Wen 20496 User manual
20VCORDLESS
PORTABLE BAND SAW
Instruction Manual
IMPORTANT: Your new tool has been engineered and manufactured to WEN’s highest standards for dependability,
ease of operation, and operator safety. When properly cared for, this product will supply you years of rugged,
trouble-free performance. Pay close attention to the rules for safe operation, warnings, and cautions. If you use
your tool properly and for its intended purpose, you will enjoy years of safe, reliable service.
NEED HELP? CONTACT US!
Have product questions? Need technical support? Please feel free to contact us:
For replacement parts and the most up-to-date instruction manuals, visit WENPRODUCTS.COM
MODEL 20496
2
CONTENTS
WELCOME 3
Introduction ..................................................................................................... 3
Specifications................................................................................................... 3
BEFORE OPERATING 11
Unpacking & Packing List...............................................................................11
Know Your Portable Band Saw....................................................................... 12
Assembly & Adjustments............................................................................... 13
OPERATION & MAINTENANCE 15
Operation ....................................................................................................... 15
Maintenance....................................................................................................16
Exploded View & Parts List.............................................................................17
Warranty Statement ........................................................................................20
SAFETY 4
General Safety Rules........................................................................................ 4
Portable Band Saw Safety Warnings................................................................ 6
Electrical Information....................................................................................... 8
Battery & Charger Safety Warnings ................................................................. 9
To purchase accessories and replacement parts for your tool, visit WENPRODUCTS.COM
Replacement Saw Blade (Model 94396B)
44.8-Inch Metal Bandsaw Blade (Model BB4550)
20V Charger (Model 20200C)
20V Max Li-Ion 4Ah Battery (Model 20204)
20V Max Li-Ion 5Ah Battery (Model 20205)
3
SPECIFICATIONS
INTRODUCTION
Thanks for purchasing the WEN Portable Band Saw. We know you are excited to put your tool to work, but first,
please take a moment to read through the manual. Safe operation of this tool requires that you read and understand
this operator’s manual and all the labels affixed to the tool. This manual provides information regarding potential
safety concerns, as well as helpful assembly and operating instructions for your tool.
NOTE: The following safety information is not meant to cover all possible conditions and situations that may occur.
WEN reserves the right to change this product and specifications at any time without prior notice.
At WEN, we are continuously improving our products. If you find that your tool does not exactly match this manual,
please visit wenproducts.com for the most up-to-date manual or contact our customer service at 1-800-232-1195.
Keep this manual available to all users during the entire life of the tool and review it frequently to maximize
safety for both yourself and others.
Indicates danger, warning, or caution. The safety symbols and the explanations with them deserve your
careful attention and understanding. Always follow the safety precautions to reduce the risk of fire, electric shock
or personal injury. However, please note that these instructions and warnings are not substitutes for proper ac-
cident prevention measures.
Model Number 20496
Included Battery 5.0Ah Battery (Model 20205)
Included Charger 20V, 2A DC (Model 20200C)
Motor 20V DC
Blade Speed 150 - 400 FPM
Blade Dimensions 44-7/8" x 1/2" x 0.025", 10/14 TPI
Cutting Capacity 5" x 5"
Product Dimensions 20" x 11-1/2" x 6-1/2"
Product Weight 12.6 Pounds
Battery Models All WEN 20V MAX Batteries*
Charger Models All WEN 20V MAX Chargers
*NOTE: Some tools may not be compatible with WEN 20V MAX 1.5Ah Batteries, model
49120B. Contact WEN customer service at 1-800-232-1195, M-F with questions.
WEN plans to continue to add more items to our 20V line. For an up-to-date list of the 20V cordless tools compatible
with the included battery and charger, visit wenproducts.com and search model number 20202 (2Ah), 20204 (4Ah)
or 20205 (5Ah). In the battery’s description, there will be a list of current products that this battery can be used with.
4
GENERAL SAFETY RULES
WORK AREA SAFETY
1. Keep work area clean and well lit. Cluttered or dark
areas invite accidents.
2. Do not operate power tools in explosive atmo-
spheres, such as in the presence of flammable liquids,
gases or dust. Power tools create sparks which may ig-
nite the dust or fumes.
3. Keep children and bystanders away while operating
a power tool. Distractions can cause you to lose control.
ELECTRICAL SAFETY
1. Power tool plugs must match the outlet. Never mod-
ify the plug in any way. Do not use any adapter plugs
with earthed (grounded) power tools. Unmodified plugs
and matching outlets will reduce risk of electric shock.
2. Avoid body contact with earthed or grounded surfac-
es such as pipes, radiators, ranges and refrigerators.
There is an increased risk of electric shock if your body
is earthed or grounded.
3. Do not expose power tools to rain or wet conditions.
Water entering a power tool will increase the risk of elec-
tric shock.
4. Do not abuse the cord. Never use the cord for car-
rying, pulling or unplugging the power tool. Keep cord
away from heat, oil, sharp edges or moving parts.
Damaged or entangled cords increase the risk of electric
shock.
5. When operating a power tool outdoors, use an ex-
tension cord suitable for outdoor use. Use of a cord
suitable for outdoor use reduces the risk of electric
shock.
6. If operating a power tool in a damp location is un-
avoidable, use a ground fault circuit interrupter (GFCI)
protected supply. Use of a GFCI reduces the risk of elec-
tric shock.
PERSONAL SAFETY
1. Stay alert, watch what you are doing and use com-
mon sense when operating a power tool. Do not use a
power tool while you are tired or under the influence
of drugs, alcohol or medication. A moment of inatten-
tion while operating power tools may result in serious
personal injury.
2. Use personal protective equipment. Always wear
eye protection. Protective equipment such as a respira-
tory mask, non-skid safety shoes and hearing protection
used for appropriate conditions will reduce the risk of
personal injury.
3. Prevent unintentional starting. Ensure the switch is
in the off-position before connecting to power source
and/or battery pack, picking up or carrying the tool.
Carrying power tools with your finger on the switch or
energizing power tools that have the switch on invites
accidents.
4. Remove any adjusting key or wrench before turning
the power tool on. A wrench or a key left attached to a
rotating part of the power tool may result in personal
injury.
5. Do not overreach. Keep proper footing and balance
at all times. This enables better control of the power
tool in unexpected situations.
6. Dress properly. Do not wear loose clothing or jew-
elry. Keep your hair and clothing away from moving
parts. Loose clothes, jewelry or long hair can be caught
in moving parts.
Safety is a combination of common sense, staying alert and knowing how your item works. The term “power tool”
in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.
SAVE THESE SAFETY INSTRUCTIONS.
WARNING! Read all safety warnings and all instructions. Failure to follow the warnings and instructions may
result in electric shock, fire and/or serious injury.
5
GENERAL SAFETY RULES
7. If devices are provided for the connection of dust
extraction and collection facilities, ensure these are
connected and properly used. Use of dust collection
can reduce dust-related hazards.
POWER TOOL USE AND CARE
1. Do not force the power tool. Use the correct power
tool for your application. The correct power tool will
do the job better and safer at the rate for which it was
designed.
2. 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.
3. Disconnect the plug from the power source and/or
the battery pack from the power tool before making
any adjustments, changing accessories, or storing
power tools. Such preventive safety measures reduce
the risk of starting the power tool accidentally.
4. Store idle power tools out of the reach of children
and do not allow persons unfamiliar with the power
tool or these instructions to operate the power tool.
Power tools are dangerous in the hands of untrained us-
ers.
5. Maintain power tools. Check for misalignment or
binding of moving parts, breakage of parts and any
other condition that may affect the power tool’s opera-
tion. If damaged, have the power tool repaired before
use. Many accidents are caused by poorly maintained
power tools.
6. Keep cutting tools sharp and clean. Properly main-
tained cutting tools with sharp cutting edges are less
likely to bind and are easier to control.
7. Use the power tool, accessories and tool bits, etc.
in accordance with these instructions, taking into ac-
count the working conditions and the work to be per-
formed. Use of the power tool for operations different
from those intended could result in a hazardous situa-
tion.
8. Use clamps to secure your workpiece to a stable
surface. Holding a workpiece by hand or using your
body to support it may lead to loss of control.
9. KEEP GUARDS IN PLACE and in working order.
SERVICE
1. Have your power tool serviced by a qualified repair
person using only identical replacement parts. This
will ensure that the safety of the power tool is main-
tained.
CALIFORNIA PROPOSITION 65 WARNING
Some dust created by power sanding, sawing, grinding,
drilling, and other construction activities may contain
chemicals, including lead, known to the State of Califor-
nia to cause cancer, birth defects, or other reproductive
harm. Wash hands after handling. Some examples of
these chemicals are:
• Lead from lead-based paints.
• Crystalline silica from bricks, cement, and other
masonry products.
• Arsenic and chromium from chemically treated
lumber.
Your risk from these exposures varies depending on
how often you do this type of work. To reduce your ex-
posure to these chemicals, work in a well-ventilated area
with approved safety equipment such as dust masks
specially designed to filter out microscopic particles.
Safety is a combination of common sense, staying alert and knowing how your item works. The term “power tool”
in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.
SAVE THESE SAFETY INSTRUCTIONS.
WARNING! Read all safety warnings and all instructions. Failure to follow the warnings and instructions may
result in electric shock, fire and/or serious injury.
6
PORTABLE BAND SAW SAFETY WARNINGS
WARNING! Do not operate the power tool until you have read and understood the following instructions and
the warning labels.
PORTABLE BAND SAW SAFETY
1. Work Environment. Do not operate the tool in wet
or damp conditions; doing so significantly increases the
risk of electrical shock. Do not operate the tool in the
presence of flammable liquids or gases; sparks generat-
ed by the grinder could ignite these flammable materials.
2. Preventing Electric Shock. Hold power tool by insu-
lated gripping surfaces, when performing an operation
where the cutting accessory may contact hidden wiring
or its own cord. Cutting accessories contacting a “live”
wire may make exposed metal parts of the power tool
“live” and could give the operator an electric shock.
3. Personal Safety. Tie back long hair. Do not wear
loose clothing or jewelry as they might get drawn in by
the tool. Always wear ANSI Z87.1-approved glasses with
side shields, hearing protection and a dust mask when
using the tool.
4. Dust Protection. Wear a dust mask and work with a
dust extraction device. Dust from material such as paint
containing lead, some wood species, minerals and metal
may be harmful (contact with or inhalation of the dust
may cause allergic reactions and/or respiratory diseases
to the operator or bystanders); certain kinds of dust are
classified as carcinogenic (such as oak and beech dust)
especially in conjunction with additives for wood condi-
tioning.
5. Saw Blade Safety. Use the correct size and style of
blade. Inspect blades for cracks and missing teeth be-
fore each use. Do not operate with dull, cracked or badly
worn blade. When replacing blades, make sure the blade
is installed in the correct direction, according to the
markings on the blade and on the band saw. Check that
the blade is properly tensioned (blade tensioning handle
tightened down) before operating.
6. Workpiece Safety. Workpieces should be securely
fastened down so they don’t twist, rock, or slip while be-
ing cut. Small pieces should be secured with clamps or
fixtures. Do not hold small pieces with your hand. Work
slowly and carefully when cutting corners, sharp edges,
ragged welds, and etc. to avoid snagging.
7. Starting The Tool. Hold the tool firmly with both
hands to resist starting torque. Turn on the tool and let
the blade come to full speed before contacting the work-
piece.
8. During Operation. To prevent personal injury, main-
tain a firm grip on the tool with both hands and keep the
tool away from your body. Keep hands, hair and other
beloved body parts away from the blade. Do not run the
tool while carrying it at your side. Never leave the band
saw unattended while it is running.
9. Prevent Burning. Cutting material and the motor
housing can get very hot during operation. Do not touch
the workpiece, saw blade or motor housing immediately
after operation.
10. Turning Off The Tool. Lift the tool from the work-
piece before turning the machine off. Do not put the saw
down until the blade comes to a complete stop. Turn off
the tool, and unplug it from its electrical outlet before
leaving.
11. Maintaining And Making Adjustments. Always turn
off and unplug the tool before cleaning, making adjust-
ments or changing attachments. Accidental start-ups
may occur if the tool is plugged in during an accessory
change or adjustment.
7
PORTABLE BAND SAW SAFETY WARNINGS
WARNING! Do not operate the power tool until you have read and understood the following instructions and
the warning labels.
KICKBACK AND RELATED WARNINGS
Kickback is a sudden reaction to a pinched or snagged
rotating wheel, backing pad, brush or any other acces-
sory. Pinching or snagging causes rapid stalling of the
blade which in turn causes the uncontrolled power tool
to be forced in the direction opposite of the accessory’s
rotation at the point of the binding. Kickback is the result
of power tool misuse and/or incorrect operating proce-
dures or conditions and can be avoided by taking proper
precautions as given below.
1. Maintain a firm grip on the power tool and position
your body and arm to allow you to resist kickback forces.
Always use auxiliary handle, if provided, for maximum
control over kickback or torque reaction during start-up.
The operator can control torque reactions or kickback
forces, if proper precautions are taken.
2. Never place your hand near the blade. The accessory
may kick back over your hand.
3. Do not position your body in the area where power
tool will move if kickback occurs. Kickback will propel
the tool in the direction opposite to the wheel’s move-
ment at the point of snagging.
4. Use special care when working corners, sharp edges
etc. Avoid bouncing and snagging the accessory. Cor-
ners, sharp edges or bouncing have a tendency to snag
the blade and cause loss of control or kickback.
VIBRATION SAFETY
This tool vibrates during use. Repeated or long-term
exposure to vibration may cause temporary or perma-
nent physical injury, particularly to the hands, arms and
shoulders.
To reduce the risk of vibration-related injuries:
1. First be examined by a doctor and then have regular
medical check-ups to ensure medical problems are not
being caused or worsened from using this tool. People
who are pregnant, have impaired blood circulation to the
hand, past hand injuries, nervous system disorders, dia-
betes, or Raynaud’s disease should NOT use this tool.
2. If you feel any symptoms related to vibration (such
as tingling, numbness, and white or blue fingers), stop
working and seek medical advice as soon as possible.
3. Do not smoke during use. Nicotine reduces the blood
supply to the hands and fingers, increasing the risk of
vibration-related injury.
4. Wear suitable work gloves to reduce the effects of vi-
bration.
5. Hold the tool firmly enough to keep safe control of it,
but NOT too tightly. The risk associated with vibration is
increased when the gripping force is high. Let the tool
do the work.
6. Take vibration-free breaks during each day of work.
These safety instructions can’t possibly warn of every scenario that may arise with this tool,
so always make sure to stay alert and use common sense during operation.
8
ELECTRICAL INFORMATION (CHARGER)
AMPERAGE REQUIRED GAUGE FOR EXTENSION CORDS
25 ft. 50 ft. 100 ft. 150 ft.
2A 18 gauge 16 gauge 16 gauge 14 gauge
IMPORTANT: Servicing a double-insulated product requires extreme care and knowledge of the system, and
should be done only by qualified service personnel using identical replacement parts. Always use original factory
replacement parts when servicing.
1. Polarized Plugs. To reduce the risk of electric shock, this equipment has a polarized plug (one blade is wider than
the other). This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the
plug. If it still does not fit, contact a qualified electrician to install a proper outlet. Do not modify the machine plug
or the extension cord in any way.
2. Ground fault circuit interrupter protection (GFCI) should be provided on the circuit or outlet used for this power
tool to reduce the risk of electric shock.
3. Service and repair. To avoid danger, electrical appliances must only be repaired by a qualified service technician
using original replacement parts.
GUIDELINES AND RECOMMENDATIONS FOR EXTENSION CORDS
When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An
undersized cord will cause a drop in line voltage, resulting in loss of power and overheating. The table below shows
the correct size to be used according to cord length and ampere rating. When in doubt, use a heavier cord. The
smaller the gauge number, the heavier the cord.
DOUBLE-INSULATED CHARGER
The charger’s electrical system is double-insulated where two systems of insulation are provided. This
eliminates the need for the usual three-wire grounded power cord. Double-insulated tools do not need
to be grounded, nor should a means for grounding be added to the product. All exposed metal parts are
isolated from the internal metal components with protecting insulation.
1. Examine extension cord before use. Make sure your extension cord is properly wired and in good condition.
Always replace a damaged extension cord or have it repaired by a qualified person before using it.
2. Do not abuse extension cord. Do not pull on cord to disconnect from receptacle; always disconnect by pulling on
plug. Disconnect the extension cord from the receptacle before disconnecting the product from the extension cord.
Protect your extension cords from sharp objects, excessive heat and damp/wet areas.
3. Use a separate electrical circuit for your tool. This circuit must not be less than a 12-gauge wire and should be
protected with a 15A time-delayed fuse. Before connecting the motor to the power line, make sure the switch is in
the OFF position and the electric current is rated the same as the current stamped on the motor nameplate. Running
at a lower voltage will damage the motor.
• Avoid dangerous environments – Do not charge the
battery pack in rain, snow or in damp or wet locations.
Do not use the battery pack or charger in the presence
of explosive atmospheres (gaseous fumes, dust or flam-
mable materials) because sparks may be generated when
inserting or removing the battery pack, which could lead
to a fire.
• Charge in a well-ventilated area – Do not block the
charger vents. Keep them clear to allow for proper ven-
tilation. Do not allow smoking or open flames near a
charging battery pack. Vented gases may explode.
NOTE: The safe temperature range for the battery charg-
ing is 41°F to 104°F. Do not charge the battery outside
in freezing weather; charge it at room temperature.
• Maintain charger cord – When unplugging the char-
ger, pull the plug, not the cord, from the receptacle to
reduce the risk of damage to the electrical plug and cord.
Never carry the charger by its cord or yank it by the cord
to disconnect it from the receptacle. Keep the cord away
from heat, oil and sharp edges. Make sure the cord will
not be stepped on, tripped over or subjected to dam-
age or stress when the charger is in use. Do not use the
charger with a damaged cord or plug. Replace a dam-
aged charger immediately.
• Do not use an extension cord unless it is absolutely
necessary – Using the wrong, damaged or improperly
wired extension cord poses a risk of fire and electric
shock. If an extension cord must be used, plug the char-
ger into a properly wired 16 gauge or larger extension
cord with the female plug matching the male plug on the
charger. Make sure that the extension cord is in good
electrical condition.
• Charger is rated for 120 volt AC only – The charger
must be plugged into an appropriate receptacle.
• Use only recommended attachments – Use of an at-
tachment not recommended or sold by WEN Products
may result in risk of fire, electric shock or personal in-
jury.
• Unplug charger when not in use – Make sure to re-
move battery packs from unplugged chargers.
• Do not burn or incinerate battery packs – Battery
packs may explode, causing personal injury or dam-
age. Toxic fumes and materials are created when battery
packs are burned.
• Do not crush, drop or damage battery packs – Do not
use the battery pack or charger if they have sustained a
sharp blow, been dropped, run over or have been dam-
aged in any way (i.e. pierced with a nail, hit with a ham-
mer, stepped on, etc.).
• Do not disassemble – Incorrect reassembly may pose
a serious risk of electric shock, fire or exposure to toxic
battery chemicals. If the battery or charger are damaged,
call WEN customer service at 1-800-232-1195 for as-
sistance.
• Battery chemicals cause serious burns – Never let a
damaged battery pack contact the skin, eyes or mouth.
If a damaged battery pack leaks battery chemicals, use
rubber or neoprene gloves to safely dispose of it. If skin
is exposed to battery fluids, wash the affected area with
soap and water and rinse with vinegar. If eyes are ex-
posed to battery chemicals, immediately flush with wa-
ter for 20 minutes and seek medical attention. Remove
and dispose of contaminated clothing.
• Store your battery pack and charger in a cool, dry
place – Do not store the battery pack or charger where
temperatures may exceed 104 °F, such as in direct sun-
light or inside a vehicle or metal building during the
summer.
• Do not short circuit – A battery pack will short circuit if
a metal object makes a connection between the positive
and negative contacts on the battery pack. Do not place
a battery pack near anything that may cause a short cir-
cuit, such as paper clips, coins, keys, screws, nails and
other metallic objects. A short-circuited battery pack
poses a risk of fire and severe personal injury.
BATTERY & CHARGER SAFETY WARNINGS
Despite all of the safety precautions, caution must always be taken when handling batteries. The following
points must be obeyed at all times to ensure safe use. Safe use can only be guaranteed if undamaged cells are
used. Incorrect handling of the battery pack can cause cell damage.
WARNING! To reduce the risk of electric shock,
always unplug the charger before performing any
cleaning or maintenance. Do not allow water to
flow into the charger. Use a Ground Fault Circuit
Interrupter (GFCI) to reduce shock hazards.
9
BATTERY & CHARGER SAFETY WARNINGS
ABOUT THE BATTERY
1. The battery pack has to be charged completely before you use the tool for the first time.
2. For optimum battery performance, avoid low discharge cycles by charging the battery pack frequently.
3. Lithium-ion batteries are subject to a natural aging process. The battery pack must be replaced at the latest when
its capacity falls to just 80% of its capacity when new. Weakened cells in an aged battery pack are no longer capable
of meeting the high power requirements needed for the proper operation of your tool, and therefore pose a safety
risk.
4. Do not throw battery packs into an open fire as this poses a risk of explosion. Do not ignite the battery pack or
expose it to fire.
5. Do not exhaustively discharge batteries. Exhaustive discharge will damage the battery cells. The most common
cause of exhaustive discharge is lengthy storage or non-use of partially discharged batteries. Stop working as soon
as the performance of the battery falls noticeably or the electronic protection system triggers. Place the battery pack
in storage only after it has been fully charged.
6. Protect batteries and the tool from overloads. Overloads will quickly result in overheating and cell damage inside
the battery housing even if this overheating is not apparent externally.
7. Avoid damage and shocks. Immediately replace batteries that have been dropped from a height of more than
one meter or those that have been exposed to violent shocks, even if the housing of the battery pack appears to be
undamaged. The battery cells inside the battery may have suffered serious damage. In such instances, please read
the waste disposal information for proper battery disposal.
8. If the battery pack suffers overloading and overheating, the integrated protective cutoff will switch off the equip-
ment for safety reasons.
9. Use only original battery packs. The use of other batteries poses a fire risk and may result in injuries or an explo-
sion.
ABOUT THE CHARGER
Protect battery charger and cord from damage. Keep the charger and its cord away from heat, oil and sharp edges.
Electrical plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with ground-
ed appliances. Unmodified plugs and matching outlets will reduce the risk of electric shock.
Keep the battery charger, battery pack(s), and the cordless tool out of the reach of children.
Do not use the supplied battery charger to charge other cordless tools.
During periods of heavy use, the battery pack will become warm. Allow the battery pack to cool to room temperature
before inserting it into the charger to recharge.
Do not overcharge batteries. Do not exceed the maximum charging times. These charging times only apply to dis-
charged batteries. Frequent insertion of a charged or partially charged battery pack will result in overcharging and
cell damage. Do not leave battery in the charger for days on end.
Never use or charge a battery if you suspect that it has been more than 12 months since last time they were charged.
There is a high probability that battery pack has already suffered dangerous damage (exhaustive discharge).
Do not use battery that have been exposed to heat during the charging process, as the battery cells may have suf-
fered dangerous damage.
Do not use battery that have suffered curvature or deformation during the charging process or those that exhibit
other atypical symptoms (gassing, hissing, cracking, etc.)
10
Components
11
Accessories
UNPACKING & PACKING LIST
UNPACKING
Carefully remove the portable band saw from the packaging and place it on a sturdy, flat surface. Make sure to take
out all contents and accessories. Do not discard the packaging until everything is removed. Check the packing list
below to make sure you have all of the parts and accessories. If any part is missing or broken, please contact cus-
20V Charger (1) 20V Battery (1)6mm Hex Wrench (1)
Portable Band Saw
Blade (1)
4mm Hex Wrench (1)
KNOW YOUR PORTABLE BAND SAW
PORTABLE BAND SAW
Refer to the following diagrams to become familiarized with all the parts and controls of your portable band saw. The
components will be referred to later in the manual for assembly and operation instructions.
Guide Bar
5.0Ah Battery Pack
Front Handle
LED Light
Blade Tensioning
Handle
Saw Blade
Back Handle
ON / OFF Switch
Speed Dial
Guide Wheels
Direction of Rotation
12
Guide Bearings Guide Bearings
Lock-Off Switch
ASSEMBLY & ADJUSTMENTS
WARNING! To avoid injury from accidental startups, be sure that the tool is switched off and disconnected
from the power supply before inspecting the unit, making adjustments, or changing accessories.
13
CHARGING THE BATTERY PACK
The 20V battery pack for this tool is supplied in a low charge condition to prevent possible problems, and must be
charged completely before you use the tool for the first time.
1. Connect charger to a 120V, 60Hz AC outlet. The green light on the charger will illuminate, indicating that the
charger is powered.
2. Slide the battery all the way into the charger until it clicks. The red light on the charger will illuminate, indicating
that the battery is charging.
Charging Indication:
• Solid Green: Ready to Charge
• Solid Red: Charging
• Solid Green: Charged
3. When the battery is charged, the red light will turn off and the green light will turn on. Remove the battery from
the charger and unplug the charger from the power supply.
NOTE: Battery will not reach full charge the first time it is charged. Allow several cycles for the battery to fully
charge. The battery pack may become warm while charging; this is normal. If the battery is hot after continuous use
in the tool, allow it to cool to room temperature before charging. This will prolong the life of your battery.
The battery pack is equipped with three LED battery life indication lights. Press and hold the power button on the
rear of the battery to check the battery’s charge status.
Battery Life Indication:
• Three Lights: The battery is fully charged.
• Two Lights: The battery is about 60% charged.
• One Light: The battery is almost out of power and needs to be charged.
INSERTING AND REMOVING THE BATTERY
1. To install the battery, slide the battery pack into the battery port at the top of the band saw. Make sure the release
latch on the rear side of the battery pack snaps into place and battery is secure before beginning operation.
2. To remove the battery pack, press the battery release latch on the front of the battery and pull the battery pack out.
ASSEMBLY & ADJUSTMENTS
1
Fig. 3
14
INSTALLING SAW BLADE
Your band saw is designed to fit saw blades 44-7/8” long, 1/2” wide
and 0.025” thick. Use the correct blade size suitable for the mate-
rial being cut. A 10/14 TPI saw blade is included with your saw.
Replacement blades can be ordered from wenproducts.com by
searching the part number 94396B or BB4550.
WARNING! Saw blades are sharp. Wear work gloves and
safety goggles while handling the blades. Inspect blades for
cracks and missing teeth before each use.
1. Turn the blade tensioning handle (Fig. 1 - 1) on the front side of
your saw clockwise to release the blade tension.
2. Flip the saw over to the back side. Hold the saw blade with the
blade teeth facing towards you, and insert it between the two sets
of guide bearings (Fig. 2 - 1). Make sure the blade is fully seated
between the guide bearings - the spine of the blade should be in
contact with the rear thrust bearing.
3. Guide the blade around the two guide wheels and press it in-
wards. Make sure the blade fits evenly around the wheels.
4. Turn the tension handle (Fig. 1 - 1) counterclockwise all the way
until the handle is tight. The blade is now properly tensioned.
5. Put on eye and hearing protection, and hold the tool away from
your body. Plug in and run the tool with no load for a few minutes to
inspect the blade and allow it to seat properly. Make sure the blade
runs evenly and steadily around the guide wheels.
REMOVING THE BLADE
1. Make sure the saw is switched off and the battery is removed.
2. Turn tension handle (Fig. 3-1) clockwise to release blade tension.
3. Wearing work gloves and safety goggles, carefully slide the blade
off the top of the guide wheels and remove it from guide bearings.
NOTE: If saw is not being used for a long time, release tension and
remove saw blade before storage. This will prolong life of the blade.
1
1
1
Fig. 1
Fig. 2
WORK AREA & WORKPIECE SET UP
1. Designate a work area that is clean and well lit. Work area must not allow access by children or pets to prevent
distraction and injury. Do not operate in wet environment or near flammable materials.
2. Use suitable detectors to find hidden utility lines or call the local utility company for assistance. Contact with
electric lines can lead to fire or electrical shock; damaging a gas line can result in an explosion; penetrating a water
pipe will cause property damage or an electrical shock.
3. Secure loose workpieces using a vise or clamps (not included) to prevent movement while working. Do not work
materials containing asbestos (asbestos is considered carcinogenic). Dust from material such as paint containing
lead, some wood species, minerals and metal may be harmful (contact with or inhalation of the dust may cause al-
lergic reactions and/or respiratory diseases to the operator or bystanders). Wear a dust mask and work with a dust
extraction device to reduce the risk of personal injuries from saw dust.
OPERATION
OPERATING THE SAW
1. Hold the tool firmly with both hands on the insulated handles.
With the workpiece secured, set the guide bar (Fig. 4 - 3) against
the workpiece, keeping blade at a 90° angle to the workpiece.
2. Press the lock-off button, then the ON / OFF trigger (Fig. 4 - 1) to
turn on the band saw. Use the speed dial (Fig. 4 - 2) to set the blade
speed to a suitable value. The blade runs between 150 - 400 feet
per minute. The LED light will automatically turn on and illuminate
the cutting area.
3. Wait a few seconds to allow the blade to reach full speed before
starting the cut.
Fig. 4
1
2
3
WARNING! The blade is exposed on the underside of the saw; hold the band saw away from your body.
4. To start a cut, use minimal force to guide the blade into the workpiece to create a groove. Then, allow the rest of
the blade to cut into the workpiece. Guide the tool to prevent blade from moving from side-to-side during cutting.
NOTE: Do not apply too much force on the tool. The weight of the tool itself will create enough force to make the cut;
let the tool do the work. Forcing or leaning on the tool may twist or break the blade, damaging the saw and possibly
causing injury.
5. As you reach the end of your workpiece, finish off the cut by slowly raising the tool slightly, bringing the blade up
and away from the workpiece. Be careful to keep your feet clear of where the cut-off piece will fall.
6. Turn off and wait for the blade to stop. Do not put the tool down until it has come to a complete stop. Moving parts
can grab the surface and pull the tool out of your control. Remove the battery, clean, then store the tool indoors out
of the reach of children.
ADJUSTING THE GUIDE BAR
The guide bar can be re-positioned as needed, depending on the cut at hand. To re-position the guide bar (Fig. 4 - 3):
1. Use a hex wrench to loosen the two flat-head screws (Fig. 4 - 4) on the face of the guide bar.
2. Slide the guide bar up or down as needed.
3. Tighten the screws using the hex wrench.
GUIDE BEARINGS AND TRACKING
The blade guide bearings, thrust bearings, and blade tracking are not adjustable. If your blade is getting off track,
the blade tension may be incorrect, the blade may be dull, or there may be debris on the wheels. Adjust the blade
tension using the tension lever, replace the blade if dull, or remove the blade and clean off the saw if there is debris.
trouble persists.
15
4
MAINTENANCE
WARNING! To avoid accidents, make sure the power switch is in the OFF position and remove the battery be-
fore cleaning or performing any maintenance. Servicing of the tool must be performed by a qualified technician.
GENERAL MAINTENANCE
1. Before each use, inspect the general condition of the tool. Check for loose hardware, misalignment or binding of
moving parts, cracked or broken parts, and any other conditions that may affect its safe operation.
2. After every operation, use a vacuum to remove dust and chips from the tool and work area. Wipe the tool clean
with a soft cloth. Make sure water does not get into the tool.
CAUTION: Most plastics are susceptible to damage from various types of commercial solvents. Do not use any
solvents or cleaning products that could damage the plastic parts.
3. Keep the ventilation openings free from dust and debris to prevent the motor from overheating.
4. Store the tool in a clean and dry place away from the reach of children.
PRODUCT DISPOSAL
Used power tools should not be disposed of together with household waste. This product contains electronic com-
ponents that should be recycled. Please take this product to your local recycling facility for responsible disposal and
to minimize its environmental impact.
16
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