General International 90-125 M1 Use and Care Manual

SETUP & OPERATION MANUAL

FEATURES

14” WOOD CUTTING BANDSAW

Cast iron frame & precision-balanced aluminum wheels with replaceable rubber tires.

Closed stand model features a rigid one piece welded stand.

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.

Hinged door, easily accessible blade tensioning knob, for fast blade changes or adjustments.

Quick release blade tension lever.

SPECIFICATIONS

WHEEL SIZE

13 7⁄8 ” (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 & 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)

MODEL

#

90-125 M1

VERSION 5_ REVISION 1 - JUNE 1/11 (91988411)

© Copyright General® International 06/2011

GENERAL® INTERNATIONAL

8360 Champ-d’Eau, Montreal (Quebec) Canada H1P 1Y3

Telephone (514) 326-1161 • Fax (514) 326-5555 • www.general.ca

THANK YOU

for choosing this General ® International model 90-125 M1 14”

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. 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 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 in this manual pertain to the unit as it was supplied from the factory 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 was supplied.

However, special orders and “after factory” modifications may render some or all information in this manual inapplicable to your machine. Further, as several generations 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 questions contact your retailer or our support line with the model and serial number of your unit for clarification.

GENERAL

®

& GENERAL

®

INTERNATIONAL WARRANTY

All component parts of General®, 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® and General®

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 the 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® and General® 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® 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 of the product being claimed for warranty, a copy of the original proof of purchase and a “letter of claim” 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 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 consumable parts or components.

Repairs made without the written consent of General® International

l

will void all warranty.

TABLE OF CONTENTS

Rules for safe operation . . . . . . . . . . . . . . .

5

Electrical requirements . . . . . . . . . . . . . . .

6

Grounding instructions . . . . . . . . . . . . . . . . . . . . . . .6

Circuit capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Extension cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Converting the motor to 220 V . . . . . . . . . . . . . . . . .6

Identification of main parts and components . . . . . . . . . . . . . . . . . . . .

7

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . .

8

List of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Additional requirements for set up . . . . . . . . . . . . .8

Placement within the shop /

Establishing a safety zone . . . . . . . . . . . . .

9

Clean up . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Miter gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 90º table stop and re-aligning the angle pointer . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Tilting the table . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Removing/installing the blade . . . . . . . . . . . . . . .16

Blade clearance . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Blade selection . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Adjusting blade tension . . . . . . . . . . . . . . . . . . . . .18

Adjusting blade tracking . . . . . . . . . . . . . . . . . . . .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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 . . . . . . . . . . . . . . . . . . . . . . . .25

Installing/using the rip fence . . . . . . . . . . . . . . . . .25

Using the miter gauge . . . . . . . . . . . . . . . . . . . . . .26

Cutting curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Cutting circles . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Lubrication . . . . . . . . . . . . . . . . . . . . . . . .

26

Periodic Maintenance . . . . . . . . . . . . . . . .

27

Required Maintenance . . . . . . . . . . . . . . .

27

Replacing the bandsaw blade . . . . . . . . . . . . . . .27

Replacing the upper and lower blade guides and thrust bearings . . . . . . . . . . . . . . . . . . . . . . . . .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 & 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 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.

1. Do not operate the bandsaw when tired, distracted or under the effects of drugs, alcohol or any medication that impairs reflexes or alertness.

2. The working area should be well lit, clean and free of debris.

3. Keep children and visitors at a safe distance when the bandsaw is in operation; do not permit them to operate the bandsaw.

4. Childproof and tamper proof your shop and all machinery with locks, master electrical switches and switch keys, to prevent unauthorized or unsupervised use.

5. Stay alert! Give your work your undivided attention.

Even a momentary distraction can lead to serious injury.

6. 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 devices.

7. Do not wear loose clothing, gloves, bracelets, necklaces or other jewelry while the bandsaw is in operation.

8. Be sure that adjusting wrenches, tools, drinks and other clutter are removed from the machine and/or the table surface before operating.

9. Keep hands well away from the blade and all moving parts. Use a brush, not hands, to clear away chips and dust.

10. 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.

11. Adjust blade tension and tracking before starting to cut.

12. Saw teeth must point down toward the table.

13. Be sure that the blade has gained full operating speed before starting to cut.

14. Always use a clean, properly sharpened blade.

Dirty or dull blades are unsafe and can lead to accidents.

15. Use suitable workpiece support if the workpiece does not have a flat surface.

16. Hold material firmly against the table.

17. Do not work on long stock without adequate support on the out feed end of the table.

18. If using a power feeder, stop the feeder before stopping the bandsaw.

19. Do not push or force stock into the blade. The bandsaw will perform better and more safely when working at the rate for which it was designed.

20. Avoid working from awkward or off balance positions. Do not overreach and keep both feet on floor.

21. Keep guards in place and in working order. If a guard must be removed for maintenance or cleaning be sure it is properly re-attached before using the tool again.

22. Never leave the machine unattended while it is running or with the power on.

23. Use of parts and accessories NOT recommended by General® International may result in equipment malfunction or risk of injury.

24. Never stand on machinery. Serious injury could result if the tool is tipped over or if the cutting tool is unintentionally contacted.

25. Always disconnect the machine from the power source before servicing or changing accessories such as blades, or before performing any maintenance or cleaning, or if the machine will be left unattended.

26. Make sure that the switch is in the “OFF” position before plugging in the power cord.

27. Make sure the tool is properly grounded. If equipped with a 3-prong plug it should be used with a three-pole receptacle. Never remove the third prong.

28. Do not use this bandsaw for other than its intended use. If used for other purposes, General® International disclaims any real implied warranty and holds itself harmless for any injury, which may result from that use.

5

Before connecting the machine to the power source, verify that the voltage of your power supply corresponds with the voltage specified on the I.D. nameplate located on the back of the machine. 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.

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 supplied motor for this machine is wired for 110V, single phase operation, and has a 3-conductor cord and 3-prong grounded 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 . (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.

Fig. 1

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 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 3prong grounding plug and a matching 3-pole receptacle that accepts the tool’s plug. Repair or replace a damaged 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 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.

MORE

THAN

0

6

10

12

NOT

MORE

THAN

6

10

12

16

VOLTS

110 V

220 V

TABLE - MINIMUM GAUGE FOR CORD

25 ft.

TOTAL LENGTH OF CORD IN FEET

50 ft.

100 ft.

50 ft.

100 ft.

200 ft.

18

18

16

14

AWG

16

16

16

12

16

14

14

-

150 ft.

300 ft.

14

12

12

-

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 to do so, you may risk serious personal injury, damage to the motor and voiding the warranty of your machine.

6

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

IDENTIFICATION OF MAIN PARTS AND COMPONENTS

FRONT VIEW

BLADE TENSION ADJUSTMENT KNOB

UPPER BLADE GUIDE LOCK KNOB

BLOWER DEVICE

TABLE INSERT

MITER GAUGE

TABLE ALIGNMENT PIN

FRONT RAIL

BASE CABINET

LOWER WHEEL COVER DOOR

TABLE TILT LOCK KNOB

FENCE LOCK LEVER

FENCE

ON/OFF SWITCH

UPPER WHEEL COVER DOOR

REAR VIEW

BLADE GUARD ADJUSTMENT KNOB

TRACKING ADJUSTMENT KNOB

BLADE TENSION INDICATOR

TENSION LEVER

DUST PORT

MOTOR

7

UNPACKING

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 packaging, you should have the following items:

QTY

BANDSAW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

BASE CABINET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

HARDWARE BAG (INSIDE BASE CABINET)

— DOOR KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

— DOOR BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TABLE & TRUNNIONS . . . . . . . . . . . . . . . . . . . . . . . . . .1

TABLE-TILT BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TENSION LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

HARDWARE BAG

— POWER CORD HOOK . . . . . . . . . . . . . . . . . . . . . .2

— LOCK KNOBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

— HEX HEAD BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . .4

— FLAT WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

— HEX NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

— SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

— HEX HEAD BOLT (LONG) . . . . . . . . . . . . . . . . . . .1

— 5 MM ALLEN KEY . . . . . . . . . . . . . . . . . . . . . . . . . .1

— 3 MM ALLEN KEY . . . . . . . . . . . . . . . . . . . . . . . . . .1

— 10 MM COMBINATION WRENCH . . . . . . . . . . . . .1

Note: Deluxe Excalibur Universal Bandsaw Rip Fence System is packaged separately. Refer to the manual supplied in the box with the Excalibuer Rip Fence for complete list of contents.

8

ADDITIONAL REQUIREMENTS FOR SET UP

• Extra person for help with lifting

• Phillips screwdriver (regular and small)

• Flat head screwdriver

• 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 unobstructed by foot traffic (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 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 whenever a machine is running for everyone but the individual operating the unit.

Fig. 2

CLEAN UP

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 sprits or paint thinner. (Dispose of potentially flammable 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 after-market surface protectant or rust inhibitor such as General International “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.

9

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.

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.

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 hol e in the door, into the door knob .

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.

The bandsaw is heavy. Do not over-exert. The help of an assistant 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 .

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 washers onto the bolts, using a 12 mm open end wrench and

12 mm socket.

10

Note: To be able to insert the hex head bolt down through the hole under the motor, you must first pivot the motor to the left.

Proceed as follows:

At the back of the bandsaw, just above the motor, there is a ratchet lever

.(See Fig. 3).

Pull it out as in Fig. 3, then pull up on the capacitor cover of the motor to pivot it to the left. (See Fig. 4).

Fig.3

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 connection 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 adjustment 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. 6

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 is not used).

3.

Place washers on the two hex bolts and and insert the bolts through the table-tilt bracket holes and into 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.

* Final tightening will be done after centering the table opening with the blade.

LOWER WHEEL HOUSING

Fig. 5

TABLE-TILT BRACKET

NOT USED

Fig. 6

11

12

ATTACHING THE TABLE

1. Remove the red insert 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.

Fig. 7

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 onto the long bolts now protruding from the underside of the table-tilt bracket and tighten loosely. (See Fig. 9)

7.

Make sure that the blade is centered in the table opening . If the blade is not centered, slide the table back or forward 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 to 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.

Fig. 9

Fig. 10

Fig. 8

UNDERSIDE VIEW OF TABLE

Fig. 11

RIP FENCE AND RAIL

This model 90-125 M1 is equipped with an Excalibur

T-fence and guide 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 preventing 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 located on the motor, then remove the motor cover .

2. Pass the the blower device hose through the hole in the motor cover and fit it securely onto the hose barb located behind the motor propeller .

3.

Re-install and secure the motor cover, using the 3 screws removed 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 .

It also acts as a feeder for advancing smaller workpieces through the sawblade with reduced risk of injury to the hands.

Fig. 16

POWER CORD HOOKS

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.

Fig. 17

13

BASIC FUNCTIONS OF THE UNIT

This 14" wood cutting bandsaw is supplied with a 3/8" wide general purpose blade and is designed to accommodate 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 ) is 13 1/2".

For cutting thicker stock or for resawing, the maximum depth of cut (or max. workpiece height) is 6" (up to

12" with optional “riser block kit” item #90-130 – Refer to section “Recommended Optional Accessories for your

Bandsaw”.

A dual position aluminum rip fence (tall for resawing or short for rip cuts) 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.

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.

Connect the 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.

2.

Uncoil the power cord and plug it into an appropriate outlet (refer back to section “Electrical Requirements" 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 to prevent unauthorized use or unintentional 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:

Insert the safety key and pull the switch toward you .

14

To STOP the bandsaw:

Push the red tab down .

SAFETY KEY*

* PREVENTS START-UP WHEN REMOVED

ON OFF

RECOMMENDED ADJUSTMENTS

ADJUSTING THE 90º TABLE STOP AND RE-ALIGNING THE ANGLE POINTER

To ensure that your 90º cuts are square and that angled cuts are accurate with the angle indicator scale, the table default position must be set to 90º to the blade and the angle indicator pointer must be set to read 0 when the table is in the default (90º ) 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 with the heel of the square flat against the saw blade, .

3. Level the table until it is exactly 90° to the saw blade.

4. Tighten the lock knobs.

See Fig. 19

5. Adjust the height of the table-stop bolt until it touches the underside of the table.

6. Turn the jam-nut clockwise until it meets the table tilt bracket and tighten it.

7.

Loosen the lock knobs and make sure the table is resting on the table-stop bolt.

8. Check the square and make sure the table is still at 90° to the blade. If not, re-adjust the table-stop bolt.

Fig. 18

Fig. 19

See Fig. 20

9.

With the table set to 90º and the stop bolt at the correct height, make sure the table tilt angle indicator pointer is set to read 0º.

10. If the pointer needs to be adjusted, loosen the screw on the pointer of the front trunnion and adjust the pointer to the 0 point on the scale. Then re-tighten the screw to secure the pointer in place.

Fig. 20

You will now be able to accurately return the table to the 90º 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 running. 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.

15

16

REMOVING/INSTALLING THE BLADE

Your bandsaw is designed 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.

BLADE CLEARANCE

Note: When performing blade installation, removal, tensioning or tracking, maximum clearance between the blade and both upper and lower bearing assemblies is required to 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 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.

3.

Tighten the two Allen bolts to lock the blade guides in position.

Fig. 21

Move the upper thrust bearing back: (See Fig. 21)

1.

Loosen the upper thumb screw .

2.

Use the micro adjust nut to move the thrust bearing 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)

Fig. 22

1. Loosen the two Allen bolts 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.

3.

Tighten the two Allen bolts to lock the blade guides in position.

4. Loosen the set screw with the 3 mm Allen key provided.

5.

Manually move the lower thrust bearing back as far as possible behind the blade.

To remove a blade:

1. Turn off the bandsaw and unplug the power cord.

2. Pull up on the tension lever toward the left (90º position) to loosen the tension on the blade. It may be necessary to also turn the tension knob counter-clo ckwise for the blade to be loose enough to remove easily.

DO NOT

Note: For blade tension quick release, pull up on the tension lever toward the left (90º position

) .

For quick blade tensioning, push the tension lever down (0º position )

.

To avoid damaging the tensioning mechanism never force the tension lever beyond 90º vertical or 0º horizontal .

DO NOT

LOOSEN TIGHTEN

3.

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 the two Phillips head screws , just enough to slide it out.

Blade teeth are sharp. Use care when handling a saw blade.

5. Open the top and bottom wheel cover doors and bring the left hand side of the loose blade toward you and out of the left hand blade guard slot. (See Fig. 23)

Note: You may want to use a thick shop towel to 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 place in your workshop if it will be re-used, or dispose of it safely if it is worn or damaged.

Do not attempt 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.

Fig. 23

Fig. 24

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® International dealer under the following parts numbers:

• #90125-B14:1/4” - 6 TPI, blade thickness: 0.65 mm

• #90125-B12: 1/2” - 4 TPI, blade thickness: 0.65 mm

• #90125-B38: 3/8” - 6 TPI, blade thickness: 0.50 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.

•Narrower, thinner blades with more teeth per inch will cut more slowly but can turn much tighter corners for cutting more 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.

• Setting blade guard assembly too high above the workpiece.

• Lumpy or improperly finished braze or weld on the blade.

•Continuous running of blade when not cutting.

17

To install a blade:

1. Turn off the bandsaw and unplug the power cord.

Beware of the blade popping open.

2. If 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: You may want to use a thick shop towel to handle the loose blade or wear a pair of heavy duty work gloves for the following steps.

Note: Steps 3 and 4 may be unnecessary if you’ve just removed a blade. (If needed, refer back to the previous page.)

3. 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 the two Phillips head screws, just enough to slide it out.

Proper installation Improper installation

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 into the left blade guard and around the wheels. Make sure the blade teeth point forward and down . (See Fig. 25)

Fig. 25

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 somewhat 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.

18

The following information can be used as a guideline or starting point to assist you in determining ideal blade tension for your needs:

• When working with wider blades, re-sawing taller stock, making straight cuts or wide sweeping curves tighter blade tensions will provide better results.

• When working with narrower blades, sawing shorter stock and making tighter curved cuts are best performed using less tension

This model 90-125 bandsaw is equipped with a blade tension indicator scale, which can 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.

DO NOT

Note: For blade tension quick release, pull up on the tension lever toward the left (90º position

) .

For quick blade tensioning, push the tension lever down (0º position )

.

To avoid damaging the tensioning mechanism never force the tension lever beyond 90º vertical or 0º horizontal .

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 tension 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 too tensioned will force and damage the blade tension mechanism.

1. Pull the tension lever down for quick blade tensionning.

2. Refering to the blade tension gauge , set the blade tension to correspond with the width of the blade installed on your bandsaw. Adjust the blade tensioning by turning the blade tension knob : a) Clockwise to tighten b) Counter-clockwise to loosen the blade tension.

3. With the saw turned off, press against the side of the blade 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 Fig. 27)

4.

Make a test cut on a sample piece of wood and if needed re-adjust the blade tension.

Fig. 26

Fig. 27

LOOSEN TIGHTEN

DO NOT

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.

19

ADJUSTING BLADE TRACKING

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).

3 mm - 1/8"

Due to natural variations in castings, blade thickness or density and tire wear, absolute perfect centering alignment 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.

Fig. 28 Fig. 29

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 alternating 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.

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 to minimize friction, which would be damaging to the blade. Refer back and follow the instructions for “blade clearance” before performing blade tracking adjustments.

To adjust the blade tracking:

1.

Open the upper wheel cover door then rotate the wheel slowly forward by hand. The blade should remain as centered 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 tilts the top of the wheel to the back and moves the blade toward the center.

B) Counter-clockwise 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.

20

Note: Turn the tracking knob in 1/2 turn increments, recheck and adjust again as needed.

Fig. 30 Fig. 31

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 workpiece to prevent the blade from flexing out of position or off-line during cutting.

Adjust the height of the blade guard to suit the thickness 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 turning the adjustment knob . Then re-tighten the lock knob .

Note: The depth gauge on the front of the blade guard can be used as a reference but it is not intended for high precision measurements.

workpiece

1/8” - 1/4”

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 1/32” 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 tracking properly. Adjust the upper and lower blade guides and thrust bearings after each blade tension and tracking adjustment. Whenever the 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 , toward the blade.

21

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 guides are at least 1/32” behind the blade teeth. (See Fig. 34) The guides must remain behind the blade teeth to prevent damage to the blade.

Fig. 32

6. Tighten the thumb screw to lock the guide bearing assembly in position.

Fig. 33

Adjust the positionning of the upper thrust bearing as follows:

1. Loosen the upper thumb screw . (Fig. 33)

2. Turn the micro adjust nut (Fig.32) to move the thrust bearing (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.

Fig. 35

1/64"

Fig. 34

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 guides along the elongated hole in the mounting bracket toward the blade. (Fig. 36)

22

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.

Fig. 36

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 provided.

5. Manually move the guide bearing mounting bracket in or out until the guides are at least 1/32” behind the blade teeth (see Fig. 38). The guides must remain behind the blade teeth to prevent damage to the blade.

Adjust the positionning of the lower thrust bearing as follows:

1. Loosen the upper set screw (Fig. 37).

2.

Manually move the thrust bearing in or out until the bearing is 1/64” behind the back edge of the blade, then retighten the set screw. (Fig. 37).

Fig. 37

1/64"

Fig. 38

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 power source to avoid unintentional start-up of the bandsaw.

2. Open the lower wheel cover door.

3. At the back of the bandsaw, just above the motor, there is a ratchet lever for loosening the tension on the drive belt. When you pull it out, as in Fig. 39 it disengages for resetting. 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).

Fig. 39

To loosen the drive belt, unscrew the bolt a few turns counterclockwise then pull up on the capacitor cover of the motor pivot the motor to the left (see Fig. 41). This loosens the belt enough to move it between one set of pulleys and the other.

Fig. 41

Fig. 40

23

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 motor capacitor cover to tighten the belt, then turn the ratchet lever clockwise until it is tight and the motor does not move.

Fig. 42 Fig. 43

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 to the bandsaw is made in the proper order starting with the general safety precaution:

1. Turn off the bandsaw and unplug the power cord.

2. Adjust blade tension.

3. Adjust blade tracking.

4. Adjust upper blade guides and thrust bearing.

5. Adjust lower blade guides and thrust bearing.

These additional safety measures should be be included in your checklist:

6. 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 vibration and normal wear and tear on the machine could throw these parts out of alignment.

24

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 connections 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 information on our complete line of dust collection systems and accessories or visit our Web Site at: www.general.ca.

OPERATIONS STEP-BY-STEP

To reduce the risk of damage to the bandsaw or the workpiece, as well as a 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 bandsaw are locked in place before starting the machine.

1.

Trace the cutting line on your workpiece with a pencil.

2. Set the height of the blade guard according to the thickness of your workpiece (see section: “Adjusting the blade guard for depth of cut” on page 20.)

3.

If a dust collector is connected to your bandsaw, turn it on.

Fig. 44

Make sure 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 cutting longer or wider workpieces, position the fence, on the right side of the saw blade.

2.

Adjust the positioning of the fence on the rail so that the distance from the inside face of the rip fence to the blade matches the required width of cut.

3.

Lock down the fence locking handle .

Make sure to lock the fence in place before starting to cut against the rip fence.

LOCK

25

USING THE MITER GAUGE

The miter gauge allows for easier and safer sawing by providing 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 counter-clockwise. Rotate the miter head to the required angle , shown on the angle indicator. Then turn the lock knob clockwise to tighten it.

CUTTING CURVES

• 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

1. Adjust the blade guard assembly to 1/8" above the workpiece.

2. Use both hands while feeding the work into the blade.

Hold the workpiece firmly against the table. Use gentle pressure. Do not force the work. Allow the blade to cut.

3. The smallest diameter circle that can be cut is determined by the width of the blade. For example, a 1/4" wide blade will cut a minimum diameter of approximately 1-1/2" .

MIN. CIRCLE

DIAM.

BLADE WIDTH

LUBRICATION

Disconnect machine from power source, before performing any lubrication or maintenance.

26

Keep the rack and pinion as well as the blade tension adjustment screw 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 needed. (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.

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. To 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 after-market 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 , using the 5 mm Allen key provided. Removing the two bolts will free the blade guides .

2. Replace the two blade guides with new ones and tighten with the two Allen bolts.

27

To replace the upper thrust bearing, proceed as follows:

1. Pull the tension lever up to loosen the blade.

SIDE VIEW

2. Unscrew the two Phillips head screws and remove the blade-guard .

REAR VIEW

3.

Loosen the upper thumb screw .

FRONT VIEW

Note: Hold the micro adjust nut while unscrewing the

Allen bolt.

4.

Unscrew the upper Allen bolt with the 3 mm Allen key provided.

5. Remove the thrust bearing and mounting shaft.

6. Use C-ring pliers to remove the "C ring" and slide the 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.

28

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.

REPLACING THE WHEEL TIRE

Wheel tires must be replaced if they get worn out or damaged. (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 tire.

ADJUSTING/REPLACING THE LOWER WHEEL BRUSH

The lo wer wheel is equipped with a cleaning brush that prevents pitch and sawdust build up on the lower tire.

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 normal 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

, 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 belt’s 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.

1. Turn off power and disconnect the bandsaw from the power source to avoid unintentional start-up.

2. Open the lower wheel cover door.

3. If needed, loosen the belt, proceeding as per step 3 in section “Changing speed settings”.

4.

Remove the belt from the groove in the pulleys and install a new one.

5.

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.

29

30

RECOMMENDED OPTIONAL ACCESSORIES FOR YOUR

BANDSAW

We offer a large variety of products to help you increase productivity, accuracy and safety 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.

* Fits model 90-125 General International bandsaw only.

MADE FROM HIGH

CARBON STEEL

FRONT

6” d

Blades

#90125-B14

1/4” - 6 TPI, blade thickness: 0.65 mm

#90125-B38


#90125-B12


#90125-B34


FRONT

6”

Riser Block Kit*

#90-130

Increases the vertical cutting capacity of your saw from 6 to 12 inches for increased re-sawing versatility. Kit includes all necessary hardware and a longer

3/8” wide blade to fit the increased height of the d

Roller Stand item #50-150 item #50-160 item #50-170

We offer a selection of roller stands to suit all your shop needs.

24” X 24” Bandsaw Table

#90-115

Quick clamping system for easy installation without damaging original table.

Includes 2 1/2” “T” style ripfence 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 prevents binding. / Removes and inhibits rust and corrosion. / Repels dust and moisture.

Mobile Base

#50-025

Easily roll your bandsaw anywhere in your shop.

Load capacity: 500 LBS.

Wheels lock when equipment is in use.

Dust Collectors and accessories

We offer a wide selection of dust collectors and accessories to suit virtually all your shop needs. Dust collectors contribute to a cleaner healthier workshop environment.

NOTES

31

32

FRAME ASSEMBLY

166

27

28

26

167

49

30 136A

160

29

19

108

24

25

115

117

161

162 2

163 2

110

116

109

OU T T

PU LL

OL

OC

22

23

20

165

2

164

2

21

121

122

120

119

118

157

158

159

154

150

169

152

151

148

156

51

52

53

2

135A

155

64

63

50

149

58

3

55

153

54

125

127

4

62

123

5

56

4

147

107

106

111

174

3

173

9

67

18

17

3

6

7

72

2

71

2

165

2

70

55

168

3

171

81

172

59

2

60

4

61

4

1A

8

146

4

145

139

143

38

131

132

103

104

105

133

92

94

93

10

8

9

114

113

112

95

96

11

WHEEL AND TABLE ASSEMBLY

34

31

32

3

81

3

39

3

40

4

41

4

42

137A

3

3

138A

36

37

38

57

58

76

78

75

2

77

2

69

134

65

2

66

9

67

85

84

2

2

83 2

78

77

6

6

86

87

68

74

85

84

83

82

79

9

80

67

2

130

12

13

89

90

44

43

12

88A

15

14

101

100

102

3

16

45

46

33

91

140

2

141

142

44

98

45

9

67

97

129

124

128A

35

47

48

33

34

PART N0. REF. N0.

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

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

90125-01A

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

45

46

47

48

41

42

43

44

37

38

39

40

33

34

35

36

49

50

51

52

53

54

29

30

31

32

25

26

27

28

21

22

23

24

17

18

19

20

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

PARTS LIST

90-125

DESCRIPTION

SAW BASE

UPPER ARM

STEEL PIN

HEX. HEAD BOLT

FLAT WASHER

LOCK WASHER

HEX. NUT

LOWER SHAFT

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 QTY

1/4 x 16mm

3/4 x 2 1/2

3/4

3/4

3/4

6204ZZ

5 x 5 x 60L

180-168

A-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

6202ZZ

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

5/16 x 1 1/4

1/4

5/16 x 5/16

16

12

3

1

1

12

3

3

3

3

2

2

1

2

1

1

1

1

1

1

1

1

2

2

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

2

1

1

2

1

1

1

2

1

4

1

1

1


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

90125-55

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

90125-88A

90125-89

90125-90

90125-91

90125-92

90125-93

90125-94

90125-95

90125-96

90125-97

90125-98

90125-102

96

97

98

102

90125-103

90125-104

103

104

90125-105 105

90125-106A 106A

92

93

94

95

88A

89

90

91

90125-107

90125-108

90125-109

90125-110

90125-111

90125-112

107

108

109

110

111

112

84

85

86

87

80

81

82

83

76

77

78

79

71

72

74

75

67

68

69

70

63

64

65

66

55

56

57

58

59N

60N

61N

62

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


M6 x 10L

6200ZZ

S-10

M6 x 16L

M6 x 45L

M6

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

5/16 x 3

5/16

5/16 x 1 1/4

MY-2000P

M5

3/8 x 19 x 2T

450

M10 x 50L

5/16

1/4 x 5/8

3 x 10L

3/16 x 3/8

3/16 x 3/8

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

2

1

1

2

1

3

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

6

6

2

2

1

2

1

3

2

1

1

2

1

1

2

2

1

1

9

1

1

2

2

2

4

1

2

4

2

3

3

1

35

36


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

90125-113

90125-114

90125-115

90125-116

90125-117

90125-118

90125-119

90125-120

90125-121

90125-122

90125-123

90125-124

121

122

123

124

90125-125

90125-126

125

126

90125-127 127

90125-128A 128A

113

114

115

116

117

118

119

120

90125-129

90125-130

90125-131

90125-132

129

130

131

132

90125-133

90125-134

133

134

90125-135A 135A

90125-136A 136A

90125-137A 137A

90125-138A 138A

90125-139

90125-140

139

140

90125-141

90125-142

141

142

90125-143N 143

90125-145 145

154

155

156

157

158

159

160

161

146

147

148

149

150

151

152

153

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

90º BLOWER ELBOW

BLOWER TUBE

STRAIN RELIEF

FLANGE SCREW

BASE CABINET

FLANGE SCREW

CHAIN

LOCK 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


M6 x 16L

1/2

4P

3/16 x 3/8

3/16 x 3/8

6N-4

M6 x 10L

5MM

M5

M5

3/16 x 1/4

3MM

M10

5/16 x 2"

5/16 x 23

5/16

1/8PT X 480L

ACC-2.5

3/16 x 3/8

3/16 x 1/4

1/4

1/4 x 1

5/16 x 16 x 1.5T

1/4 x 5.2T

15 x 66.15L

26 x 20T

15 x 34.5L

M6 x 12L

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

3/16 x 12 x 1

3/16 x 2-1/4

3/16x1/2

P3B

1

1

1

1

1

1

1

1

1

1

1

1

1

1

8

4

1

1

1

2

4

2

2

1

4

1

2

1

2

3

3

1

1

4

1

4

8

1

2

2

1

2

2

1

1

1

1

4

2

2

2

1

1

2

1


90125-169

90125-171

169

171

90125-172 172

90125-173N 173

90125-174

90125-200

174

200

PARTS LIST 90-125

DESCRIPTION

WAVE WASHER

RIGHT DUST COLLECTOR

LEFT DUST COLLECTOR

DUST CHUTE (4”)

FLANGE SCREW

COMBINATION WRENCH

NOTES


3/16” x 3/8”

10 MM

1

1

1

1

3

1

37

MOTOR

38

PART N0.

90125-106A-01

90125-106A-02

90125-106A-03

90125-106A-04

90125-106A-05

90125-106A-06

90125-106A-07

90125-106A-08

90125-106A-09

90125-106A-10

90125-106A-11

90125-106A-12

90125-106A-13

90125-106A-14

90125-106A-15

90125-106A-16

90125-106A-17N

90125-106A-18N

90125-106A-19

90125-106A-20

90125-106A-21

90125-106A-22

90125-106A-23

90125-106A-24

90125-106A-25

90125-106A-26

90125-106A-27

90125-106A-28

90125-106A-29

90125-106A-30

REF. N0.

25

26

27

28

29

30

21

22

23

24

17

18

19

20

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

PARTS LIST

90-125

DESCRIPTION

SHAFT

ROTOR

STATOR

COPPER WINDING

WIRE

BEARING

BEARING

MOTOR COVER(FRONT)

MOTOR COVER(REAR)

MOTOR HOUSING

CAPACITOR

CAPACITOR TUBE

CAPACITOR COVER

CENTRIFUGAL SWITCH SET

TERMINAL

STRAIN RELIEF

TUBE

TUBE

COVER (LOWER)

COVER (UPPER)

FLANGE SCREW

FLANGE SCREW

FLANGE SCREW

FLANGE SCREW

SPROCKET WASHER

COPPER WASHER

LOCK WASHER

HEX. NUT

POWER CORD (FEMALE)

WIRE

QTY

4

4

1

1

1

1

1

4

2

6

1

1

1

1

2

1

1

1

1

1

1

1

1

1

6

1

1

1

1

1

BLOWER DEVICE ASSEMBLY

PART N0.

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. N0.

9

10

11

12

13

14

15

7

8

5

6

3

4

1

2

PARTS LIST

90-125

DESCRIPTION

BLOWER FAN HOUSING

WASHER

BLOWER WHEEL

BLOWER PINS

BLOWER COVER

LOCK WASHER

SCREW

HOSE BARB

BLOWER HOSE

SPONGE

COVER

MOTOR FAN

MOTOR COVER

SCREW

FLANGE SCREW


147 x 13

176 x 88

1/4 x 3/8

3/16 x 3/8

1

1

3

1

1

1

1

3

2

1

3

1

3

1

3

39

MODEL 90-125 M1

8360 Champ-d’Eau, Montreal (Quebec) Canada H1P 1Y3

Tel.: (514) 326-1161

Fax: (514) 326-5565 - Parts & Service / Fax: (514) 326-5555 - Order Desk [email protected]

www.general.ca

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.

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