Foreword

We are proud to offer the Model G0592 Metal Cutting Bandsaw. This machine is part of a grow- ing Grizzly family of fine metalworking machinery. When used according to the guidelines set forth in this manual, you can expect years of trouble-free, enjoyable operation and proof of Grizzly???s com- mitment to customer satisfaction.

We are pleased to provide this manual with the Model G0592. It was written to guide you through assembly, review safety considerations, and cover general operating procedures. It repre- sents our effort to produce the best documenta- tion possible.

The specifications, drawings, and photographs illustrated in this manual represent the Model G0592 as supplied when the manual was pre- pared. However, owing to Grizzly???s policy of con- tinuous improvement, changes may be made at any time with no obligation on the part of Grizzly. For your convenience, we always keep current Grizzly manuals available on our website at www. grizzly.com. Any updates to your machine will be reflected in these manuals as soon as they are complete. Visit our site often to check for the lat- est updates to this manual!

G0592 Metal Cutting Bandsaw

Contact Info

If you have any comments regarding this manual, please write to us at the address below:

Grizzly Industrial, Inc.

C/O Technical Documentation Manager

P.O. Box 2069

Bellingham, WA 98227-2069

We stand behind our machines. If you have any service questions or parts requests, please call or write us at the location listed below.

Grizzly Industrial, Inc.

1203 Lycoming Mall Circle

Muncy, PA 17756

Phone: (570) 546-9663

Fax: (800) 438-5901 E-Mail: techsupport@grizzly.com Web Site: http://www.grizzly.com

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Identification

A

B

M

P

C

D

E

Figure 1. G0592 Machine Identification.

A.Blade Tension Handle

B.Lift Handle

C.Vise Handwheel

D.Coolant Pan

E.Work Stop

F.Rotational Degree Scale

G.Spray Gun

H.Electrical Enclosure

I.Speed Adjustment Knob

J.Control Panel

K.Blade Guide Scale

L.Blade Guide Knob

M.Coolant Valve Controls

N.Bow

O.Speed & Blade Selection Chart

P.Blade Guides

I

A

B

Control Panel

F

1.READ THROUGH THE ENTIRE MANUAL

BEFORE STARTING MACHINERY.

Machinery presents serious injury hazards to untrained users.

2.ALWAYS USE ANSI APPROVED

SAFETY GLASSES WHEN OPERATING MACHINERY. Everyday eyeglasses only have impact resistant lenses, they are NOT safety glasses.

3.ALWAYS WEAR AN NIOSH APPROVED

RESPIRATOR WHEN OPERATING

MACHINERY THAT PRODUCES DUST.

Wood dust is a carcinogen and can cause cancer and severe respiratory illnesses.

4.ALWAYS USE HEARING PROTECTION

WHEN OPERATING MACHINERY.

Machinery noise can cause permanent hearing damage.

5.WEAR PROPER APPAREL. DO NOT wear loose clothing, gloves, neckties, rings, or jewelry which may get caught in moving parts. Wear protective hair covering to con- tain long hair and wear non-slip footwear.

6.NEVER OPERATE MACHINERY WHEN

TIRED, OR UNDER THE INFLUENCE OF DRUGS OR ALCOHOL. Be mentally alert at all times when running machinery.

7.ONLY ALLOW TRAINED AND PROP-

ERLY SUPERVISED PERSONNEL TO OPERATE MACHINERY. Make sure operation instructions are safe and clearly understood.

8.KEEP CHILDREN AND VISITORS AWAY.

Keep all children and visitors a safe dis- tance from the work area.

9.MAKE WORKSHOP CHILD PROOF. Use padlocks, master switches, and remove start switch keys.

10.NEVER LEAVE WHEN MACHINE IS RUNNING. Turn power OFF and allow all moving parts to come to a complete stop before leaving machine unattended.

11.DO NOT USE IN DANGEROUS ENVIRONMENTS. DO NOT use machin- ery in damp, wet locations, or where any flammable or noxious fumes may exist.

12.KEEP WORK AREA CLEAN AND WELL LIT. Clutter and dark shadows may cause accidents.

13.USE A GROUNDED EXTENSION CORD

RATED FOR THE MACHINE AMPERAGE.

Undersized cords overheat and lose power. Replace extension cords if they become damaged. DO NOT use extension cords for 220V machinery.

14.ALWAYS DISCONNECT FROM POWER

SOURCE BEFORE SERVICING MACHINERY. Make sure switch is in OFF position before reconnecting.

15.MAINTAIN MACHINERY WITH CARE.

Keep blades sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories.

16.MAKE SURE GUARDS ARE IN PLACE

AND WORK CORRECTLY BEFORE

USING MACHINERY.

17.REMOVE ADJUSTING KEYS AND WRENCHES. Make a habit of checking for keys and adjusting wrenches before turn- ing machinery ON.

18.CHECK FOR DAMAGED PARTS BEFORE USING MACHINERY. Check for binding and alignment of parts, broken parts, part mounting, loose bolts, and any other conditions that may affect machine operation. Repair or replace damaged parts.

19.USE RECOMMENDED ACCESSORIES.

Refer to the instruction manual for recom- mended accessories. The use of improper accessories may cause risk of injury.

20.DO NOT FORCE MACHINERY. Work at the speed for which the machine or acces- sory was designed.

21.SECURE WORKPIECE. Use clamps or a vise to hold the workpiece when practi- cal. A secured workpiece protects your hands and frees both hands to operate the machine.

22.DO NOT OVERREACH. Keep proper foot- ing and balance at all times.

23.MANY MACHINES WILL EJECT THE

WORKPIECETOWARDTHEOPERATOR.

Know and avoid conditions that cause the workpiece to "kickback."

24. ALWAYS LOCK MOBILE BASES

(IF USED) BEFORE OPERATING

MACHINERY.

25.BE AWARE THAT CERTAIN DUST MAY BE HAZARDOUS to the respiratory sys- tems of people and animals, especially fine dust. Make sure you know the hazards associated with the type of dust you will be exposed to and always wear a respirator approved for that type of dust.

1.BLADE CONDITION. Do not operate with dull, cracked or badly worn blade. Inspect blades for cracks and missing teeth before each use.

2.HAND PLACEMENT. Never position fin- gers or thumbs in line with the cut. Hands could be crushed in vise or by falling machine components or cut by the blade.

3.ENTANGLEMENT HAZARDS. Do not operate this bandsaw without blade guard in place. Otherwise, loose clothing, jewelry, long hair and work gloves can be drawn into working parts.

4.BLADE REPLACEMENT. When replacing blades, make sure teeth face toward the workpiece. Wear gloves to protect hands and safety glasses to protect eyes.

5.WORKPIECE HANDLING. Always sup- port the workpiece with table, vise, or other support fixture. Flag long pieces to avoid a tripping hazard. Never hold the workpiece with your hands during a cut.

6.LOSS OF STABILITY. Unsupported workpieces may jeopardize machine sta- bility and cause the machine to tip and fall, which could cause serious injury.

7.POWER INTERRUPTION. Unplug machine after power interruption. Machines without magnetic switches can start up after power is restored.

8.FIRE HAZARD. Use EXTREME CAUTION if cutting magnesium. Using the wrong cut- ting fluid will lead to chip fire and possible explosion.

9.CUTTING FLUID SAFETY. Always follow manufacturer???s cutting fluid safety instruc- tions. Pay particular attention to contact, contamination, inhalation, storage and dis- posal warnings. Spilled cutting fluid is a slipping hazard and a toxicity hazard.

10.ATTENTION TO WORK AREA. Never leave a machine running and unattended. Pay attention to the actions of others in the area to avoid unintended accidents.

11.MAINTENANCE/SERVICE. All inspec- tions, adjustments, and maintenance are to be done with the machine OFF and the power disconnected to the machine. Wait for all moving parts to come to a complete stop.

12.HEARING PROTECTION & HAZARDS.

Noise generated by blade and workpiece vibration, material handling, and power transmission can cause permanent hear- ing loss over time and interfere with com- munication and audible signals. Always wear hearing protection.

13.HOT SURFACES. Due to friction, the workpiece, chips, and some machine com- ponents can be hot enough to burn you.

220V Single-Phase

Serious personal injury could occur if you connect the machine to the power source before you have completed the set up pro- cess. DO NOT connect the machine to the power source until instructed to do so.

Amperage Draw

The Model G0592 motor draws the following amps under maximum load:

Circuit Requirements

We recommend using a dedicated circuit for this machine. You MUST connect your machine to a grounded circuit that is rated for the amperage given below. Never replace a circuit breaker on an existing circuit with one of higher amper- age without consulting a quali???ed electrician to ensure compliance with wiring codes. If you are unsure about the wiring codes in your area or you plan to connect your machine to a shared circuit, consult a qualified electrician.

Plug/Receptacle Type

Grounding

In the event of an electrical short, grounding reduces the risk of electric shock. The grounding wire in the power cord must be properly connect- ed to the grounding prong on the plug; likewise, the outlet must be properly installed and ground- ed. All electrical connections must be made in accordance with local codes and ordinances.

Electrocution or fire could result if this machine is not grounded correctly or if your electrical con- figuration does not com- ply with local and state codes. Ensure compliance by checking with a quali- fied electrician!

Extension Cords

We do not recommend the use of extension cords. Instead, arrange the placement of your equipment and the installed wiring to eliminate the need for extension cords.

If you find it absolutely necessary to use an extension cord at 220V with your machine:

???Use at least a 12 gauge cord that does not exceed 50 feet in length!

Figure 3. NEMA L6-20 plug and receptacle.

The extension cord must also contain a ground wire and plug pin.

A qualified electrician MUST size cords over 50 feet long to prevent motor damage.

Set Up Safety

This machine presents serious injury hazards to untrained users. Read through this entire manu- al to become familiar with the controls and opera- tions before starting the machine!

Wear safety glasses dur- ing the entire set up pro- cess!

machine. Serious per- sonal injury may occur if safe moving methods are not followed. To be safe, you will need assistance and power equipment when moving the ship- ping crate and remov- ing the machine from the crate.

Items Needed for Set Up

The following items are needed to complete the set up process, but are not included with your machine:

Unpacking

The Model G0592 was carefully packed when it left our warehouse. If you discover the machine is damaged after you have signed for delivery, please immediately call Customer Service at (570) 546-9663 for advice.

Save the containers and all packing materials for possible inspection by the carrier or its agent.

Otherwise, filing a freight claim can be difficult.

When you are completely satisfied with the con- dition of your shipment, you should inventory the contents.

Inventory

After all the parts have been removed from the crate, you should have the following items:

In the event that any nonproprietary parts are missing (e.g. a nut or a washer), we would be glad to replace them, or for the sake of expedi- ency, replacements can be obtained at your local hardware store.

NOTICE

Some hardware/fasteners on the inventory list may arrive pre-installed on the machine. Check these locations before assuming that any items from the inventory list are miss- ing.

Clean Up

The unpainted surfaces are coated with a waxy oil to protect them from corrosion during ship- ment. Remove this protective coating with a sol- vent cleaner or citrus-based degreaser such as Grizzly???s G7895 Degreaser. To clean thoroughly, some parts may need to be removed. For opti- mum performance from your machine, make sure you clean all moving parts or sliding contact surfaces that are coated. Avoid chlo- rine-based solvents, such as acetone or brake parts cleaner, as they will damage painted sur- faces should they come in contact. Always follow the manufacturer???s instructions when using any type of cleaning product.

Gasoline and petroleum products have low flash points and could cause an explosion or fire if used to clean machinery. DO NOT use gasoline or petroleum products to clean the machinery.

Many of the solvents commonly used to clean machinery can be toxic when inhaled or ingest- ed. Lack of ventilation while using these sol- vents could cause seri- ous personal health risks or fire. Take precautions from this hazard by only using cleaning solvents in a well ventilated area.

Site Considerations

Floor Load

Refer to the Machine Data Sheet for the weight and footprint specifications of your machine. Some floors may require additional reinforcement to support both the machine and operator.

Working Clearances

Consider existing and anticipated needs, size of material to be processed through each machine, and space for auxiliary stands, work tables or other machinery when establishing a location for your new machine. See Figure 5 for the minimum working clearances.

Figure 5. Minimum working clearances.

Unsupervised children and visitors inside your shop could cause serious per- sonal injury to themselves. Lock all entrances to the shop when you are away and DO NOT allow unsupervised children or visitors in your shop at any time!

Moving & Placing

Base Unit

machine. Serious per- sonal injury may occur if safe moving methods are not followed. To be safe, you will need assistance and power equipment when moving the ship- ping crate and remov- ing the machine from the crate.

Use a forklift and straps rated for the machine weight to lift the machine off the pallet and onto a suitable location (see Figure 6).

Figure 6. G0592 lifting points.

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Mounting to Shop

Floor

Although not required, we recommend that you mount your new machine to the floor. Because this is an optional step and floor materials may vary, floor mounting hardware is not included. Generally, you can either bolt your machine to the floor or mount it on machine mounts. It will be necessary to level your machine after mount- ing. If you choose to set your machine on the floor, four M12-1.75 x 50 leveling bolts have been included.

Bolting to Concrete Floors

Lag shield anchors with lag bolts (Figure 7) and anchor studs are two popular methods for anchoring an object to a concrete floor.

NOTICE

Anchor studs are stronger and more per- manent alternatives to lag shield anchors; however, they will stick out of the floor, which may cause a tripping hazard if you decide to move your machine.

Using Machine Mounts

Using machine mounts, shown in Figure 7, gives the advantage of fast leveling and vibration reduc- tion. The large size of the foot pads distributes the weight of the machine.

Figure 7. Typical options for machine mounting.

G0592 Metal Cutting Bandsaw

Shipping Bracket

A bracket has been installed to keep the saw in alignment during shipping. Before using your saw you will need to remove it. Store it for safe keep- ing, in the event you move your saw to a different location.

Figure 8. Shipping bracket.

To remove the shipping bracket:

1.Remove the upper hex bolt with a 12mm wrench.

2.Remove the two lower cap screws with a 5mm hex wrench.

Workstop

The workstop on the Model G0592 has three main parts including the workstop rod, arm and work- stop. The workstop is easy to adjust and can be set up on either side of the vise.

To install the workstop:

1.Slide the workstop rod in the hole in the base of the vise and tighten the set screw.

2.Slide the arm onto the workstop rod and tighten the set screw.

Set screw

Arm

Figure 9. Workstop assembly.

3.Insert the workstop into the arm and secure with the knob.

Chip Trays & Splash

Guard

The upper chip tray needs no hardware and rests on the vise and vise base as shown in Figure 11.

The lower chip tray rests on the base directly under the upper chip tray. It is not secured so it can be removed for easy clean-up.

Upper Chip Tray

1.Adjust the feed stop bolt and jam nut (Figure 13), so the bandsaw blade teeth are just below the vise table surface when the cut is complete.

Feed Stop

Jam Nut

Figure 13. Feed stop.

Recommended

Adjustments

The adjustments listed below have been per- formed at the factory. However, because of the many variables involved with shipping, we recom- mend that you at least verify the following adjust- ments to ensure accurate cutting results.

Step-by-step instructions on verifying these adjust- ments can be found in SECTION 7: SERVICE

ADJUSTMENTS.

Factory adjustments that should be verified:

1.Blade Tracking (Page 35).

2.Blade Guide Bearings (Page 36).

Test Run

Projectiles thrown from the machine could cause serious eye injury. Wear safety glasses during assembly and operation.

Starting the machine:

1.Read the entire instruction manual.

2.Make sure all tools and foreign objects have been removed from the machine.

3.Put on safety glasses and secure loose clothing or long hair.

4.Connect the bandsaw to power.

5.Raise the bandsaw and close the feed con- trol knob to keep the saw in place.

Figure 14. Control panel.

6.Start the bandsaw while keeping your finger near the EMERGENCY STOP/OFF button (Figure 14) at all times during the test run. The bandsaw should run smoothly with little or no vibration.

Note: If the EMERGENCY STOP/OFF button is pressed, it needs to be twisted until it pops out or the bandsaw will not start.

???If you suspect any problems, immediately stop the bandsaw and correct before con- tinuing.

???If you need any help with your bandsaw call our Tech Support at (570) 546-9663.

Operation Safety

Damage to your eyes, lungs, and ears could result from using this machine without proper protective gear. Always wear safety glasses, a respirator, and hearing protection when operating this machine.

Loose hair and cloth-

ing could get caught in

machinery and cause seri-

ous personal injury. Keep

loose clothing and long hair away from moving machinery.

NOTICE

This bandsaw is for trained operators only. WE STRONGLY RECOMMEND that you read books, trade magazines, and get formal training before beginning any projects. Regardless of the content in this section, Grizzly Industrial will not be held liable for accidents caused by lack of training.

Vise

The vise on the Model G0592 can be positioned for cutting on both sides of the vise. It also has a ratcheting type leadscrew that allows for fast jaw adjustments.

To change vise positions:

1.Remove the chip trays and the splash guard.

2.Raise the bow to the maximum height and lock in place.

3.Loosen the two vise locks at the base of the vise and remove the upper chip tray (see

Figure 15).

Vise Locks

Half Open

Figure 15. Changing vise positions.

Figure 16. Vise to the right.

Always turn the saw OFF and allow the blade to come to a complete stop before using the vice! Failure to follow this caution may lead to injury.

The vise jaw width can be quickly adjusted when changing from one sized material to another.

To rapidly change the vise jaw gap:

1.Use the handwheel to relieve any pressure on the vise jaw.

2.Flip the latch up to disengage it from the leadscrew (see Figure 17).

3.Pull or push the jaw in the desired direction.

4.Engage the lever with the leadscrew and fin- ish tightening the jaw with the handwheel.

Note: Figure 18 shows the proper methods for holding different workpiece shapes.

Figure 18. Workholding options by material shape.

Cutting Angle

The G0592 has a locking turret that can be adjust- ed to 60?? clockwise to 45?? counterclockwise.

To change the angle:

1.Raise the bow to the highest position and lock in place.

2.Flip the stop out as shown in Figure 19.

Stop

Stop Set Screw

Figure 19. Stop.

3.Loosen the swivel lock lever (Figure 20), rotate the turret to the desired angle, then re- tighten the swivel lock lever.

Swivel Lock Lever

Blade Selection

The Model G0592 uses 132" x 1" bandsaw blades.

Selecting the right blade for the job depends on a variety of factors, such as the type of material being cut, hardness of the material, material shape machine capability, and operator technique.

We suggest you do some research for your spe- cific situation so you get the best blade to match your needs.

Blade Speed

The Model G0592 has a variable speed control ranging from 98 to 394 feet per minute (FPM).

NOTICE

Only change speeds while the motor is run- ning. Changing speeds when machine is OFF may result in damage to your machine. Always make sure belt guard is in use.

Grizzly offers a variety of selections that can be found in the current catalog and in SECTION 5: ACCESSORIES on Page 28.

The chart shown in Figure 21 is a reproduction of the chart you will find on the blade cover of your G0592. Use it as a rough guideline.

To change blade speeds:

1.Turn the bandsaw ON and allow it to come up to speed.

2.Turn the speed adjustment knob (Figure 23), clockwise to decrease blade speed and counterclockwise to increase blade speed.

The table shown in Figure 22 is a sampling of speed rates for various materials. Use these as a guideline.

Figure 22. Material speed table.

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Feed Rate Dial

Figure 23. Feed rate dial (shown with guard removed).

Feed Rate

The speed at which the saw blade will cut through a workpiece is controlled by blade type, feed rate, and feed pressure. The feed rate is controlled by two knobs on the control panel.

Note: If a lubricant is used on the cut, the feed rate can be increased by approximately 15%.

To set the feed rate:

1.Raise the bow to the highest position.

2.Set the Feed Rate Dial to the desired feed rate. Range is from 1 being slowest, to 9 being fastest.

3.Turning the Feed Control Knob to the left to lower the bow at the feed rate you have set. Turning the knob to the right locks the bow in position.

???If you get a tightly curled, warm shavings, brown to black in color, you are using too much downward pressure.

???Blue looking chips are from extreme heat with a high band saw speed.

???Thin powder-like chips are from insuffi- cient feed pressure. This will dull your blade rapidly.

???The best cut and feed rate will give you evenly shaped spiraled curls with very little color change, if any at all.

G0592 Metal Cutting Bandsaw

Blade Guides

The rear blade guide should be as close to the workpiece as possible. This will help ensure straight cuts by keeping the blade from twisting and drifting off the cut line.

To adjust the rear blade guide:

1.Loosen the knob shown in Figure 24 and slide the rear blade guide as close to the workpiece as possible, then tighten the knob.

Knob

Blade Guides

Figure 24. Blade guides.

The front blade guide has a wire brush that makes contact with the blade to help clear away chips and extend blade life (see Figure 25).

Blade Brush

Figure 25. Blade brush.

G0592 Metal Cutting Bandsaw

Coolant System

FIRE HAZARD! DO NOT cut magnesium when using oil-water solutions as a cutting fluid! Always use a cutting fluid intend- ed for magnesium. The water in the solution will cause a magnesium-chip fire.

This bandsaw has a built-in coolant system that extends the life of your bandsaw blades by lower- ing the temperature of the blade and workpiece. It also has a convenient spray gun to help you clean the saw at the end of the day.

See Cutting Fluid on Page 27 for additional information.

To use the coolant system:

1.Access the reservoir by removing the front panel (see Figure 26).

2.Thoroughly clean and remove any foreign material that may have fallen inside the res- ervoir during shipping.

3.Fill the reservoir with your chosen cutting fluid solution and replace the front panel.

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Figure 26. Coolant system reservoir and cover.

4.Adjust the valves on the coolant hoses to control the flow of coolant (see Figure 27). Make sure that the pressure is not so high that coolant spills on the floor and creates a slipping hazard.

Coolant Control Valve

Figure 27. Coolant control valve.

5.Turn the coolant pump switch ON before making your cut.

NOTICE

Keep the tray chip screen clear so coolant can recycle to the pump reservoir. NEVER operate the pump with the reservoir below the low mark or you will over-heat the pump and void your warranty!

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6.Monitor the coolant level frequently to keep the system working properly. DO NOT let coolant level fall out of view on the sight glass (see Figure 28).

Figure 28. Coolant level sight glass. To use the spray gun:

1.Close the coolant control valves.

2.Turn the coolant pump switch ON. You are ready to spray.

Figure 29. Spray gun.

G0592 Metal Cutting Bandsaw

BIOLOGICAL AND POISON HAZARD! Use proper personal protection equipment when handling cutting fluid and dispose by following federal, state, and fluid manufacturer requirements to properly dispose of cutting fluid.

While simple in concept and function, many issues must be taken into account to find and use the correct cutting fluid. Always follow all product warnings and contact the fluid manufacturer for unanswered questions.

Use the selections below to choose the appro- priate cutting fluids:

???For cutting low alloy, low carbon, and gen- eral-purpose category metals with a bi-metal blade???use a water soluble cutting fluid.

???For cutting stainless steels, high carbon, and high alloy metals, brass, copper and mild steels???use "Neat Cutting Oil" (commonly undiluted mineral oils) that have extreme pressure additives (EP additives).

???For cutting cast iron, cutting fluid is not rec- ommended.

Remember: Too much flow at the cutting fluid nozzle will make a mess and can make the work area unsafe; and not enough fluid at the cut will heat the blade, causing the blade teeth to load up and break.

G0592 Metal Cutting Bandsaw

The following tips will help you safely and effec- tively operate your bandsaw, and help you get the maximum life out of your saw blades.

Tips for horizontal cutting:

???Use the work stop to quickly and accurately cut multiple pieces of stock to the same length.

???Clamp the material firmly in the vise jaws to ensure a straight cut through the material and use the positive lock to speed produc- tion.

???Let the blade reach full speed before engag- ing the workpiece.

???Never start a cut with the blade in contact with the workpiece and do not start a cut on a sharp edge.

???Chips should be curled and silvery. If the chips are thin and powder like, increase your feed rate.

???Burned chips indicate a need to reduce your blade speed.

???Wait until the blade has completely stopped before removing the workpiece from the vise, and avoid touching the cut end???it could be very hot!

???Support long pieces so they won't fall when cut, and flag the ends to alert passers-by of potential danger.

???Adjust the blade guides as close as possible to the workpiece to minimize side-to-side blade movement.

???Use coolant when possible to increase blade life.

NOTICE

Loosen blade tension at the end of each day to prolong blade life.

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Tool Steel Blades

H2303???132 x 1 x .032 10 TPI Raker H2304???132 x 1 x .032 14 TPI Raker

Variable Pitch Bi-Metal Blades H1146???132 x 1 x .032 3-4 Variable Pitch H1147???132 x 1 x .032 4-6 Variable Pitch H1148???132 x 1 x .032 5-8 Variable Pitch H1149???132 x 1 x .032 6-10 Variable Pitch H1150???132 x 1 x .032 8-12 Variable Pitch H1151???132 x 1 x .032 10-14 Variable Pitch

Figure 30. Blades

H5408???Blade Tensioning Gauge

The Blade Tensioning Gauge ensures long blade life, reduced blade breakage, and straight cutting by indicating correct tension. A precision dial indi- cator provides you with a direct readout in PSI.

Figure 31. H5408 Blade Tensioning Gauge.

H5405???Lenox?? Lube Tube???

Lenox?? Lube Tube??? is a stick lubricant designed to prevent heat buildup. Apply it directly to the blade to improve overall blade life and productiv- ity. Can be used on ferrous and non-ferrous met- als. Biodegradeable, non-toxic, and non-staining 14.5 oz tube.

Figure 32. Lenox?? Lube Tube???.

G7897???Machining Fluid

This biostable, soluble oil for heavy-duty machin- ing applications provides stable pH performance, which resists bacteria, fungal growth, rancidity and odors. Can be used in light or heavy machin- ing. Mix with water, 1:21 for general use or 1:11- 1:16 for heavy use.

Figure 33. G7897 Machining Fluid.

G5618???Deburring Tool with Two Blades G5619???Extra Aluminum Blades G5620???Extra Brass and Cast Iron Blade

The quickest tool for smoothing freshly machined metal edges. Comes with two blades???one for steel/aluminum and one for brass/cast iron.

H1302???Standard Earmuffs

H4979???Deluxe Twin Cup Hearing Protector

H4977???Work-Tunes Radio Headset Earmuffs

Protect yourself comfortably with a pair of cush- ioned earmuffs. Especially important if you or employees operate for hours at a time.

H1302

H4979

H4977

Figure 34. G5618 Deburring tool.

G7984???Face Shield

H1298???Dust Sealed Safety Glasses

H1300???UV Blocking, Clear Safety Glasses

H2347???Uvex?? Spitfire Safety Glasses

H0736???Shop Fox?? Safety Glasses

Safety Glasses are essential to every shop. If you already have a pair, buy extras for visitors or employees. You can't be too careful when it comes to shop safety!

Figure 36. Our most popular earmuffs.

G9256???6" Dial Caliper

G9257???8" Dial Caliper

G9258???12" Dial Caliper

These traditional dial calipers are accurate to 0.001" and can measure outside surfaces, inside surfaces, and heights/depths. Features stainless steel, shock resistant construction and a dust proof display.

Figure 35. Our most popular safety glasses.

Figure 37. Grizzly?? Dial Calipers.

Always disconnect power to the machine before performing maintenance. Failure to do this may result in serious person- al injury.

Schedule

For optimum performance from your machine, follow this maintenance schedule and refer to any specific instructions given in this section.

Daily Check:

???Loose mounting bolts.

???Damaged saw blade.

???Worn or damaged wires.

???Any other unsafe condition.

???Clean after each use.

???Proper blade tension.

???Coolant level.

Monthly Check:

???Lubricate vise screw.

???Check gear box fluid level.

Annual Check:

???Change gear box oil (every four months if being used daily).

Cleaning

Cleaning the Model G0592 is relatively easy. After using your bandsaw, remove excess chips by using the spray gun and by sweeping. Then remove chips for recycling.

-30-

Lubrication

Before applying lubricant to any area, wipe the area clean to avoid contamination. Lubricate the vise leadscrew and the grease fittings at the pivot point shown in Figure 38 with general purpose grease.

All bearings on the Model G0592 are lubricated and sealed for the life of the bearing. No further attention is needed until it is time to replace the bearing.

Drain Plug

Grease Fittings

Figure 38. Lubrication points.

The gearbox should be drained and refilled after the first 50 hours of use and then once every four months. Use a high quality, ISO 680 grade synthetic gear oil.

To change the gear oil:

1.Run the bandsaw for ten minutes to warm up the oil in the gearbox.

2.DISCONNECT THE BANDSAW FROM THE

POWER SOURCE!

3.Raise the bow to the highest angle and close the feed control knob to lock the bow in posi- tion.

4.Drain the gearbox by removing the drain plug shown in Figure 38.

G0592 Metal Cutting Bandsaw

Fill Cap

Sight Glass

Figure 39. Gear box lubrication.

5.Replace the drain plug, then lower the bow to its lowest position.

6.Open the fill cap and fill the gearbox with oil until you see the oil level reach the halfway point in the sight glass (see Figure 39).

7.Tighten the fill plug, connect the machine to power and run the saw for a minute or two???then reinspect the oil level. Add more oil if needed to maintain level at the halfway mark in the sight glass.

G0592 Metal Cutting Bandsaw

8. Lubricate the leadscrew as needed with general purpose grease. Apply a thin layer all along the leadscrew surface (see Figure 40).

Leadscrew

Figure 40. Vise leadscrew lubrication area.

-31-

Blade Change

Blades should be changed when they become dull, damaged, or when you are using materials that require a blade of a certain type or tooth count.

To change the blade on the bandsaw:

1.DISCONNECT THE BANDSAW FROM

POWER!

2.Raise the bow of the bandsaw to the highest position, close the feed control knob, and remove the wheel access cover.

3.Slide the blade guard all the way down as shown in Figure 41.

Tension Handle

Blade Guard

Figure 41. Tension handle and blade.

4.Remove the blade guard and wire wheel from the front of the bandsaw as shown in Figure 42.

CUTTING HAZARD! Blades are sharp! Wear heavy leather gloves when handling blades to prevent cuts.

-34-

Front Blade Guard

Figure 42. Removing front blade guard.

5.Loosen the blade tension handle in Figure 41 and slip the blade off of the wheels.

6.Install the new blade through both blade guide bearings, as shown in Figure 43, and around the bottom wheel.

Figure 43. Installing the blade.

7.Hold the blade around the bottom wheel with one hand and slip it around the top wheel with the other hand, keeping the blade between the blade guide bearings.

G0592 Metal Cutting Bandsaw

Note: It is sometimes possible to flip the blade inside out, in which case the blade will be installed in the wrong direction. Check to make sure the blade teeth are facing toward the workpiece, as shown in Figure 44, after mounting on the bandsaw. Some blades will have a directional arrow as a guide.

Figure 44. Blade cutting direction.

8.When the blade is around both wheels, adjust the position so the back of the blade is against the shoulder of the wheels.

9.Complete the blade change by following the steps in the next section, Blade Tension & Tracking.

Blade Tension &

Tracking

Proper blade tension is essential to long blade life, straight cuts, and efficient cutting. The Model G0592 features a blade tension indicator to assist you with blade tensioning.

Two major signs that you do not have proper blade tension are: 1) the blade stalls in the cut and slips on the wheels, and 2) the blade frequently breaks from being too tight.

NOTICE

Loosen blade tension at the end of each day to prolong blade life.

G0592 Metal Cutting Bandsaw

To tension the blade on the bandsaw:

1.Turn the blade tension handle clockwise to tension the blade.

2.Use the graduated scale on the blade tension indicator (Figure 45) to determine blade ten- sion in PSI.

???For carbon blades, the blade tension should be 20,000 PSI.

???For bi-metal blades, like the one supplied with your machine, the blade should be tensioned from 30,000 to 35,000 PSI.

3.To fine tune blade tension, use a blade tensioning gauge, like the one found in

SECTION 5: ACCESSORIES on Page 28. Please follow the instructions included with your gauge and the blade manufacturer's recommendations on blade tension.

Figure 45. Blade tension guide.

The blade tracking has been properly set at the factory. The tracking will rarely need to be adjusted if the bandsaw is used properly. The blade is tracking properly when the back of the blade is lightly touching the flange of both wheels.

To adjust the blade tracking on the bandsaw:

1.Turn the tracking set screw (hidden from view) in Figure 45 until the blade is tracking properly.

-35-

Blade Guide

Bearings

The blade guide bearings are adjusted at the fac- tory but may need adjustment depending on the use of your bandsaw. Use Figures 46 & 47 to

guide you through the following steps.

Figure 46. Blade guide adjustments.

To adjust the blade guide bearings:

1.Before making adjustments, make sure the blade is tensioned and tracking correctly.

2.DISCONNECT THE BANDSAW FROM

POWER!

3.Lower the bow until it makes contact with the horizontal stop.

4.Remove the blade guides.

5.The back of the blade should make light con- tact with the backing bearing.

???If it does not, loosen the two cap screws shown in Figure 46. Lower the blade guide until the back of the blade makes light con- tact with the backing bearing. Then tighten the two cap screws.

6.Loosen the set screw in Figure 47 to allow the eccentric bushing to turn.

7.Turn the hex nut on the eccentric shaft to adjust the distance of the guide bearing. The guide bearings and blade should make light contact or have a maximum clearance of 0.002".

8.Adjust the other eccentric blade guide bear- ing in the same manner.

Set Screw

Hex Nut

Figure 47. More blade guide adjustments.

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-40-

Bandsaw Cutting Metal G0592

Breakdown Parts Base

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Bandsaw Cutting Metal G0592

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Bandsaw Cutting Metal G0592

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Bandsaw Cutting Metal G0592

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Bandsaw Cutting Metal G0592

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