Lumberjack BS200 Installation manual

SAFETY AND OPERATING MANUAL
8” BAND SAW
BS200
ORIGINAL INSTRUCTIONS
BS200

TABLE OF CONTENTS
Welcome to Lumberjack!
Dear customer, Congratu n your purchase. Before using the
Product for the first me please be sure to read these instruc ons for use.
They provide you with all informa necessary for using the product safely and to
ensure its long service life.
Closely observe all safety informa on in these instruc
General Power Tool Safety Warnings………………………………….…......01
Symbols ……….…………………………….………………………………………………04
Specifica ons ……………………………………………………………………………..05
Assembly……………………………………………………………………………………..06
Features & Set up ………………………….…………….……………………………..08
Ope n & Maintenance.………………………………………………………… .11
Trouble sho ………………………………………………………………………16
Lumberjack Guarantee…………………………………………………………………17
De on of conformity……………………………………………………………19
Parts list……………………………………………………………………………………...20
Parts Diagram………………………………………………………………………………22
BS200

BS200
GENERAL POWER TOOL SAFETY WARNINGS
WARNING Read all safety warnings and
all instrucons. Failure to follow the warnings
and instrucons may result in electric shock, fire
and/or serious injury.
Save all warnings and instrucons for
future reference. The term "power tool" in
the warnings refers to your electric power tool.
1. Work area safety
a) Keep work area clean and well lit. Cluered
or dark areas invite accidents.
b) Do not operate power tools in explosive
atmospheres, such as in the presence of
flammable liquids, gases or dust. Power tools
create sparks which may ignite the dust or
fumes.
c) Keep children and bystanders away while
operang a power tool. Distracons can cause
you to lose control.
2. Electrical safety
a) Power tool plugs must match the outlet.
Never modify the plug in any way. Do not use
any adapter plugs with grounded power tools.
Unmodified plugs and matching outlets will
reduce risk of electric shock.
b) Avoid body contact with grounded surfaces,
such as pipes, radiators, ranges and
refrigerators.There is an increased risk of
electric shock if your body is grounded.
c) Do not expose power tools to rain or wet
condions. Water entering a power tool will
increase the risk of electric shock.
d) Do not abuse the cord. Never use the cord for
carrying, pulling or unplugging the power tool.
Keep cord away from heat, oil, sharp edges or
movingparts. Damaged or entangled cords
increase the risk of electric shock.
e) When operang a power tool outdoors, use an
extension cord suitable for outdoor use. Use of a
cord suitable for outdoor use reduces the risk of
electric shock.
f) If operang a power tool in a damp locaon is
unavoidable, use a residual current device (RCD)
protected supply. Use of an RCD reduces the risk
of electric shock.
3. Personal safety
a) Stay alert, watch what you are doing and use
common sense when operang a power tool. Do
not use a power tool while you are red or under
the influence of drugs, alcohol or medicaon. A
moment of inaenon while operang power
tools may result in serious personal injury.
b) Use personal protecve equipment. Always
wear eye protecon. Protecve equipment such
as dust mask, non-skid safety shoes, hard hat, or
hearing protecon used for appropriate condions
will reduce personal injuries.
c) Prevent unintenonal starng. Ensure the
switch is in the offposion before connecng to
power source and/or baery pack, picking up or
carrying the tool. Carrying power tools with your
finger on the switch or energising power tools that
have the switch on invites accidents.
d) Remove any adjusng key or wrench before
turning the power tool on. A wrench or a key le
aached to a rotang part of the power tool may
result in personal injury.
01

GENERAL POWER TOOL SAFETY WARNINGS
e) Do not overreach. Keep proper foong and
balance at all mes. This enables better control
of the power tool in unexpected situaons.
f) Dress properly. Do not wear loose clothing or
jewellery. Keep your hair, clothing and gloves
away from movingparts. Loose clothes,
jewellery or long hair can be caught in moving
parts.
g) If devices are provided for the connecon of
dust extracon and collecon facilies, ensure
these are connected and properly used. Use of
dust collecon can reduce dust-related hazards.
4. Power tool use and care
a) Do not force the power tool. Use the correct
power tool for your applicaon. The correct
power tool will do the job beer and safer at the
rate for which it was designed.
b) Do not use the power tool if the switch does
not turn it on and off.Any power tool that
cannot be controlled with the switch is
dangerous and must be repaired.
c) Disconnect the plug from the power source
and/or the baery pack from the power tool
before making any adjustments, changing
accessories, or storing power tools. Such
prevenve safety measures reduce the risk of
starng the power tool accidentally.
d) Store idle power tools out of the reach of
children and do not allow persons unfamiliar
with the power tool or these instrucons to
operate the power tool.Power tools are
dangerous in the hands of untrained users.
e) Maintain power tools. Check for misalignment
or binding of moving parts, breakage of parts and
any other condion that may affect the power
tool’s operaon. If damaged, have the power tool
repaired before use. Many accidents are caused
by poorly maintained power tools.
f) Keep cung tools sharp and clean. Properly
maintained cung tools with sharp cung edges
are less likely to bind and are easier
g) Use the power tool, accessories and tool bits
etc. in accordance with these instrucons, taking
into account the working condions and the work
to be performed. Use of the power tool for
operaons different from those intended could
result in a hazardous situaon.
5. Service
a) Have your power tool serviced by a qualified
repair person using only idencal replacement
parts. This will ensure that the safety of the power
tool is maintained.
b) If the replacement of the supply cord is
necessary, this has to be done by the
manufacturer or its agent in order to avoid a
safety hazard.
BS20002

BS200
GENERAL POWER TOOL SAFETY WARNINGS
6. Addional Safety and working
Instrucons
6.1. Dust from materials such as lead-containing
coangs, some wood types, minerals and
metals can be harmful toone’s health and
cause allergic reacons, leading torespiratory
infecons and/or cancer. Materials containing
asbestos may only be worked by specialists.
Observe the relevant regulaons in your country
for the materials to be worked.
6.2. Prevent dust accumulaon at the
workplace. Dust can easily ignite.
7 Addional Safety Warning for Band
Saws
7.1 Never stand on the power tool. Serious
injuries can occur when the power tool ps
over or when inadvertently coming into
contact with the saw blade.
7.2 Never remove cung remainders, wood
chips, etc. from the sawing area while the
machine is running.
7.3 Keep handles dry, clean and free from oil
and grease. Greasy, oily handles are slippery
causing loss of control.
7.4 Operate the power tool only when the work
area to the work piece is clear of any adjusng
tools, wood chips, etc. Small pieces of wood or
other objects that comein contactwith the
rotang saw blade can strike the operator with
high speed.
7.5 Keep the floor free of wood chips and
material remainders. You could slip or trip.
7.6 Use the machine only for cung the
materials listed under Intended Use.
Otherwise, the machine can be subject to
overload.
7.7 Donot touch the saw blade aer working
before it has cooled. The saw blade becomes
very hot whileworking.
7.8 Check the cable regularly and have a
damaged cable repaired only through an
authorised customer service agent. Replace
damaged extension cables. This will ensure that
the safety of the power tool is maintained.
7.9 Store the machine in a safe manner when
not being used. The storage locaon must be
dry and lockable. This prevents the machine
from storage damage and from being operated
by untrained persons.
03

GENERAL POWER TOOL SAFETY WARNINGS / SYMBOLS
7.10 Never leave the machine before it has
come to a complete stop. Cung tools that
are sll running can cause injuries.
7.11 Never use the machine with a damaged
cable. Do not touch the damaged cable and
pull the mains plug when the cable is
damaged while working. Damaged cables
increase the risk of an electric shock.
Cauon! Wear ear-muffs.
Cauon! Wear safety goggles.
Cauon! Wear a breathing mask.
Cauon! Risk of injury!
Read these instrucons for use
carefully.
The
impact of noise can causedamage
to hearing.
Sparks generated during working
or splinters, chips and dust
emied by the device can cause
loss of sight.
Wear protecve gloves.
Dust which is injurious to health
can be generated when working
on wood and other materials.
Never use the device to work on
anymaterials containing asbestos!
Failure
tokeep your hands away from
the blade will result in serious
personal injury.
The machine must be
disconnected from the supply
before maintenance! Disconnect
the mains plug prior to the repair,
cleaning, and maintenance of
the saw!
Keep children and bystanders off
and away.
BS20004

BS200
SPECIFICATION
Machine Details
AC Motor 230-240V 50Hz, n0
1487 min-1
Power P (S2 15min)*250W
Lamp 6.4V DC, 1W
Protection Category IP 20
SafetyClass I
Throat Capacity 195 mm
Max. Cutting Height
80 mm @ 90°
45 mm @ 45°
Blade Wheel Dia. 205 mm
Blade Length 1400 mm
Blade Width: 3.5-12 mm
Cutting Speed 950 m/min
Table Size 302×304 mm
Table Tilt 90° - 45°
Weight 17.5 kg
*S2, Short-time duty. After continuous operation of
15 minutes the machine stops until the device tem-
perature deviates by less than 2 K (2°C) from the room
temperature.
Sound pressure level(LpA)82.6 db(A)* k=3 db(A)
Sound power level(LwA)93.6 db(A)* k=3 db(A)
*The noise was measured according to EN 61029-2-
5:2011+A11.
ENVIRONMENTAL
CONTENTS SUPPLIED
Recycle unwanted materials instead
of disposing of them as waste. All
tools, hoses and packaging should
be resorted, taken to the local
recycling center and disposed of in
an environmentally safe way.
1. Main Machine
2. Push Stick
3. Work Table
4. Rip Fence
5. Table Insert
6. Operator’s Manual
7. Allen Key, 4mm
8. Allen Key, 3mm
9. Blade Key
10. Hardware Bag
The band saw comes partially assembled and is
shipped in carefully packed carton. After all the
parts have been removed from the carton, you
should have:
4
1
3
2
5
6
7
8
10
A
B
9
05

ASSEMBLY
This band saw was partially assembled at the
factory. To assemble your machine follow the
below instructions.
Work Table
1. Remove the two screws, two knurled nuts
and U shape block from the work table.
2. Guide work table over the blade and place
it on the table trunnion. Positon the table
insert on the work table properly.
3. Attach the work table with three each
screws M6×16 to the table trunnion.
4. Fasten the work table with three nuts M6
and three flat washers.
5. Attach two screws and two knurled nuts
with U shape block that were removed in
step one and fasten.
ASSEMBLY
1
2
Work Table
Table Insert
3
TOP
VIEW
BOTTOM
VIEW
Work Table
M6 ×16 (×3)
Bench Angle Gauge
M6 Nut (×3)
M6 ×16 ×3 A
BS20006

BS200
ASSEMBLY
Locker
Push Stick
1. Fix the screw and nuts on the machine,
leaving room for push stick.
2. Hang the push stick on the screw.
Rip Fence
Clamp the rip fence. It can be used on both
sides of blade.
M6 ×35 (×1)
M6 Nut (×1)
M6 ×35 ×1 B
07

FEATURES & SET UP
KNOW YOUR MACHINE
Features and Controls
Rip Fence
Setting Knob for Work Table
ON/OFF Switch
Blade
Locking Knob for Blade Guard
Lower Housing Door
Suction Connector
Upper Housing Door
Setting Knob for Blade Tension
Setting Knob for Blade Guard
Work Table
Motor
Door Lock
Door Lock
Power Cord and Plug
Push Stick
Setting Knob for Blade Tracking
Adjustment
Lamp (65160A Only)
BS20008

BS200
FEATURES & SET UP
Set Up
Adjusting the Blade Tension
This tracking adjustment is required to have
the blade run dead center on the rubber tyres
of the band saw wheels:
●Turning the setting knob clockwise increases
the blade tension.
●Turning the setting knob counter- clockwise
reduces the blade tension.
Adjusting the Work Table Tilting
After loosening both locking screws, the work
table tilts steplessly through 45° to the blade.
Work Table Alignment
Saw Table Lateral Alignment
1. Loosen the three fastening screws that hold
the lower table trunnion.
2. Align working table so that the blade runs
through the centre of the table insert’s slot.
3. Tighten the three fastening screws again.
Working Table
Angle Scale
Limit Stop
Screw
Pointer
Locking Screw Min: 0°
Max: 45°
09

FEATURES & SET UP
Aligning the work table at right angles to the
blade
1. Raise upper blade guide fully. Check band
saw blade tension.
Setting Up the Rip Fence
The rip fence is clamped to the front. It can be
used on both sides of the blade.
2. Loosen locking screws.
3. Using a try square, set the table at right
angles to the blade and tighten the locking
screws again.
4. Loosen locking nut and adjust limit stop
screw until it touches the working table.
5. Tighten locking nut.
Work Table
Limit Stop Screw
Locking Nut
Try Square
Adjusting the Blade Guard
The blade guard protects against unintentional
contact with the saw blade and from chips
flying about. In order for the upper blade guard
to provide adequate protection against contact
with the band saw blade, it must always be
set as close as possible against the workpiece
(max. distance 3 mm).
1. Loosen the locking knob.
2. Rotate the setting knob to adjust the blade
guard in the right position, then fasten the
locking knob.
1
3
2
Locking Knob
3 mm
Setting
Knob
BS20010

BS200
OPERATION & MAINTENANCE AND SERVICE
Operation
Start the saw only after the following
preparations are completed:
●The saw is fastened;
●The saw table is installed and aligned;
●
Safety devices have been checked.
Connect the saw to the mains supply
onlyafterall of theabove preparations
are completed! Otherwise there is
a risk of an unintentional starting
of the saw, which can cause severe
personal injury.
Mounting the saw in the stable and flat
supporting surface
1. Drill 4 holes in the supporting surface.
2. Put fixing bolts through the base plate and
secure with nuts.
Supporting Surface
Base Plate
305mm
305mm
220mm
220mm
M6-Bolt (×4)
Ø6.5mm
diameter
hole (×4)
ON/OFF Switch
The saw can be switched on by pressing the
green pushbutton.
The red pushbutton has to be pressed to switch
off the machine.
Danger by jamming workpiece!
When using the rip fence with a
tilted saw table, the rip fence must
be installed on the lower side of the
working table.
Green “I” button
Red “O” button
Alwaysmake atrial cut in apiece
of scrap to verify settings; correct
if necessary before cutting the
workpiece.
Machine has suction connector,
user can connect the machine to a
proper suction unit when working.
11

OPERATION & MAINTENANCE AND SERVICE
Warning! Prior to any adjustment,
m a intenance or service w ork
disconnect the mains power plug!
Danger! Risk of injury, even with the
band saw blade at standstill. Wear
gloves when changing blades.
General Maintenance Measures
Keep all safety devices, air vents and the
motor housing free of dirt and dust as far as
possible. Wipe the equipment with a clean
cloth or blow it with compressed air at low
pressure.
We recommend that you clean the device
immediately each time you have finished using
it.
Clean the equipment regularly with a damp
cloth and some soft soap. Do not use cleaning
agents or solvents; these could attack the
plastic parts of the equipment. Ensure that no
water can seep into the device. The ingress of
water into an electric tool increases the risk of
an electric shock.
In order to extend the service life of the tool,
oil the rotary parts once monthly. Do not oil
the motor.
Use only suitable band saw blades.
1. Loosen the 2 knurled screws and remove
the U shape blocker.
2. Open both housing doors.
3.
Loosen setting knob until the band saw
blade has slackened.
4. To remove the band saw blade, guide it
through the slot in the working table.
5. Fit fresh band saw blade. Ensure correct
position: the teeth must point towards the
front of the saw (where the doors are).
6. Center band saw blade on the rubber tyres
of the band saw wheels.
Saw Blade Change
MAINTENANCE
1M6 ×16 (×2)
2
7. Tighten setting knob until blade does no
longer slip off the band saw wheels.
8. Close both housing doors.
9. Tension band saw blade;
Align band saw blade and align blade guides;
let saw test run for at least one minute;
Stop saw, unplug and recheck settings.
BS20012

BS200
OPERATION & MAINTENANCE AND SERVICE
3
4
Adjusting the Blade Tension
This tracking adjustment is required to have
the blade run dead center on the rubber tyres
of the band saw wheels:
●Turning the setting knob clockwise increases
the blade tension.
●Turning the setting knob counter - clockwise
reduces the blade tension.
Band Saw Blade Alignment
If the band saw blade does not run in the centre
of the rubber tyres, the tracking needs to be
corrected by adjusting the tilt of the upper
band saw wheel:
1. Loosen locking nut.
2. Turn setting knob:
●Turn setting knob clockwise if the band saw
blade runs towards the front of the saw.
●Turn setting knob counter- clockwise if the
band saw blade runs towards the rear of the
saw.
3. Tighten locking nut.
13

OPERATION & MAINTENANCE AND SERVICE
1 3
2
Upper Blade Guide Alignment
The upper blade guide consists of:
●a thrust bearing (supports the band saw
blade from the rear),
●two guide pins (providing lateral support).
The bearing and guide pins need to be
readjusted after every band saw blade change
or tracking.
Thrust bearing adjustment
1. If necessary, align and tighten the band saw
blade.
2. Loosen the thrust bearing’s locking screw.
3. Adjust thrust bearing position (distance
thrust bearing - band saw blade = 0.5 mm
- if the band saw blade is turned by hand, it
shall not touch the thrust bearing.
NOTE: Periodically check all bearings
for wear, if necessary replace both
guide bearings at the same time.
0.5 mm 0.5 mm
Lower Blade Guide Alignment
The lower blade guide consists of:
●a thrust bearing (supports the band saw
blade from the rear),
●two guide pins (providing lateral support).
Guide pin adjustment
1. Loosen screws.
2. Press guide pins together, keep 0.5 mm
distance between guide pin and the saw
blade.
3. Tighten screws again.
4. Tighten the thrust bearing locking screw.
NOTE: Periodically check thrust
bearings and guide pins for wear, if
necessary replace both guide pins
at the same time.
BS20014

BS200
OPERATION & MAINTENANCE AND SERVICE
0.5 mm 0.5 mm
Table Insert
Table Insert Replacement
The table insert needs replacement when its
slot has become enlarged or damaged.
1. Remove table insert from saw table (push
up from underneath).
2. Fit new table insert.
Thrust bearing adjustment
1. Loosen the two screws and remove the
under blocks.
2. Loosen the three screws and Remove the
working table from the table trunnion .
3. Loosen the two knobs and remove the
bench angle gauge.
4. Open the lower housing door.
5. Raise upper blade guide fully.
6. If necessary, align and tighten the band saw
blade.
7. Loosen the thrust bearing's locking screw.
8. Adjust thrust bearing position (distance
thrust bearing - band saw blade = 0.5 mm
- if the band saw blade is turned by hand, it
shall not touch the thrust bearing.
Guide pin adjustment
1. Loosen screws.
2. Press guide pins together, keep 0.5 mm
distance between guide pin and the saw
blade.
3. Tighten screws again.
4. Attach the working table to the table
trunnion.
5. Fit the U shape under block to the working
table.
9. Tighten the thrust bearing locking screw.
Bench Angle Gauge
15

TROUBLESHOOTING
TROUBLE SHOOTING
Problem Cause Remedy
Motor does not
work
1. Motor, cable or plug defective,
fuses burnt
2. Housing cover open (limit
switch)
1. Arrange for inspection of the
machine by a specialist. Neverrepair
the motor yourself. Danger! Check
fuses and replace as necessary
2. Close housing cover exactly
The motor starts
up slowly and does
not reach operating
speed
Voltage too low, coils damaged,
capacitor burnt
Contact the utility provider to check
the voltage
Arrange for inspection of the motor by
a specialist
Arrange for replacement of the
capacitor by a specialist
Motor makes
excessive noise Coils damaged, motor defective Arrange for inspection of the motor by a specialist
The motor does not
reach its full power
Circuits in the network are
overloaded (lamps, other motors,
etc.)
Do not use any other equipment or
motors on the same circuit
Motor overheats
easily
Overloading of the motor,
insufficient coolinof the motor
Avoid overloading the motor while
cutting, remove dust from the motor in
order to ensure optimal cooling of the
motor
Saw cut is rough
orwavy
Saw blade dull, tooth shape
not appropriate forthe material
thickness
Resharpen saw blade and/or use
suitable saw blade
Workpiece pulls
awayand/or
splinters
Excessive cutting pressure and/
or saw bladenot suitable for use Insert suitable saw blade
Saw blade is not
running straight
1. Guide has been wrongly set
2. Wrong saw blade
1. Set the saw blade guide according
to the operating instructions
2. Select a saw blade according to the
operating instructions
Burn marks appear
on the wood during
the cutting work
1. Blunt saw blade
2. Wrong saw blade
1. Change the saw blade
2. Select a saw blade according to the
operating instructions
Saw blade jams
during cutting work
1. Blunt saw blade
2. Deposits on the saw blade
3. Guide has been set poorly
1. Change the saw blade
2. Clean the saw blade
3. Set the saw blade guide according
to the operating instructions
BS20016

BS200
LUMBERJACK GUARANTEE
1. Guarantee
1.1 Lumberjack guarantees that for a
period of 12 months from the date of
purchase the components of
qualifying products (see clauses 1.2.1
to 1.2.8) will be free from defects
caused by faulty construcon or
manufacture
1.2 During this period, Lumberjack, will
repair or replace free of charge any
parts which are proved to be faulty
in accordance with paragraph 1.1
providing that:
1.2.1 You follow the claims procedure
set out in clause 2.
1.2.2 Lumberjack and its Authorised
Dealers are given reasonable
opportunity aer receiving noce
of the claim to examine the
product.
1.2.3 If asked to do so by lumberjack or
its Authorised Dealer, you return
the product at your own cost to
Lumberjack’s or the supplying
Authorised Dealer’s Premises -
For the examinaon to take place clearly
stang the Returns Material Authorisaon
Number given.
1.2.4 The fault in queson is not caused by
industrial use, accidental damage, fair wear
and tear, wilful damage, neglect, incorrect
electrical connecon, misuse, alteraon or
repair of the product without approval.
1.2.5 The product has been used in a
domesc environment only.
1.2.6 The fault does not relate to
consumable items such as blades, bearings,
drive belts or other wearing parts which
can reasonably be expected to wear at
different rates depending on usage.
1.2.7 The product has not been used for
hire purposes.
1.2.8 The product has been purchased by
you, as the guarantee is not transferable
from a private sale.
17

LUMBERJACK GUARANTEE
2. Claims Procedure
2.1 In the first instance please contact the
Authorised Dealerwho supplied the product to
you. In ourexperience many inial problems
with machines that arethought to be fault due
to faulty partsare actually solved by correct
seng up oradjustment of the machine. A good
Authorised Dealershould be able to resolve the
majority of these issues much more quickly than
processing a claim underthe guarantee. If a
return isrequested by the Authorised Dealer or
Lumberjack, you will be provided with a Returns
Material Authorisaon Numberwhich must be
clearly stated on the returned package, and any
accompanying correspondence. Failure to
provide a ReturnsMaterial Authorisaon
Number may result in item being refused
delivery.
2.2 Any issues with the product resulng in a
potenal claim underthe guarantee must be
reported to the Authorised Dealerfrom which it
was purchased within 48 hours of receipt.
2.3 If the authorised Dealer who supplied the
product to you has been unable to sasfy your
query, any claims made under this guarantee
should be made directly to Lumberjack. The
claim itself should be made in a leerseng out
the date and place of purchase, giving a brief
explanaon of the problem which has led to the
claim.
2.4 Please note that it is essenal that the leer of
claim reachesLumberjack on the last day of this
guarantee at the latest. Late claimswill not be
considered.
3. Limitaon of Liability.
3.1 We only supply productsfordomesc and
private use. You agree not to use the product for
any commercial, business orresale purposes and
we have no liability to you forany loss of profit,
loss of business, business interrupon orloss of
business opportunity.
3.2 This guarantee doesnot confer any rights
otherthan these expressly set out above and does
not cover any claims forconsequenal loss or
damage. This guarantee isoffered as an extra
benefit and does not affect yourstatutory rights
as a consumer.
4. Noce
This guarantee applies to all product purchased
from an Authorised Dealer of Lumberjack within
the United Kingdom. Terms of guarantee may vary
in othercountries
BS20018