Metabo BAS 261 Precision Band Saw - Operating Instructions and Safety Guide

1. Declaration of Conformity

Metabo declares that the BAS 261 Precision band saws, identified by type and serial number *1), meet all relevant requirements of directives *2) and standards *3). Test report *4), issuing testing authority *5), and technical documents are available.

2. Please Read First!

These instructions are designed for safe and efficient operation. Read them thoroughly before use, paying close attention to safety information. Intended for users with basic technical knowledge. Keep all documentation for future reference.

Information Marking:

• Danger! Risk of personal injury or environmental damage.
• Risk of electric shock! Risk of personal injury by electric shock.
• Entanglement hazard! Risk of personal injury by body parts or clothing being drawn into the rotating saw blade.
• Caution! Risk of material damage.
• Note: Additional information.

3. Specified Conditions of Use

Suitable for cutting wood, plastics, and non-ferrous metals (not hard metal or hardened metal). Round stock requires jigs. Thin stock on edge needs a guide. Any other use is not specified and voids manufacturer liability.

Modifications or use of unapproved parts can cause damage.

4. General Safety Information

General Hazards

• Keep work area tidy.
• Be alert and work with reason. Do not operate when impaired.
• Ensure good lighting and firm footing.
• Use suitable supports for long stock.
• Do not operate near flammable liquids or gases.
• Only trained persons aware of dangers should operate.
• Persons under 18 require supervision.
• Keep bystanders and children away.
• Do not overload the machine.
• Use the correct power tool for the application.

Risk of Electric Shock

• Do not expose to rain or operate in damp/wet environments.
• Avoid contact with earthed objects.
• Do not misuse the power cable.
• Unplug before adjustments, servicing, or when not in use.

Risk of Injury by Moving Parts

• Do not operate without guards.
• Maintain distance from the saw belt; use feeding aids if needed.
• Wait for the saw belt to stop before removing debris.
• Cut only stock that can be safely held.
• Do not stop the belt by pushing work piece against its side.
• Disconnect power before servicing.
• Ensure no tools are left in the machine before switching on.
• Unplug when not in use.
• Replace damaged cables immediately.
• Use only approved extension cables outdoors.

Cutting Hazard

• Wear gloves when changing tools.
• Store saw belts safely.

Risk of Kickback

• Do not jam work pieces.
• Use fine-toothed belts for thin stock. Always use sharp belts.
• Check work pieces for foreign matter (nails, screws).
• Never cut multiple work pieces or bundles.
• Use jigs for round stock to prevent turning.

Entanglement Hazard

• Do not wear loose clothing, jewelry, or gloves.
• Contain long hair with a hairnet.
• Never cut work pieces with attached ropes, cords, wires, etc.

Hazard from Insufficient PPE

• Wear hearing protection.
• Wear safety glasses.
• Wear dust mask.
• Wear suitable work clothes.
• Wear non-slip footwear.
• Wear gloves for handling belts and rough work pieces.

Risk of Wood Dust

• Some wood dusts (oak, beech, ash) are carcinogenic. Work only with dust extraction.
• Minimize dust release: remove dust, fix leaks, ensure ventilation.

Hazard from Blocking Workpieces

• If blockage occurs: Switch off, unplug, wear gloves, clear with tool.

4.1 Symbols on the Machine

Danger! Disregard of warnings may lead to serious injury or damage.

• Read instructions.
• Wear protective goggles and ear protectors.
• Disconnect power before adjustments/maintenance.
• Do not direct light beam into eyes.

On Machine Labels:

• Wear ear protectors.
• Height adjustment.
• Set saw belt track.

4.2 Safety Devices

Upper Belt Guard

Protects against contact and flying chips. Must maintain 3mm distance from workpiece.

Lower Belt Guard

Protects against contact with the saw belt below the table. Must be installed during operation.

Housing Doors

Protect against contact with powered parts. Equipped with interlocks that shut off the motor when a door is opened while the saw is running. Must be closed during use.

Push Stick

Extends the hand and protects against contact with the saw belt. Use when distance to rip fence is < 120mm. Hold at 20-30 degrees to the table surface.

Replace if damaged.

5. Overview

Key components include:

• 1: On/Off switch (with cutting line illumination)
• 2: On switch
• 3: Off switch
• 4: Housing doors
• 5: Turn-lock fastener (for housing doors)
• 6: Upper saw belt guard
• 7: Lower saw belt guard
• 8: Push stick
• 9: Hole in saw table
• 10: Saw table
• 11: Table insert
• 12: Chip extraction nozzle
• 13: Clamping screw (saw table inclination)
• 14: Saw table fastening screws
• 15: Rip fence screw on saw table
• 16: Fence guide extrusion
• 17: Parallel stop (rip fence)
• 18: Parallel stop clamping lever
• 19: Setting knob for saw belt tension
• 20: Mitre fence
• 21: Clamping handle on mitre fence
• 22: Setting knob (height adjustment for upper belt guide)
• 23: Lock nut (height adjustment for upper belt guide)
• 24: Upper belt guide
• 25: Dust guard strip
• 26: Lock nut (for angle setting of upper band saw rollers)
• 27: Setting knob for angle of upper band saw rollers
• 28: Upper thrust bearing
• 29: Screws for upper thrust bearing
• 30: Upper guide bearing
• 31: Screw for upper guide bearing
• 32: Lower thrust bearing
• 33: Screws for lower thrust bearing
• 34: Lower guide bearing
• 35: Screw for lower guide bearing

6. Unpacking, Erection, Assembly and Transport

6.1 Unpacking

Unpack and transport with assistance. Do not lift by the upper belt guard.

6.2 Fix Saw

Secure on a stable base. Drill holes and fasten to a workbench.

6.3 Installing the Saw Table

Guide table over belt, place on guide, fasten with screws (14) and washers, but do not fully tighten yet for alignment.

6.4 Align the Saw Table

Align laterally (belt in middle of insert) and at right angles to the belt.

• Lateral Alignment: Align table so belt is centered in insert (11). Tighten screws (14).
• Right Angle Alignment: Position upper belt guide (24) fully up. Check belt tension (8.2). Loosen clamping screw (13). Tilt table (10) to horizontal stop. Retighten (13). Check perpendicularity with an angle gauge. Adjust end stop screw (15) via hole (9) if needed (turn anticlockwise to adjust, clockwise to touch housing).

6.5 Installing Fence Guide Extrusion

Fasten extrusion (16) to table with wing nuts and washers.

6.6 Fit Parallel Stop

Can be fitted left or right of belt. Hook into rear table edge, place on extrusion (16), clamp with lever (18).

6.7 Transport

Lower upper belt guide (24). Remove protruding accessories. Do not lift by safety devices. Transport with assistance.

7. Machine Details

ON/OFF Switch

Green button (2) for ON, red button (3) for OFF. Restart protection prevents automatic startup after power failure.

Housing Door Turn-lock Fastener

Use fastener (5) to open/close doors. Opening doors activates interlock, shutting off motor.

Setting Knob for Saw Belt Tension

Correct belt tension using knob (19) (details in 8.2).

Setting Knob for Angle of Upper Band Saw Roller

Adjust angle using knob (27) to align belt centrally on rollers (details in 10.2).

Saw Table Tilt

Loosen screw (13) to tilt table (10) up to 45.

Rip Fence

Clamped at front, secured at back. Can be used on either side.

Mitre Fence

Inserted into table groove. Turns 60 each way for mitre cuts. Has stops for 45 and 90. Release handle (21) to adjust angle. Ensure handle (21) is tight when sawing.

8. Initial Operation

General Preparations

Ensure saw is mounted, table installed/aligned, and safety devices checked before connecting to power.

8.1 Connect Chip Extraction

Connect dust collector or vacuum to nozzle (12). Minimum air speed of 20 m/s required for effective dust extraction. Operation without extraction is only permitted outdoors, for short periods (max 30 min), or with a dust mask.

8.2 Tighten Saw Belt

Set upper belt guide (24) to top. Check tension by pressing belt laterally (3-5mm deflection). Adjust tension with knob (19) (clockwise to tighten, anticlockwise to loosen).

8.3 Connection to Power Mains

Use only in dry environments. Connect to power source matching voltage/frequency on rating label. Use FI switch (30mA). Ensure outlets are properly installed and earthed. Check house connection if unsure.

Route cable to avoid interference or damage. Protect cable from heat, liquids, sharp edges. Use appropriate extension cables. Do not pull cable to unplug.

9. Operation

General Safety for Operation

• Wear PPE: dust mask, ear protection, safety goggles.
• Cut only one workpiece at a time.
• Always hold workpiece down on the table.
• Do not jam workpieces.
• Do not slow belt by pushing workpiece against it.
• Use push stick if rip fence to belt distance <= 120mm.
• Use workpiece supports for long stock.
• Use dust collector.
• Use jigs for round stock.
• Use guides for thin stock on edge.
• Check saw belt and guards before use. Replace damaged parts.
• Assume correct work position; saw teeth must point towards operator.
• Never cut multiple workpieces or bundles.

Entanglement Hazard

• No loose clothing, jewelry, or gloves.
• Contain long hair.
• Never cut workpieces with attached ropes, cords, wires.

9.1 Set Height of Belt Guide

Adjust upper belt guide (24) before each cut to be approx. 3mm above workpiece. Adjust after belt changes or table adjustments. Switch off machine and wait for belt to stop before adjusting. Loosen lock nut (23), turn knob (22) to set height, retighten (23).

9.2 Sawing

Adjust table tilt if needed. Use rip fence (17) or mitre fence (20) as required. Ensure workpiece is not jammed. Ensure upper belt guide is 3mm above workpiece. Make a trial cut. Place workpiece, start saw, cut in one pass. Switch off if not continuing immediately.

10. Care and Maintenance

General Precautions

Switch off, unplug, and wait for saw to stop before any maintenance. Re-check safety devices after work. Use only genuine Metabo parts. Only qualified personnel for repairs beyond this manual.

10.1 Change Saw Belt

Wear gloves. Use suitable belts. Remove rip fence (17) and fence guide extrusion (16). Open housing doors (4). Fold lower guard (7) forward. Lower upper belt guide (24). Loosen belt tension with knob (19). Remove dust guard strip (25). Remove old belt. Insert new belt, ensuring teeth point forward and it sits centrally on rubber tyres. Tighten belt with knob (19). Replace dust guard strip (25). Close lower guard (7). Close housing doors (4). Then, tension belt (8.2), align belt (10.2), set guides (10.3, 10.4), run for 1 min, switch off, unplug, and re-check settings.

10.2 Align Saw Belt (Set Run)

If belt is not centered on tyres, adjust tilt of upper roller using knob (27). Clockwise moves belt rearward, anticlockwise moves it forward. Release/retighten lock nut (26).

10.3 Align Upper Belt Guide

Adjust thrust bearing (28) and guide bearings (30) after belt change/alignment. Thrust bearing: Loosen screw (29), align bearing (0.5mm gap), retighten (29). Guide bearings: Loosen screw (31), move bearing (30) to lightly touch belt, retighten (31). Repeat for other side.

10.4 Align Lower Belt Guide

Similar adjustment for lower thrust bearing (32) and guide bearings (34) using screws (33) and (35).

10.5 Replacing Band Saw Tyre

Check tyres for wear. Replace in pairs. Remove belt, lift tyre with screwdriver, pull off, mount new tyre, reinstall belt.

10.6 Table Insert Change

Replace insert (11) if sawing gap is damaged. Remove screws, remove insert, insert new one, tighten screws.

10.7 Cleaning the Saw

Open lower door. Remove chips/dust with brush or vacuum from housing, belt guides, and controls.

10.8 Storage

Store where unauthorized persons cannot operate it and no one can be injured. Do not store outdoors or in damp areas without protection.

11. Accessories

Use only genuine Metabo accessories that meet specified requirements.

See www.metabo.com for full accessory range.

12. Repairs

Have repairs done by qualified personnel using original parts. If mains cable is damaged, it must be replaced by an original Metabo cable. Contact Metabo representative for repairs. Spare parts lists available at www.metabo.com.

13. Environmental Protection

Dispose of machines, packaging, and accessories according to national regulations for environmentally compatible disposal and recycling. Dispose of packaging materials according to labelling and municipal guidelines. For EU countries: Do not dispose of power tools in household waste. Collect used tools separately for recycling.

14. Troubleshooting Guide

Motor Does Not Run

• Check housing doors are closed (interlock).
• If undervoltage relay tripped: switch on again.
• If no mains voltage: check cable, plug, outlet, fuse.
• If motor overheated: remove cause, let cool, restart.

Saw Belt Wanders Off Line

• If belt not centered on wheels: adjust upper roller angle (10.2).

Saw Belt Breaks

• Incorrect tension: correct tension (8.2).
• Load too high: reduce pressure/feed rate.
• Incorrect belt: replace belt (10.1) with appropriate width for workpiece.

Saw Belt Warped

• Load too high: avoid lateral pressure.

Saw Vibrates

• Insufficient mounting: fix saw securely.
• Saw table loose: align and fasten table.
• Motor mount loose: check and tighten screws.

Dust Extraction Port Blocked

• No dust collector or insufficient suction: connect collector or increase suction power (>= 20 m/s at nozzle).

15. Technical Specifications

Explanation of symbols:

• U = Mains voltage
• I = Rated current
• F = Min. fuse protection
• P1 = Rated input power
• P2 = Power output
• n0 = No-load speed
• v0 = Cutting speed
• SL = Saw belt length
• SB = Saw belt width
• SD = Max. belt thickness
• H = Max. cutting height
• B = Lateral passage
• W = Saw table swivel range
• A1 = Machine dimensions (LxWxH)
• A2 = Saw table dimensions (LxW)
• Ah = working height without stand
• m = weight
• D1 = connection diameter of extraction nozzle
• ~ = AC Power
• Machine in protection class II

Technical Data Table:

Emission Values: These values help assess and compare emissions. Actual load may vary. Consider breaks and lower load periods for assessment.

Vibration Total Value: Determined per EN 61029.

Typical A-weighted Sound Levels: LpA, LWA, KpA, KWA values provided. Wear ear protectors!