125 56 90125 57 90125 58 90125 59N 90125 60N 90125 61N 90125 62 90125 63 90125 64 90125 65 90125 66 90125 67 90125 68 90125 69 90125 70 90125 71 90125 72 90125 74 90125 75 90125 76 90125 77 90125 78 90125 79 90125 80 90125 81 90125 82 90125 83 90125 84 90125 85 90125 86 90125 87 90125 88 90125 89 90125 90 90125 91 90125 92 90125 93 90125 94 90125 95 90125 96 90125 97 9
26. afety when using your bandsaw Here s a small sampling of accessories available from your local General International dealer For a complete list visit our website at www general ca Fifs model 90 125 General International bandsaw only MADE FROM HIGH CARBON STEEL Blades 90125 14 1 4 TPI blade thickness 0 65 mm 90125 B38 3 8 6 TPI blade thickness 0 50 mm 90125 B12 1 2 ATPI blade thickness 0 65 mm 90125 B34 3 4 4 TPI blade thickness 0 65 mm 24 X 24 Bandsaw Table 90 115 Quick clamping system for easy installation without damaging original table Includes 2 1 2 T style rip fence and rails and a curved resaw attachment TOP SAVER cleaner item GC 010 All in one table top rust remover and lubricant Reduces friction and pre vents binding Removes and inhibits rust and corro sion Repels dust and moisture Riser Block Kit 90 130 Increases the vertical cut ting capacity of your saw from 6 to 12 inches for in creased re sawing versatili ty Kit includes all necessary hardware and a longer 3 8 wide blade to fit the increased height of the saw Roller Stand 50 150 50 160 50 170 We offer q selection of roller stands to suit all your shop needs Mobile Base 450 025 Easily roll your bandsaw anywhere in your shop Load capacity 500 LBS Wheels lock when equipment is in use Dust Collectors
27. armless for any injury that may result from the improper use of it s equipment 10 11 12 13 14 Do not operate the bandsaw when tired distracted or under the effects of drugs alcohol or any medi cation that impairs reflexes or alertness The working 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 unsu pervised use 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 and whenever possible use a dust collector Wear face eye ear respiratory and body protection de vices 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 mo ving parts Use a brush not hands to clear away chips and dust Adjust and position upper and lower blade guides before starting to cut Upper blade guide should be adjusted to approximately 1 8 above the material to be cut
28. dicator scale which be used as a reference for the ideal setting with various blade widths It is also equipped with a lever for blade tension quick release Note For blade tension quick release pull up on the tension lever toward the left 90 position For quick blade tension ing push the tension lever down 0 position To avoid damaging the tensioning mechanism never force the tension lever beyond 90 vertical Q or 0 horizontal LOOSEN TIGHTEN To adjust blade tension proceed as follows Note Always verify the level of blade tension before pulling the blade tension quick release lever down Refer to the blade ten sion gauge The indicated level of tension must correspond to the width of the blade installed on your bandsaw Pulling the tension lever down with the blade foo tensioned will force and damage the blade tension mechanism KULI 1 Pullthe tension lever O down for quick blade tension ning 2 Refering to the blade tension gauge O set the blade tension to correspond with the width of the blade instal led on your bandsaw Adjust the blade tensioning by turning the blade tension knob Clockwise to tighten b Counterclockwise to loosen the blade tension 3 With the saw turned off press against the side of the bla de to test the tautness of the blade For ideal results with most blade widths and cutting applications the blade should flex in no more than 1 4 to 3 8 See
29. e bandsaw and unplug the power cord 2 Pull up on the tension lever toward the left 90 position Q to loosen the tension on the blade It may be necessa ry to also turn the tension knob counter clockwiseO for the blade to be loose enough to remove easily Note For blade tension quick release pull up on the tension lever toward the left 90 position Q For quick blade tension ing push the tension lever down 0 position To avoid damaging the tensioning mechanism never force the tension lever beyond 90 vertical Q or 0 horizontal Q LOOSEN TIGHTEN 3 Remove the table alignment pin from the table slot O and the red circular insert from the center of the table 4 Remove the right hand side blade guard by loosening the two Phillips head screws just enough to slide it out Blade teeth are sharp Use care when handling a IN saw blade 5 Open the top and bottom wheel cover doors and bring the leff hand side of the loose blade toward you and out of the leff hand blade guard slot See Fig 23 Note You may want to use a thick shop towel fo handle the loose blade or wear a pair of heavy duty work gloves 6 With the blade perpendicular to the wheels feed the blade through the table slot to free it from the saw See Fig 24 7 Carefully hang the blade on a hook in a safe dry pla ce in your workshop if it will be re used or dispose of it safely if it is worn or damaged Do not at
30. ed to handle several blade widths ranging from 1 4 and 3 8 used for tight radius curves up to 1 2 and 3 4 for larger radius curves or for cutting thicker stock Note When performing blade installation removal tensioning or tracking maximum clearance between the blade and both upper and lower bearing assemblies is required fo minimize friction which would be damaging to the blade Proceed as follows Move the upper blade guides away from the blade See Fig 21 1 Loosen the two Allen bolts O with the 5 mm Allen key pro vided Slide the two blade guides along the elongated hole in the mounting bracket O as far away as possible from the blade Tighten the two Allen bolts to lock the blade guides in po sition Move the upper thrust bearing back See Fig 21 1 Loosen the upper thumb screw 2 Use the micro adjust nut O to move the thrust bearing O back until it is as far as possible behind the blade Move the lower blade guides and thrust bearing away from the blade See Fig 22 1 Loosen the two Allen bolts O with the 5 mm Allen key provided 2 Slide the two blade guides along the elongated hole in the mounting bracket as far away as possible from the blade Tighten the two Allen bolts to lock the blade guides in position Loosen the set screw with the 3 mm Allen key provided Manually move the lower thrust bearing back as far as possible behind the blade To remove a blade Turn off th
31. he tool However the Limited Lifetime Warranty does not cover any product used for profes sionnal 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 amp and General amp International agree 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 amp 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 of the product being claimed for warranty a copy of the original proof of purchase and a lette
32. ide rail system Follow all assembly and adjustment instructions in the 90 075A manual supplied in the box with the Excalibur Universal Bandsaw Rip Fence System CONNECTING THE BLOWER DEVICE A flexible blower tube which connects to the motor can be positionned so as to direct air againt the blade for pre venting accumulation of sawdust thereby allowing the cutting line to remain well visible at all times while cutting Connect the blower device hose to the motor as follows 1 Unscrew and remove the three Phillips head screws 2 Pass the blower device hose through the hole O located on the motor then remove the motor co in the motor cover O and fit it securely onto the ho ver se barb located behind the motor propeller Q 3 Re install and secure the motor cover using the 3 screws removedi in step 1 MITER GAUGE The miter gauge rides in the table slot to the right of the blade and can be set to any angle up to 30 to the left or right O It also acts as a feeder for advancing smaller work pieces through the sawblade with reduced risk of injury to the hands When the bandsaw is not in use we recommend that the power cord be wound up neatly around the two hooks provided This keeps the power cord off of the floor and out of harms way Attach the hooks with the two Phillips head bolts to the threaded holes on the back of the upper arm of the bandsaw as shown in Fig 17 BASIC FUNCTIONS OF T
33. intricate work Common causes of blade breakage Poor guide bearing alignment and adjustment Forcing or twisting a wide blade around a short radius Feeding the workpiece too quickly Dull teeth Too much blade tension e Setting blade guard assembly too high above the workpiece e Lumpy or improperly finished braze or weld on the blade Continuous running of blade when not cutting To install a blade Note You may want fo use a thick shop towel to handle the loose blade or wear a pair of heavy duty work gloves for the following steps 1 Turn off the bandsaw and unplug the power cord Beware of the blade popping open 2 f you are installing a new blade carefully remove the blade from its package Hold it firmly with one hand as you remove the twist ties Slowly separate the coils of the blade until it unravels into one hoop Note Steps 3 and 4 may be unnecessary if you ve just removed a blade If needed refer back to the previous page Remove the table alignment pin from the table slot and the red circular insert from the center of the table 4 Remove the right hand side blade guard by loosening Proper installation Improper installation the two Phillips head screws just enough to slide it out 5 With the blade perpendicular to the wheels guide it through the table slot then rotate the side of the blade nearest you back toward the left side of the wheels 6 Feed the blade int
34. mal wear over time the brush hairs will soften and will not clean the surface of the wheel as well You then must lower the brush slightly Proceed as follows 1 Loosen the Phillips head screw 2 Slide the brush slightly down along the mounting hole O so that a fresh stiffer part of the hairs touches the wheel tire 3 Tighten the screw to lock the brush in position REPLACING LOWER WHEEL MOTOR BELT The lower wheel is driven by one belt mounted on either of the two pulleys powered by the motor The belts tension should be verified upon reception of the machine then every 6 months Slightly push on the belt with your finger The belt must not move more than 1 8 If the belt becomes too loose due to wear or if a breakage occurs you must replace it Turn off power and disconnect the bandsaw from the power source to avoid unintentional start up Open the lower wheel cover door If needed loosen the belt proceeding as per step 3 in section Changing speed settings Remove the belt from the groove in the pulleys and install a new one ow NM Having installed a new belt push down firmly on the motor capacitor cover to tighten the belt then turn the ratchet lever clockwise until it is tight and the motor does not move 6 Close the lower wheel cover door 30 RECOMMENDED OPTIONAL ACCESSORIES FOR YOUR BANDSAW We offer a large variety of products to help you increase productivity accuracy and s
35. o the left blade guard and around the wheels Make sure the blade teeth point forward and down O See Fig 25 lt With the blade properly installed proceed to blade tension adjustments and blade tracking adjustments as per instructions on the next few pages ADJUSTING BLADE TENSION Determining ideal blade tension is somewhat subjective It is learned through practice and experience and is some what dependant on personal preference and individual work habits A properly tensioned blade is critical to obtaining maximum performance from any bandsaw A properly tensioned 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 and will be difficult to work with when making tighter radius cuts The following information can be used as a guideline or starting point to assist you in determining ideal blade ten sion for your needs Y When working with wider blades re sawing taller stock making straight cuts or wide sweeping curves tight er blade tensions will provide better results When working with narrower blades sawing shorter stock and making tighter curved cuts are best per formed using less tension 18 This model 90 125 bandsaw is equipped with a blade tension in
36. omplete list of contents ADDITIONAL REQUIREMENTS FOR SET UP e Extra person for help with lifting Phillips screwdriver regular and small Flat head screwdriver e 12 mm Open end wrench 12 mm and 10 mm Hex socket Feeler gauge set Combination square PLACEMENT WITHIN THE SHOP ESTABLISHING A SAFETY ZONE Serious personal injury could occur if you connect the machine to the power source before you have completed the installation and assembly steps DO NOT connect the machine to the power source until instructed to do so This model 90 125 bandsaw is heavy 224 LBS 102 kg Do not over exert The help of an assistant will be needed for the following step 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 bandsaw 224 LBS 102 kg and the operator Using the dimensions shown in Fig 2 as a guideline plan for placement within your shop that will allow the operator to work unencumbered and unob structed by foot traffic either passing shop visitors or other shop workers or other tools or machinery ESTABLISHING 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
37. or cover of the motor to pivot it to the left See Fig 4 INSTALLING THE TENSION LEVER HANDLE Thread the tension lever onto the tension lever seat ATTACHING THE DUST PORT The dust port has a 4 opening to accommodate con nection to a dust collector not included Install the dust outlet on the back of the bandsaw as follows Align the 3 holes in the dust port with the 3 holes on the rear of the machine and insert screws through the into the dust port and tighten ATTACHING THE TABLE TILT BRACKET The work table mounts on a bracket which allows adjust ment from flat 0 to any angle up to 45 to the right Adjustments can be made easily with the angle scale and lock knobs 1 Remove the two hex bolts and and their washers from the lower wheel housing Fig 5 See Fig 2 Place the table tilt bracket on the lower wheel housing and align holes and to the threaded holes in the lower wheel housing hole Q is not used 3 Place washers on the two hex bolts and and in sert the bolts through the table tilt bracket holes and in to the threaded holes in the lower wheel housing 4 Tighten loosely using a 12 mm open end wrench and 12 mm socket 5 Thread a nut onto the longer table stop bolt and screw the bolt into the hole on the rear tab of the table tilt bracket A Final tightening will be done after centering the table opening with the blade ATTACHING TH
38. r and safer sawing by pro viding workpiece support when cutting straight 90 or angled ends 0 to 30 The miter gauge supplied with your bandsaw is adjustable from 0 to 30 right to left To use a setting other than 90 loosen the lock knob by turning it counterclockwise Rotate the miter head to the required angle shown on the angle indicator Then turn the lock knob clockwise to tighten if 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 e 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 1 Adjust the blade guard assembly to 1 8 above the workpiece i MIN CIRCLE 2 Use both hands while feeding the work into the blade DIAM Hold the workpiece firmly against the table Use gentle zD UD pressure Do not force the work Allow the blade to cut V2 BLADE WIDTH 3 The smallest diameter circle that can be cut is deter mined by the width of the blade For example a 1 4 wide blade will cut a minimum diamete
39. r of approxi mately 1 1 2 LUBRICATION AN Disconnect machine from power source before performing any lubrication or maintenance Keep the rack and pinion Q as well as the blade tension adjustment screw Q well greased and free of dust or debris Clean and remove dust debris and old grease after every 10 15 hours of use After cleaning reapply grease as need ed Use any all purpose grease The motor and all bearings are sealed and permanently lubricated no further lubrication is required No other part of this bandsaw needs lubrication 26 PERIODIC MAINTENANCE Never operate the bandsaw with any damaged part Replace a damaged part at the first visible signs of damage 1 Inspect test the ON OFF switch before each use Do not operate the bandsaw with a damaged switch replace a damaged switch immediately 2 Periodically inspect the power cord plug and the blade for damage To avoid eye injury from blowing debris wear safety goggles when blowing out sawdust 3 Keep the machine clean and free of sawdust Frequently blow out or vacuum up the sawdust and wipe down the machine occasionally with a damp rag Note The wheels must always be kept clean Dirt on the wheels will cause blade slippage 4 Do not allow dirt pitch or gum to build up on the table blade guide thrust bearings Clean as needed with gum and pitch remover Note Do not immerse the bearings in the gum and pitch remover 5
40. r of claim must be included a warranty claim form can also be used and can be obtained upon request from General amp International or an authorized distributor clearly stating the model and serial number of the unit if applicable and including an expla nation of the complaint or presumed defect in material or workmanship CONDITIONS AND EKCEPTIONS This coverage is extended to the original purchaser only Prior warranty registration is not required but documented proof of purchase 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 after inspection by General or General International to have been directly or indirectly caused by or 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 con sumable parts or components Repairs made without the written consent of General International will void all warranty TABLE OF CONTENTS Rules for safe operation 5 Electrical requirements 6 Grounding instructions 6 Circuit capacity t uw ce eb RR aaa Converting the motor to 220 V
41. ra tion and normal wear and fear on the machine could throw these parts out of alignment CONNECTING TO A DUST COLLECTOR A dust port with a 4 opening is provided to accommodate connection to a dust collector not included Once the dust port has been installed See earlier section Attaching the dust port be sure to use appropriate sized hose and fittings not included and check that all connec tions are sealed tightly to help minimize airborne dust If you do not already own a dust collection system consider contacting your General International distributor for informa tion on our complete line of dust collection systems and acces sories or visit our Web Site at www general ca 24 OPERATIONS STEP BY STEP AN To reduce the risk of damage to the bandsaw or the workpiece as well as a potential for personal injury after ini tial set up as well as before each use make sure that everything is securely installed and that all fasteners and moving parts on this bandsaw are locked in place before starting the machine 1 Trace the cutting line on your workpiece with a pencil 2 Setthe height of the blade guard according to the thick ness of your workpiece see section Adjusting the bla de guard for depth of cut on page 20 3 If a dust collector is connected to your bandsaw turn it on T Make sure
42. remain behind the bla I I I I I de teeth to prevent damage to the blade I I I Adjust the positionning of the lower thrust bearing as follows Y 1 Loosen the upper set screw Fig 37 2 Manually move the thrust bearing O in or out until the bearing is 1 64 behind the back edge of the blade then retighten the set screw Fig 37 CHANGING SPEED SETTINGS This model 90 125 14 wood cutting bandsaw has 2 different speed settings low and high Low speed is to be used for cutting soft woods over 4 in height or hard woods over 2 in height High speed is best for cutting soft woods under 4 in height or hard woods under 2 in height Note If wood starts to burn at high speed stop and change to the lower speed setting To change the speed setting 1 Turn off power and disconnect the bandsaw from the po wer source to avoid unintentional start up of the bandsaw 2 Openthe lower wheel cover door 3 Atthe back of the bandsaw just above the motor there is a ratchet lever O for loosening the tension on the drive belt When you pull it out as in Fig 39 it disengages for re setting When you release it as in Fig 40 it engages the bolt for screwing or unscrewing You can tell when it is enga ged by the orange indicater button showing To loosen the drive belt unscrew the bolt a few turns counter clockwise then pull up on the capacitor cover of the motor Q pivot the motor to the left see
43. rounded plug to fit a matching grounded type receptacle Do not attempt to modify the plug or remove the 3rd prong grounding pin from the plug to make it fit into an old 2 hole wall socket or extension cord If an adaptor plug is used it must be attached to the metal screw of the receptacle Q Fig 1 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 to your electrical outlet consult a qualified eletrician 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 con tact a qualified technician 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 I D plate An undersized cord
44. tempt to coil up the blade as it was when you first purchased it as it has a tendancy to pop open unexpectedly and could cause injury BLADE SELECTION There are a variety of different types of bandsaw blades on the market to suit various cutting applications Your results may vary based on usage experience and personal preference standard size 93 1 2 2375 mm replacement blades made from high carbon steel can be purchased in a variety of widths from your General amp International dealer under the following parts numbers 90125 B14 1 4 6 TPI blade thickness 0 65 mm 90125 B38 3 8 6 TPI blade thickness 0 50 mm 90125 B12 1 2 4 TPI blade thickness 0 65 mm 90125 B34 3 4 4 TPI blade thickness 0 65 mm or depending on availability from your local tool dealer These are standard sizes that should be readily available in most areas The use of any other size is not recommended and can lead to serious injury and or damage to the machine Some general guidelines to consider when choosing bandsaw blades Wider blades with fewer teeth per inch are best suited to cutting straight lines re sawing and for sweeping curves but will not turn tight radius curves They will cut quickly and aggressively but do have a tendency to bind or get stuck in the cut if turned too sharply e Narrower thinner blades with more teeth per inch will cut more slowly bu can turn much tighter corners for cutting more
45. to have on safety glasses at all times when using the bandsaw Make sure you are wearing safe appropriate workshop attire Roll up long sleeves secure long hair and remove any jewelry watches rings bracelets or anything that could get stuck into the moving parts of the bandsaw potentially causing serious injuries 5 Pull the switch toward you to start the bandsaw Note The yellow safety key must first be inserted into the switch 6 Align the cutting line on your workpiece with the blade and feed the workpiece into the blade Tip The use of a roller stand provides an extra support for more convenience when working with longer workpieces TO STOP THE MACHINE 1 Push the red tab down and remove the yellow key 2 Turn your dust collector off INSTALLING USING THE RIP FENCE 1 Set the fence down on the rail either to the left or right of the blade Note For narrow workpieces that fit between the frame of the saw and the blade position the fence at the left side of the blade For cufting longer or wider workpieces position the fence on the right side of the saw blade 2 Adjustthe positioning of the fence on the rail so that the distance from the inside face of the rip fence to the bla de matches the required width of cut 3 Lock down the fence locking handle Make sure to lock the fence in place before start ing to cut against the rip fence USING THE MITER GAUGE The miter gauge allows for easie
46. 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 corres ponds with that of the unit with which it was supplied However special orders and after factory modifica tions may render some or all information in this manual inapplicable to your machine Further as several gene rations of this model of 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 machine exactly If you have any doubts or ques tions contact your retailer or our support line with the model and serial number of your unit for clarification GENERAL amp GENERAL INTERNATIONAL WARRANTY All component parts of General amp General amp International and Excalibur by General International amp 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 amp and General amp International agree 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 life of t
47. u connect the machine to the power source before you have completed the installation and assembly steps DO NOT connect the machine to the power source until instructed to do so ATTACHING THE DOOR KNOB 1 Remove the door knob assembly from inside the base cabinet where it is stored for shipping 2 From the inside insert the door bolt through the hole in the door into the door knob O 3 Tighten the door bolt INSTALL THE BANDSAW ONTO THE BASE CABINET The bandsaw is mounted onto a base cabinet which provides storage space for the miter gauge and replacement blades AN The bandsaw is heavy Do not over exert The help of an assistan will be needed for the following step Do not grip the bandsaw by the lower wheel cover door when lifting Keep hands away from blade at all times 1 Position the bandsaw over the four holes on top of the base cabinet Q 2 Insert four hex head bolts and flat washers down through the holes in the legs of the bandsaw and into the base cabinet Then open the door and from the inside tighten four hex nuts with wa shers O onto the bolts using a 12 mm open end wrench and 12 mm socket Note To be able to insert the hex head bolt down through the hole under the motor you must first pivot the motor fo the left Proceed as follows At the back of the bandsaw just abo ve the motor there is a ratchet lever See Fig 3 Pull it out as in Fig 3 then pull up on ihe capacit
48. uides are at least 1 32 behind the blade teeth See Fig 34 The guides must remain behind the blade teeth to prevent da mage to the blade 6 Tighten the thumb screw to lock the guide bearing assem bly in position Adjust the positionning of the upper thrust bearing as follows 1 Loosen the upper thumb screw Fig 33 2 Turn the micro adjust nut O Fig 32 to move the thrust bea ring Fig 33 in or out until the bearing is 1 64 behind the back edge of the blade Fig 35 then tighten the thumb screw POSITIONING THE LOWER BLADE GUIDES AND THRUST BEARING The lower blade guides and thrust bearing perform the same function as the upper blade guides and thrust bearing except they do so after the blade has contacted the stock being cut Adjust the positioning of the lower blade guide as follows 1 Loosen the two Allen bolts and slide the two blade gui des along the elongated hole in the mounting bracket toward the blade Fig 36 2 Place a feeler gauge between one of the bearings and the blade and tighten the Allen bolt until there is a 0 02 gap left between the blade guide and the blade 22 3 Repeat step 2 for the other guide on the other side of the blade 4 Loosen the lower set screw with the 3 mm Allen key pro vided 5 Manually move the guide bearing mounting bracket O in or out until the guides are at least 1 32 behind the blade teeth see Fig 38 The guides must
49. 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 or perimeter of each machines safety zone Take steps to ensure that all operators and shop visitors are aware that these areas are off limits when ever a machine is running for everyone but the individ ual operating the unit CLEAN UP The protective coating on the saw table prevents rust from forming during shipping and storage Remowve it by rubbing with a rag dipped in kerosene mineral sprits or paint thinner Dispose of potentially flamma ble solvent soaked rags according to manufacturer s safety 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 such as General Interna tional Top Saver item GC 010 Tip With a screw driver push a solvent saturated rag into the T slot to remove the grease so the miter gauge will slide freely ASSEMBLY INSTRUCTIONS For your convenience This bandsaw is shipped from the factory partially assembled and requires only minimal assembly and set up before being put into service IN Serious personal injury could occur if yo
50. will cause a drop in line voltage resulting in loss of power and overheating Ihe accompanying chart shows the correct size exten sion cord to be used based on cord length and motor 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 AMPERE VOMS TOTAL LENGTH OF CORD IN FEET RATING nov 25m som om CONVERTING THE MOTOR TO 220V Should you need to convert your machine s motor from 110V to 220V power there is an electrical schematic drawing on the inside of the motor cover plate Unless you are a qualified electrician we do not recommend attempting this conversion on your own If you choose fo do so you may risk serious personal injury damage to the motor and voiding the warranty of your machine We suggest you ask your local General International distributor to recommend qualified electricians in your area or perhaps one of their own technicians who can make this conversion properly and safely 14 WOOD CUTTING BANDSAW 90 125 E IDENTIFICATION OF MAIN PARTS AND COMPONENTS FRONT VIEW BLADE TENSION ADJUSTMENT KNOB TABLE ALIGNMENT PIN FENCE LOCK LEVER UPPER BLADE GUIDE LOCK KNOB FRONT RAIL FENCE O BLOWER DEVICE O BASE CABINET ON OFF SWITCH TABLE INSERT O LOWER WHEEL COVER DOOR UPPER WHEEL COVER DOOR MITER GAUGE TABLE TILT LOCK KNOB
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