General International 90-060 M1 Installation guide

Brand: General International

Model: 90-060 M1

Type: Installation guide

ELECTRICAL REQUIREMENTS

Connect the motor plugs and then plug the bandsaw into a proper

receptacle. Your power tools should be connected to a dedicated

electrical circuit of not less than #12 wire and should be protected with

a 15 amp time lag fuse.

GROUNDING: In the event of an electrical malfunction or short circuit,

grounding reduces the risk of electric shock t o. The motor of this

machine is wired for 110V single phase operation and is equipped

with a 3-conductor cord and a 3-prong grounded plug to fit a ground-

ed type receptacle, . Do not remove the 3rd prong (grounding pin)

to make it fit into an old 2-hole wall socket. If an adaptor plug is used,

, 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.

Before connecting the machine to the power source, verify that the voltage of your power supply corresponds

with the voltage specified on the motor I.D. nameplate. A power source with greater voltage 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.

DO NOT MODIFY THE PLUG PROVIDED.

If it will not fit your receptacle, have the proper receptacle installed by a qualified electrician.

CHECK with a qualified electrician or service person if you do not completely understand these grounding instruc-

tions, or if you are not sure the tool is properly grounded.

EXTENSION CORDS:

USE ONLY 3-WIRE EXTENSION CORDS THAT HAVE 3-PRONG GROUNDING PLUGS AND 3-POLE RECEPTACLES THAT ACCEPT

THE TOOLS’ PLUG. REPAIR OR REPLACE A DAMAGED OR WORN POWER CORD OR PLUG IMMEDIATELY.

If you find it necessary to use an extension cord with your machine make sure the cord rating is suitable for the

amperage listed on the motor I.D. 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 gauge number, the

heavier the cord.

AMPERES

(AMPS)

EXTENSION CORD LENGTH

25 FEET 50 FEET 100 FEET 150 FEET

<6 18 16 16 14

6TO10 18 16 14 12

10 TO 12 16 16 14 12

12 TO 16 14 12 NA NA

NA = Not Available

BLADE TENSION KNOB

WORK LIGHT

MITER GAUGE

TABLE ALIGNING PIN

DUST PORT

BLADE

ON/OFF SWITCH

UPPER BLADE GUIDE LOCK KNOB

TABLE TILT LOCK KNOB

STAND

FOOT PAD

TABLE INSERT

UPPER WHEEL COVER DOOR

LOWER WHEEL COVER DOOR

LASER LINE MARKER

IDENTIFICATION OF MAIN PARTS AND COMPONENTS

12” BANDSAW

90-060

LIST OF CONTENTS

Once the parts have been removed from the

packaging, you should have the following items:

Qty

BANDSAW W/MOTOR .........................1

TABLE W/EXTENSION WING .....................1

TRUNNION SUPPORT BRACKET ..................1

MITER GAUGE ...............................1

DUST PORT ..................................1

• Philips screwdriver

• Adjustable wrench

• Straightedge

• Extra person for help with lifting

UNPACKING

Carefully unpack and remove the bandsaw 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.

UNPACKING & SET UP

SCREWS ................................2

POWER CORD HOOKS ........................2

ALLEN KEY ................................2

TABLE TILT LOCK KNOBS .......................2

WORK LIGHT ................................1

BOLT 5/16” X 1” ..............................1

BOLT 5/16” X 1 1/4” ...........................4

HEX NUT 5/16” ...............................5

LARGE WASHER ..............................4

HARDWARE BAG .............................1

CARRIAGE BOLT ..................32

HEX. NUT ........................32

WASHER ........................32

FOOTPAD .......................4

TOPPLATE ...................................1

SHORT LOWER BRACKET .......................2

LONG LOWER BRACKET .......................2

LEG ........................................4

LASER LINE MARKER (WITH HARDWARE) ..........1

ADDITIONAL TOOLS NEEDED

ASSEMBLY INSTRUCTIONS

ASSEMBLING THE STAND

Lay the top plate upside dow n on a f lat sur-

face.

2. Attach the 4 legs to the outside of top plate

using 4 carriage bolts, washers, and nuts

Note: Do not tighten hex nuts until all fasteners are

attached.

3. Attach 2 long brackets and 2 short brackets

to the inside for the legs, using carriage bolts,

w ashers, and nuts .

4. Place the foot pads on the bottom of each

leg.

5. Place the stand on a flat surface to square it up

and finally tighten all the nuts.

The bandsaw is heavy. The help of an assis-

tant will be needed to lift the bandsaw.

1. Lift the saw body with the help of an assistant

and place it on the stand.

2. Using 4 long hex head bolts , 8 flat washers

, and 4 hex nuts , secure the bandsaw to

the stand and tighten all mounting bolts.

ATTACHING THE BANDSAW TO STAND

ATTACHING DUST PORT

1. Remove the bolts and w ashers from the dust

port.

2. Open the lower wheel cov er door

3. Attach the dust port to the edge of the door

using the same hex head bolts and washers .

4. Tighten the bolts and close the door.

The dust port has a 2-1/2” opening

to accommodate

connection to a dust collector (not included).

The door knob and its threaded pin are used as the

fasteners to secure the laser line marker mounting

bracket to the door.

To install the laser line marker on the door, first remove

the door knob and its pin. Then re-install the knob with

its pin through the hole in the laser line markers’

mounting bracket in the order of assembly shown

INSTALLING THE LASER LINE MARKER

MOUNTING THE TRUNNION SUPPORT BRACKET

1. Remove the 2 hex head bolts and washers

, located on the lower band saw housing.

2. Place the trunnion support bracket on the

saw body, aligning the mounting holes.

3. Place the washers on the hex head bolts, and

insert into the threaded holes , through the

bracket and saw body. Tighten.

5. Place a lock knob on each bolt and adjust

the table, aligning the zero scale mark to the

pointer , then tighten the knobs .

90° CW

INSTALLING 90° TABLE TILT STOP BOLT

1. Remove the table insert from the table.

2. The extension table must be removed before

placing table onto saw. Unscrew the stop-

screw on the rear extension table guide bar

and pull the extension table off of the main

table.

1. Thread the nut onto the table stop bolt and

screw bolt into the rear tab on the trunnion

support bracket. Tighten the nut down onto the

bracket tab.

2. After installing the table, the 90° s top bolt can be

adjusted up or down as needed to “stop” the

table at 90° to the blade.

INSTALLING THE BANDSAW TABLE

3. Guide the table slot over the saw blade and

rotate 90° clockwise so the slot is perpendicular

to the blade.

4. Slip the 2 table tilt trunnion bolts through the

holes in the trunnion brac kets (fr ont & rear) as

shown.

6. Re-install the table insert .

7. Insert the table aligning pin in the hole at

the side of the table.

8. Re-install the extension table and re-attach the

stop-screw

Store the miter gauge on the supplied bracket on the

stand as shown.

bottom

view

MITER GAUGE

Attach the power cord brackets to the rear of

the saw, as shown using the 2 Phillips head screws

To prevent damage, stow the cord by wrap-

ping it onto the brackets whenever the saw is not

in use.

Remove 4 phillips screws from machine body. Install

the work light and the power cord to the machine

body by using 4 phillips screws and tighten.

The worklight uses a standard 110V household light-

bulb, 60 Watts - Not Included.

INSTALLING POWER CORD STORAGE BRACKETS

ATTACHING THE WORK LIGHT

REMOVING & INSTALLING THE BLADE

Before replacing or adjusting the blade, make sure the switch is in the “OFF” position and that the pow er cord is unplugged.

1. To remov e blade, release blade tension by turning

the blade tension knob counter-clockwise until

it stops.

2. Remove the table insert and table aligning pin.

3. Open upper and lower wheel cover doors.

4. Loosen the 2 Phillips screws and remov e the

upper blade guard .

Note: Extension table m ust be removed when removing/installing the blade. See Step2&8inINSTALL THE BANDSA W TABLE, pg. 8 & 9.

Remove the blade from the upper and lower

blade guides. Carefully pull the blade from the

side slot and from the wheels

6. Swing the left side of the blade toward you, turning

the blade so it will fit through the slot in the table

and remove.

RECOMMENDED ADJUSTMENTS

Before making any adjustments, make sure that the switch is in the “OFF” position and that the power cord is

unplugged.

TILTING THE TABLE

1. Loosen both table lock knobs underneath the table.

2. Manually tilt the table to the desired angle on the

scale under the table.

3. Tighten the knobs to secure the table at the desired

angle.

ADJUSTING THE 90° TABLE STOP

1. Loosen both table lock knobs underneath the table

and tilt the table to the right.

2. Loosen the nut on the table stop bolt and lower

the stop bolt as far as possible.

3. Place a combination square on the table against

the saw blade.

4. Adjust the tilt of the table left or right until it is 90° to the

blade. Make sure there is no space between the square

and the blade. Tighten the lock knobs .

5. Adjust the table stop bolt up until it touches the

underside of the table.

6. Loosen the lock knobs and verify that the table is rest-

ing on the stop bolt .

7 . Check the square to make sure the table is still

90° to the blade. If not, re-adjust the stop bolt as

needed.

8 . When the adjustment is accurate at 90°, tighten down

the nut on the stop bolt , tighten the table lock knobs

and align the pointer to the 0° mark on the angle

indicator scale

Make sure the blade is in the center of the table insert slot before operating.

To install a blade, repeat the previous steps (Pg. 9) in

reverse order, making sure that the blade is installed with

the teeth pointing forward and down as shown.

With the blade installed, re-attach the extension table and

then proceed to “BLADE TENSION ADJUSTMENTS” and

“BLADE TRACKING ADJUSTMENTS” in the “RECOMMENDED

ADJUSTMENTS” section of this manual, Pg. 11.

Proper installation

Improper installation

The gauge on the bracket at the rear of the upper

wheel housing indicates the proper tension for the various

blade widths.

1. Set the blade tension gauge to correspond with the

width of the blade in use.

2. Turn the blade tension knob clockwise, raising the

upper wheel to tighten the blade. Turn the knob count-

er-clockwise to lower the upper wheel, loosening the

blade.

Note: Changes in blade width and the type of material

being cut will have an effect on the blade tension. Too

much or too little tension could break the blade. When

the band saw is not in use, loosen the tension on the

blade, to prolong blade life.

Before making blade tension adjustments, make sure that the switch is in the “OFF” position and that the power

cord is unplugged.

BLADE TENSION ADJUSTMENTS

BLADE TRACKING ADJUSTMENTS

Note: The blade must be tensioned properly before

adjusting the tracking.

1. Open the upper wheel cover door and move the

blade guides and support bearings away from

the blade, if necessary. See page 12-13 for bearing

and guide adjustment.

2. Rotate the wheel slowly forward by hand, and check

the position of the blade on the wheel. The blade

should remain centered on the wheel as it turns.

A) If the blade moves toward the front of the wheel, turn

the tracking knob on the back of the band saw

clockwise. This tilts the top of the wheel to the back and

moves the blade toward the center.

B) If the blade moves toward the back edge, turn the

tracking knob counter- clockwise, moving the blade

toward the center.

Note: Turn the tracking knob in 1/2 turn increments ,

re-check and adjust again as needed.

Back View

Turn CW

if blade

moves

to front

Turn

CCW if

blade

moves

to back

UPPER BLADE GUIDE

To avoid injury, make sure that the switch is in the “OFF” position and that the power cord is unplugged.

1. Loosen the set screws and move the roller bearing

as close to the blade as possible without pinching it.

2. Using a feeler gauge, make sure the space between

each bearing and the blade measures 0.02” (the thick-

ness of a dollar bill).

3. Re-tighten the set screws and loosen the side thumb

screw by turning counter-clockwise.

4. Move the blade guide bracket shaft in or out until the

roller bearings are at least 1/32” behind the blade

teeth.

5. The roller bearing must remain behind the blade

teeth during operation to prevent damage to the

blade. Tighten the thumb screw

Note: Make sure the blade is tensioned and tracking properly. Adjust the blade guide and support bearings after each

blade tension and tracking adjustment. Whenever the upper blade guide and support bearings are adjusted, the lower

guide and support bearings should also be adjusted.

ADJUSTING THE BLADE GUARD FOR DEPTH OF CUT

1. Loosen the lock knob and manually move the blade

guard assembly up or down to set the guard to

1/8” - 1/4” above the workpiece.

2. Re-tighten the lock knob, before turning on the saw.

3. Adjust the height of the blade guard to suit the thick-

ness of the workpiece .

POSITIONING THE UPPER SUPPORT BEARING

Note: The blade support bearing prevents the blade

from moving back too far and damaging the saw teeth

setting.

1. To re-position the support bearing, loosen the thumb

screw .

2. Move the support bearing shaft in or out, until the

bearing is 1/64” behind the blade.

3. Tighten the thumb screw .

Note: In the drawing below, the blade guard has been removed for clarity of illustration. To avoid injury, never operate

the bandsaw without all guards in place and in proper working order.

”

LOWER BLADE GUIDES

Note: The lower blade guides and support bearings

should always be adjusted after the blade is tensioned,

tracking is adjusted, and the upper blade guides and

upper support bearings are properly adjusted.

1. Loosen both front hex socket screws with a hex

wrench and move the bearings as close to the sides

of the blade as possible without pinching it.

2. Using the feeler gauge, measure the spaces between

the guide and the blade. Adjust to 0.02”.

3. Tighten the hex screws and loosen the side hex sock-

et screw . Move the guide support bracket in or out

until the guides are at least 1/32” behind the saw teeth.

Tighten the screw.

LOWER SUPPOR T BEARING

1. Loosen the bearing hex socket screw with the hex

wrench.

2. Move the blade support bearing shaft in or out until

the support bearing is 1/64” behind the saw blade.

3. Tighten the bearing hex socket screw .

PULLEY ALIGNMENT

Note: The pulley alignment has been pre-set and verified

at the factory and should not need re-adjustment. If

adjustment is needed or the belt needs replacing:

1. Place a straight edge in the front groove of both pul-

leys, behind the blade wheel.

2. Turn the set screw in the side of the motor pulley to

loosen the pulley on the shaft.

3. Adjust the pulley in or out on the shaft to align the

edges of the two pulleys.

4. When aligned, re-tighten the set screw on the side of the

motor pulley.

LASER LINE MARKER

This model 90-060 is equipped with a laser line marker, loca-

ted on the front right side hand of the upper wheel cov er door

, allowing y ou to easily mark a straight cut line on your

w orkpiece.

Note: Requires two AAA batteries (not included). Slide up-

wards and remove the battery cover .

Align the laser beam on the blade as follows:

Move ON/OFF switch up to turn the laser marker

on.

Move the beam adjustment knob in any direction

until the beam is aligned with the blade .

ON / OFF SWITCH

BEAM

ADJUSTMENT KNOB

CLOSE UP

OFF

General International 90-060 M1 Installation guide

General International 90-060 M1 Installation guide

General International 90-060 M1 Installation guide

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