CORDLESS POWER SHEAR 19.2 volts 99735 Set up and Operating Instructions Distributed exclusively by Harbor Freight Tools. 3491 Mission Oaks Blvd., Camarillo, CA 93011 Visit our website at: http://www.harborfreight.com Read this material before using this product. Failure to do so can result in serious injury. Save this manual. Copyright 2008 by Harbor Freight Tools. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing improvements, actual product may differ slightly from the product described herein. Tools required for assembly and service may not be included. For technical questions or replacement parts, please call 1-800-444-3353.
Save This Manual Keep this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures. Write the product s serial number in the back of the manual (or month and year of purchase if product has no number). Keep this manual and the receipt in a safe and dry place for future reference. Safety Alert Symbol and Signal Words In this manual, on the labeling, and all other information provided with this product: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE is used to address practices not related to personal injury. CAUTION, without the safety alert symbol, is used to address practices not related to personal injury. IMPORTANT SAFETY INSTRUCTIONS Instructions Pertaining to a Risk of Fire or Injury to Persons WARNING When using tools, basic precautions should always be followed, including the following: To reduce the risks of fire and inju- ry to persons, read all the instructions before using the Shear. a. a. Do not operate the Shear in ex- plosive atmospheres, such as in the presence of flammable liquids, gases, or dust. This tool is able to create sparks resulting in the ignition of the dust or fumes. b. c. General Work area Keep the work area clean and well lighted. Cluttered benches and dark areas increase the risks of fire and injury to persons. Keep bystanders, children, and visitors away while operating the tool. Distractions are able to result in the loss of control of the Shear. SKU 99735 For technical questions, please call 1-800-444-3353. Page 2
Stay alert. Watch what you are do- ing and use common sense when operating the tool. Do not use the shear while tired or under the influence of drugs, alcohol, or medication. A moment of inattention while operating the Shear increases the risk of injury to persons. a. b. c. d. Personal safety Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair increases the risk of injury to persons as a result of being caught in moving parts. Avoid unintentional starting. Be sure the Power Switch is off before connecting to the Battery. Do not carry the tool with your finger on the Power Switch. Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the Shear in unexpected situations. e. Use safety equipment. A dust mask, non-skid safety shoes and a hard hat must be used for the applicable conditions. Wear heavy-duty work gloves during use. f. Always wear eye protection. Wear ANSI-approved safety goggles. h. a. g. Always wear NIOSHapproved hearing protection when using the Shear. Prolonged exposure to high intensity noise is able to cause hearing loss. DANGER! Keep hands and body away from cutting area and Blades. Contact with the Blades will result in a serious injury. Tool use and care Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against the body is unstable and is able to lead to loss of control. b. Do not force the Shear. Use the correct tool for the application. The correct tool will do the job better and safer at the rate for which the tool is designed. c. d. e. Do not use the Shear if the Power Switch does not turn the tool on or off. Any tool that cannot be controlled with the Trigger is dangerous and must be repaired. Disconnect the Shear from its Battery before making any adjustments, changing accessories, or storing the tool. Such preventive safety measures reduce the risk of starting the Shear unintentionally. Store the Shear when it is idle out of reach of children and other untrained persons. Any tool is dangerous in the hands of untrained users. Maintain the Shear with care. f. Keep a cutting tool sharp and clean. A properly maintained tool, with sharp cutting edges reduces the risk of binding and is easier to control. SKU 99735 For technical questions, please call 1-800-444-3353. Page 3
g. h. a. b. c. Check for misalignment or binding of moving parts, breakage of parts, and any other condition that affects the Shear s operation. If damaged, have the tool serviced before using. Many accidents are caused by poorly maintained tools. Use only accessories that are identified by the manufacturer for the specific tool model. Use of an accessory not intended for use with the specific tool model, increases the risk of injury to persons. Service Tool service must be performed only by qualified repair personnel. When servicing a tool, use only identical replacement parts. Use only authorized parts. Use only the lubricants supplied with the tool or specified by the manufacturer. Save these instructions. Symbols and Specific Safety Instructions Symbol n o.../min PSI ft-lb BPM CFM SCFM NPT NPS Symbol Definitions Property or statement No-load speed Revolutions or reciprocation per minute Pounds per square inch of pressure Foot-pounds of torque Blows per minute Cubic Feet per Minute flow Cubic Feet per Minute flow at standard conditions National pipe thread, tapered National pipe thread, straight WARNING marking concerning Risk of Eye Injury. Wear ANSI-approved eye protection. WARNING marking concerning Risk of Hearing Loss. Wear hearing protection. WARNING marking concerning Risk of Respiratory Injury. Wear NIOSHapproved dust mask/respirator. WARNING marking concerning Risk of Explosion. Specific Safety Instructions DANGER! Keep hands and body away from cutting area and Blades. Keep your second hand on Motor Housing. Contact with the Blades will result in a serious injury. SKU 99735 For technical questions, please call 1-800-444-3353. Page 4
3. 4. 5. 6. 7. 8. 9. Only use with accessories rated to handle the forces exerted by this tool during operation. Other accessories not designed for the forces generated may break and forcefully launch pieces. Use this tool with both hands only. Using tools with only one hand can result in loss of control. Do not lay 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. Before using the Shear, make sure the Blades on the Blade Holder (14) are properly attached to the tool. Also, make sure the Blades are not dull, cracked, or bent. The Blades will become hot while cutting. Allow the Blades to completely cool before touching. Allow the Blades to move at full speed before feeding them into the workpiece. Do not force the Blades into the workpiece when cutting. Apply moderate pressure, allowing the Blades to cut without being forced. When turning off the Shear, allow the Blades to stop on their own. Do not press against the Blades to stop them. Always use recommended replacement Blades. The recommended replacement Blades are available from Harbor Freight Tools. The warnings and precautions discussed in this manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator. Vibration Precautions This tool vibrates during use. Repeated or long-term exposure to vibration may cause temporary or permanent physical injury, particularly to the hands, arms and shoulders. To reduce the risk of vibration-related injury: Anyone using vibrating tools regularly or for an extended period should first be examined by a doctor and then have regular medical checkups to ensure medical problems are not being caused or worsened from use. Pregnant women or people who have impaired blood circulation to the hand, past hand injuries, nervous system disorders, diabetes, or Raynaud s Disease should not use this tool. If you feel any medical or physical symptoms related to vibration (such as tingling, numbness, and white or blue fingers), seek medical advice as soon as possible. SKU 99735 For technical questions, please call 1-800-444-3353. Page 5 3. 4. 5. 6. Do not smoke during use. Nicotine reduces the blood supply to the hands and fingers, increasing the risk of vibration-related injury. Wear suitable gloves to reduce the vibration effects on the user. Use tools with the lowest vibration when there is a choice between different processes. Include vibration-free periods each day of work. Grip tool as lightly as possible (while still keeping safe control of it). Let the tool do the work.
7. To reduce vibration, maintain tool as explained in this manual. If abnormal vibration occurs, stop immediately. Save these instructions. POWER SWITCH (29) LOCK-OFF BUTTON (30) Specifications (32) Electrical Requirements Cutting Capacity Cutting Speed Activation Method Accessories Power Source: 19.2 VDC Battery Battery Type: NI/CD Rechargeable Charge Time: 1 Hour with Auto Cut-Off Charger Type: Class 2 Charger Charger Input: 120 V~ / 60 Hz / 80 W Charger Power Plug Type: 2-Prong, Polarized Charger Power Cord Type: 18AWG x 2C Straight Cutting: 1/16 Thick Curved Cutting: 3/64 Thick 4500 RPM Slide Power Switch (ON/OFF) Power Switch Lock Included Thickness Gauge (Qty. 1) 3mm Hex Wrench (Qty. 1) BLADE (12) CHARGER (34) FIGURE A THICKNESS GAUGE (35) HEX WRENCH (36) Unpacking When unpacking, check to make sure that the item is intact and undamaged. If any parts are missing or broken, please call Harbor Freight Tools at the number shown throughout the manual as soon as possible. PRODUCT FEATURES Read the entire Important Safety Information section at the beginning of this manual including all text under subheadings therein before set up or use of this product. Note: For additional information regarding the parts listed in the following pages, refer to the Assembly Diagram near the end of this manual. Operating Instructions Read the entire Important Safety Information section at the beginning of this manual including all text under subheadings therein before set up or use of this product. Inspect the Cordless Shear before use. Check for damaged, loose, and missing parts. If any problems are found, do not use tool until repaired. To prevent serious injury from accidental operation: Turn off the Shear and remove its Battery (32) before SKU 99735 For technical questions, please call 1-800-444-3353. Page 6
3. performing any inspection, maintenance, or cleaning procedures. To prevent serious injury: Do not adjust or tamper with any control or component in a way not specifically explained within this manual. Improper adjustment can result in tool failure or other serious hazards. Work Area Set Up Designate a work area that is clean and well-lit. The work area must not allow access by children or pets to prevent injury and distraction. Secure loose workpieces using a vise or clamps (not included) to prevent movement while working. There must not be hazardous objects (such as utility lines or foreign objects) nearby that will present a hazard while working. b. Plug the Charger s (34) Power Cord into the nearest 120 volt, grounded, electrical outlet. (See Figure B.) c. The Battery (32) will immediately commence charging, as indicated by the illuminated RED Charging Light on the Charger (34). (See Figure B.) d. In approximately one hour the RED Charging Light will automatically go out, and the GREEN Fully Charged Light on the Charger will illuminate. (See Figure B.) e. Once fully charged, unplug the Charger (34) from its electrical outlet. Then remove the Battery (32) from the Charger. (See Figure B.) FIGURE B (32) CHARGER (34) General Operating Instructions To Charge The Battery: RED MEANS CHARGING GREEN MEANS FULLY CHARGED Prior to its first use, and before subsequent uses, the Battery (32) must be charged. The charge time for the Battery is one hour. Do not overcharge the Battery, as damage to the Battery and Charger (34) may occur. To charge the Battery: (32) CHARGER (34) a. Insert the Battery (32) onto the Charger (34). (See Figure B.) RED MEANS CHARGING GREEN MEANS FULLY CHARGED SKU 99735 For technical questions, please call 1-800-444-3353. Page 7
To Attach The Battery To The Shear: To Operate The Shear: Depress the Battery Connector Button located on each side of the Battery (32). Then insert the Battery into the bottom of the Shear until the Battery Connector Buttons click into place. (See Figure C.) FIGURE C (32) ALWAYS wear ANSI-approved safety goggles and heavy duty work gloves when operating the Shear. IMPORTANT: Before first use, it is recommended to test the Shear on scrap material to determine the cutting capacity of the Blades (up to 1/16 thick steel when straight cutting or 3/64 thick steel when cutting curves). If the tool requires more force to accomplish the task, a larger Shear should be used. Make sure to hold the Shear with your hands and body safely away from the Blade (12). The Lock-Off Button: The Power Switch (29) features a Lock-Off Button (30) to prevent accidental starting of the Shear. To lock the Power Switch (29) in its OFF position, slide the Lock-Off Button (30) forward. To turn the Power Switch to its ON position, slide the Lock-Off Button backward. (See Figure D.) FIGURE D 3. Move the Lock-Off Button (30) backward and turn the Power Switch (29) to its ON position. (See Figure E, next page.) 4. 5. When the Shear comes to full speed, align the Blade (12) with the cut line on the workpiece. Make sure the workpiece sits atop the Blade Holder (14). (See Figure E, next page.) Slowly move the Shear s Blade (12) along the cutline of the workpiece until the cut is completely finished. (See Figure E, next page.) 6. When finished cutting the workpiece, move the Power Switch (29) to stop its OFF position. Move the Lock- Off Button (30) forward to lock the tool off. (See Figure E, next page.) LOCK-OFF BUTTON (30) POWER SWITCH (29) SKU 99735 For technical questions, please call 1-800-444-3353. Page 8
POWER SWITCH (29) Maintenance Instructions LOCK-OFF BUTTON (30) FIGURE E Procedures not specifically explained in this manual must be performed only by a qualified technician. TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION: Turn off the Shear and remove its Battery (32) before performing any inspection, maintenance, or cleaning procedures. WORKPIECE To Remove The Battery From The Shear: Depress the Battery Connector Button located on each side of the Battery (32). Then pull the Battery from the bottom of the Shear. (See Figure F.) FIGURE F (32) BEFORE EACH USE, examine the general condition of the Shear. Check for loose screws, misalignment or binding of moving parts, broken parts, damaged electrical wiring, and any other condition that may affect its safe operation. If a problem occurs, turn off the Shear immediately, remove its Battery (32), and have the problem corrected before further use. Do not use a damaged tool. THE SHEAR IS EQUIPPED WITH A 19.2 VOLT NICKEL-CADMIUM (18). With proper care, the Battery can be recharged many, many times. Follow the steps below to ensure proper Battery care: a. Always switch to a fresh Battery (32) when tool performance begins to diminish. Severe heat is most destructive to a Battery. The more heat generated, the faster the Battery loses power. Never over-discharge a Battery by using the tool even after tool performance is decreasing. Never attempt to discharge a Battery by continuing to squeeze the tool s Power Switch (29). When tool performance begins to diminish, SKU 99735 For technical questions, please call 1-800-444-3353. Page 9
3. stop the tool, recharge the Battery and use the fresh Battery for optimal performance. b. The charging room temperature should be between 50 Fahrenheit and 104 Fahrenheit. c. If the Battery (32) has charged for approximately one hour but will not power the Shear, the Battery may need replacement. Purchase replacement batteries only from Harbor Freight Tools. Do not attempt to repair the Battery. d. Contact local hazardous waste disposal authorities for proper Battery (32) disposal. Never set fire to a Battery. TO ADJUST THE BLADE CLEAR- ANCE: Periodically, the Blade (12) clearance will need to be adjusted for proper tool operation. To do so: a. Use the Hex Wrench (36) to unscrew and remove the Blade Screw (13) under the Blade Holder (14). b. Use the Hex Wrench (36) to unscrew and remove the Adjustment Screw (16) and Nut (17) from the side of the Blade Holder (14). c. Use the Thickness Gauge (35) at 1/10 thickness and insert the Gauge between the two Blades (12, 15). Screw in the Adjustment Screw (16) until both Blades touch the Thickness Gauge. Then tighten the Nut (17) to secure the Adjustment Screw in place. d. The Thickness Gauge (35) should barely slide between the two Blades (12, 15). If the Blade clearance is too small, the cutting speed will be affected. If cutting a curve, adjust the Blade clearance larger to facilitate the operation. (See Figure G.) ADJUSTMENT SCREW (16) NUT (17) BLADE SCREW (13) FIGURE G 3. AFTER EACH USE, keep the exterior of the Shear free of excess grease and oil. Use only a mild detergent and damp cloth when cleaning. Do not use a flammable or combustible solvent. Do not immerse the tool in liquid. 4. 5. WHEN STORING, keep the tool in a clean, dry, safe location out of reach of children and other unauthorized persons. CAUTION: All maintenance, service, and repairs not mentioned in this manual must only be performed by a qualified service technician. SKU 99735 For technical questions, please call 1-800-444-3353. Page 10
Troubleshooting Problem Possible Causes Possible Solutions Tool does not turn on. Housing heats during use. Undesireable cut. Battery not properly attached to tool. 3. Battery not charged. Defective battery. 4. Internal mechanism contaminated. Incorrect lubrication or not enough lubrication of internal parts.. Worn parts. 3. Properly attach battery. Charge battery for approximately one hour. Replace battery. Dull, bent, or cracked blades. Replace blades. 4. Have qualified technician clean and lubricate mechanism. Have a qualified service technician lubricate using air tool oil and grease. Have qualified technician inspect internal mechanism and replace parts as needed. PARTS LIST Part # Description Qty. Part # Description Qty. 1 Front Cover Screw 4 20 Motor 1 2 Front Cover Assy. 1 21 Upper Label 1 3 Connecting Rod Assy. 1 22 Main Housing 1 4 Spindle Assy. 1 23 Label 1 5 Bearing Housing Assy. 1 24 Wires 1 6 Fan 1 25 Wires 1 7 Ring 1 26 Wires 1 8 Bushing 1 27 Battery Connector 1 9 Set Screw (M8x20) 1 28 Housing Screw 6 10 Finger Protector 1 29 Power Switch 1 11 Machine Screw (M5x10) 1 30 Lock-Off Button 1 12 Blade (#4.5) 1 31 Spring 1 13 Blade Screw 2 32 Battery 1 14 Blade Holder 1 33 Battery Label 1 15 Blade (M4) 1 34 Charger 1 16 Adjustment Screw 1 35 Thickness Gauge 1 17 Nut 1 36 Hex Wrench (3mm) 1 18 Screw 2 37 Charger Upper Label 1 19 Motor Housing 1 38 Charger Lower Label 1 SKU 99735 For technical questions, please call 1-800-444-3353. Page 11
assembly diagram SKU 99735 For technical questions, please call 1-800-444-3353. Page 12
PLEASE READ THE FOLLOWING CAREFULLY The manufacturer and/or distributor has provided the parts list and assembly diagram in this manual as a reference tool only. Neither the manufacturer or distributor makes any representation or warranty of any kind to the buyer that he or she is qualified to make any repairs to the product, or that he or she is qualified to replace any parts of the product. In fact, the manufacturer and/or distributor expressly states that all repairs and parts replacements should be undertaken by certified and licensed technicians, and not by the buyer. The buyer assumes all risk and liability arising out of his or her repairs to the original product or replacement parts thereto, or arising out of his or her installation of replacement parts thereto. LIMITED 90 DAY WARRANTY Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper installation, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special or consequential damages arising from the use of our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation of exclusion may not apply to you. This warranty is expressly in lieu of all other warranties, express or implied, including the warranties of merchantability and fitness. To take advantage of this warranty, the product or part must be returned to us with transportation charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise. If our inspection verifies the defect, we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will return repaired products at our expense, but if we determine there is no defect, or that the defect resulted from causes not within the scope of our warranty, then you must bear the cost of returning the product. This warranty gives you specific legal rights and you may also have other rights which vary from state to state. 3491 Mission Oaks Blvd. PO Box 6009 Camarillo, CA 93011 (800) 444-3353 Record Product s Serial Number Here: Note: If product has no serial number, record month and year of purchase instead. Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 99735 For technical questions, please call 1-800-444-3353. Page 13