Harbor Freight Tools 97099 User Manual
METAL CUTTING BANDSAW
Model
97009
7” X 12”
SET UP AND OPERATING INSTRUCTIONS
Diagrams within this manual may not be drawn proportionally.
Due to continuing improvements, actual product may differ slightly from the product described herein.
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© 2007 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.
For technical questions or replacement parts, please call 1-800-444-3353.
TABLE OF CONTENTS
Important Safety Information ...................................................................3
General Safety Rules.................................................................................4
Specic Safety Rules.................................................................................6
Grounding...................................................................................................8
Extension Cords.........................................................................................9
Symbology.................................................................................................10
Product Specications.............................................................................10
Set Up Instructions....................................................................................11
Operating Instructions..............................................................................12
Maintenance and Servicing......................................................................25
Troubleshooting Guide.............................................................................29
Parts Lists..................................................................................................30
Assembly Diagrams..................................................................................38
Electrical Schematics...............................................................................43
Warranty Information................................................................................46
Page 2SKU 97009 For technical questions, 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 near the assembly diagram (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.
IMPORTANT SAFETY INFORMATION
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.
DANGERDANGER
WARNINGWARNING
CAUTIONCAUTION
NOTICENOTICE
CAUTIONCAUTION
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.
Page 3SKU 97009 For technical questions, please call 1-800-444-3353.
GENERAL SAFETY RULES
WARNING! Read all instructions
Failure to follow all instructions listed below may result in electric shock,
re, and/or serious injury. The term “power tool” in all of the warnings listed
below refers to your line-operated (corded) power tool.
SAVE THESE INSTRUCTIONS
1.
2.
Work area safety
Keep work area clean and well lit. Cluttered or dark areas invite accidents.
a.
Do not operate power tools in explosive atmospheres, such as in the
b.
presence of ammable liquids, gases or dust. Power tools create sparks
which may ignite the dust or fumes.
Keep children and bystanders away while operating a power tool.
c.
Distractions can cause you to lose control.
Electrical safety
Power tool plugs must match the outlet. Never modify the plug in any way.
a.
Do not use any adapter plugs with grounded power tools. Unmodied plugs
and matching outlets will reduce risk of electric shock.
Avoid body contact with grounded surfaces such as pipes, radiators, ranges
b.
and refrigerators. There is an increased risk of electric shock if your body is
grounded.
Do not expose power tools to rain or wet conditions. Water entering a power
c.
tool will increase the risk of electric shock.
Do not abuse the cord. Never use the cord for carrying, pulling or unplugging
d.
the power tool. Keep cord away from heat, oil, sharp edges or moving parts.
Damaged or entangled cords increase the risk of electric shock.
3.
When operating a power tool outdoors, use an extension cord suitable for
e.
outdoor use. Use of a cord suitable for outdoor use reduces the risk of
electric shock.
Personal safety
Stay alert, watch what you are doing and use common sense when operating
a.
a power tool. Do not use a power tool while you are tired or under the
inuence of drugs, alcohol or medication. A moment of inattention while
operating power tools may result in serious personal injury.
Use safety equipment. Always wear eye protection. Safety
b.
equipment such as dust mask, heavy duty work gloves, or
hearing protection used for appropriate conditions will reduce
personal injuries.
Page 4SKU 97009 For technical questions, please call 1-800-444-3353.
Avoid accidental starting. Ensure the switch is in the off-position before
c.
plugging in.
Remove any adjusting key or wrench before turning the power tool on. A
d.
wrench or a key left attached to a rotating part of the power tool may result in
personal injury.
Do not overreach. Keep proper footing and balance at all times. This
e.
enables better control of the power tool in unexpected situations.
Dress properly. Do not wear loose clothing or jewelry. Keep your hair,
f.
clothing and gloves away from moving parts. Loose clothes, jewelry or long
hair can be caught in moving parts.
4.
Power tool use and care
Do not force the power tool. Use the correct power tool for your application.
a.
The correct power tool will do the job better and safer at the rate for which it
was designed.
Do not use the power tool if the switch does not turn it on and off. Any power
b.
tool that cannot be controlled with the switch is dangerous and must be
repaired.
Disconnect the plug from the power source and/or the battery pack from the
c.
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.
Store idle power tools out of the reach of children and do not allow people
d.
unfamiliar with the power tool or these instructions to operate the power tool.
Power tools are dangerous in the hands of untrained users.
Maintain power tools. Check for misalignment or binding of moving parts,
e.
breakage of parts and any other condition that may affect the power tool’s
operation. If damaged, have the power tool repaired before use. Many
accidents are caused by poorly maintained power tools.
Keep cutting tools sharp and clean. Properly maintained cutting tools with
f.
sharp cutting edges are less likely to bind and are easier to control.
5.
Use the power tool and accessories in accordance with these instructions
g.
and in the manner intended for the particular type of power tool, taking into
account the working conditions and the work to be performed. Use of the
power tool for operations different from those intended could result in a
hazardous situation.
Service
Have your power tool serviced by a qualied repair person using only
a.
identical replacement parts. This will ensure that the safety of the power tool
is maintained.
Page 5SKU 97009 For technical questions, please call 1-800-444-3353.
SPECIFIC SAFETY RULES
1.
2.
3.
4.
5.
6.
7.
8.
Maintain labels and nameplates on the tool. These carry important safety
information. If unreadable or missing, contact Harbor Freight Tools for a
replacement.
Make sure the Bandsaw is located on a at, level, sturdy surface capable of
supporting the weight of the tool, accessories, and workpieces. Always “chock”
the Wheels to prevent the Bandsaw from accidentally moving.
Make sure the Table of the Bandsaw and surrounding area are clear with the
exception of the workpiece to be cut.
Before using the Bandsaw, check to make sure the Saw Blade is properly
mounted and in good condition.
Never stand on the Bandsaw. Serious injury could result if the Bandsaw is tipped
or if the rotating Saw Blade is accidentally contacted.
Never attempt to cut more than one workpiece at a time.
When cutting a large workpiece, make sure its entire length is properly
supported. If necessary, use a roller stand (not included).
Do not lean on the Bandsaw when the tool is in its upright position.
9.
10.
11.
12.
13.
14.
15.
16.
When moving the Bandsaw, always have its Head lowered to its horizontal
position.
Allow the Saw Blade to rotate to full speed before feeding the Blade into a
workpiece. When turning off the Bandsaw, allow the Saw Blade to spin down
and stop on its own. Do not press against the Saw Blade to stop it.
To avoid injury, always wear ANSI-approved safety goggles and heavy duty work
gloves when changing the Saw Blade.
The Saw Blade becomes hot while cutting. Allow the Blade to completely cool
before handling.
Do not force the Saw Blade into the workpiece when cutting. Apply moderate
pressure, allowing the Blade to cut without being forced.
Turn off the Bandsaw and allow the Saw Blade to completely stop if the Blade is
to be backed out of an incomplete cut.
Never attempt to remove material stuck in the moving parts of the Bandsaw while
it is plugged in and running.
Keep all safety guards in place and in proper working order.
17.
Always adjust and position the Blade Guide Arm before starting the cut.
Page 6SKU 97009 For technical questions, please call 1-800-444-3353.
18.
When cutting magnesium, use soluble oils or emulsions (oil/water mix) as water
only will greatly intensify any accidental magnesium chip re. See your industrial
coolant supplier for specic coolant recommendations when cutting magnesium.
19.
20.
21.
22.
23.
24.
Avoid unintentional starting. Prepare to begin work before turning on the tool.
Do not leave the tool unattended when it is plugged into an electrical outlet. Turn
off the tool, and unplug it from its electrical outlet before leaving.
Use the Vise or other practical ways to secure and support the workpiece to the
Support Plate. Holding the work by hand or against your body is unstable and
may lead to loss of control, and personal injury.
This product is not a toy. Keep it out of reach of children.
The brass components of this product contain lead, a chemical known to the
State of California to cause birth defects (or other reproductive harm). California
Health & Safety Code 25249.5, et seq.)
People with pacemakers should consult their physician(s) before use.
Electromagnetic elds in close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure. In addition, people with
pacemakers should:
• Avoid operating alone.
• Do not use with power switch locked on.
• Properly maintain and inspect to avoid electrical shock.
• Any power cord must be properly grounded. Ground Fault Circuit Interrupter
(GFCI) should also be implemented – it prevents sustained electrical shock.
25.
26.
Some dust created by power sanding, sawing, grinding, drilling, and other
construction activities, contains chemicals known [to the State of California] to
cause cancer, birth defects or other reproductive harm. Some examples of these
chemicals are:
Lead from lead-based paints
Crystalline silica from bricks and cement or 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 exposure to these chemicals: work in a well ventilated
area, and work with approved safety equipment, such as those dust masks that
are specially designed to lter out microscopic particles. (California Health &
Safety Code § 25249.5, et seq.)
The warnings, precautions, and instructions discussed in this instruction 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.
Page 7SKU 97009 For technical questions, please call 1-800-444-3353.
SAVE THESE INSTRUCTIONS.
GROUNDING
WARNINGWARNING
1.
2.
Tools marked with “Grounding Required” have a three wire cord and three prong
grounding plug. The plug must be connected to a properly grounded outlet. If
the tool should electrically malfunction or break down, grounding provides a low
resistance path to carry electricity away from the user, reducing the risk of electric
shock. (See 3-Prong Plug and Outlet.)
The grounding prong in the plug is connected through the green wire inside the
cord to the grounding system in the tool. The green wire in the cord must be the
only wire connected to the tool’s grounding system and must never be attached
to an electrically “live” terminal. (See 3-Prong Plug and Outlet.)
Improperly connecting the grounding wire can result in
electric shock.
Check with a qualied electrician if you are in doubt as to
whether the outlet is properly grounded. Do not modify
the power cord plug provided with the tool. Never remove
the grounding prong from the plug. Do not use the tool if
the power cord or plug is damaged. If damaged, have it
repaired by a service facility before use. If the plug will not
t the outlet, have a proper outlet installed by a qualied
electrician.
Grounded Tools: Tools with Three Prong Plugs
3.
The tool must be plugged into an appropriate outlet, properly installed and
grounded in accordance with all codes and ordinances. The plug and outlet
should look like those in the following illustration.
(See 3-Prong Plug and Outlet.)
3-Prong Plug and Outlet
Outlets for 2-Prong Plug
Page 8SKU 97009 For technical questions, please call 1-800-444-3353.
Double Insulated Tools: Tools with Two Prong Plugs
1.
2.
1.
2.
3.
Tools marked “Double Insulated” do not require grounding. They have a special
double insulation system which satises OSHA requirements and complies
with the applicable standards of Underwriters Laboratories, Inc., the Canadian
Standard Association, and the National Electrical Code.
(See Outlets for 2-Prong Plug.)
Double insulated tools may be used in either of the 120 volt outlets shown in the
preceding illustration. (See Outlets for 2-Prong Plug.)
EXTENSION CORDS
Grounded tools require a three wire extension cord. Double Insulated tools can
use either a two or three wire extension cord.
As the distance from the supply outlet increases, you must use a heavier gauge
extension cord. Using extension cords with inadequately sized wire causes a
serious drop in voltage, resulting in loss of power and possible tool damage.
(See Table A.)
The smaller the gauge number of the wire, the greater the capacity of the cord.
For example, a 14 gauge cord can carry a higher current than a 16 gauge cord.
(See Table A.)
4.
5.
6.
7.
8.
When using more than one extension cord to make up the total length, make
sure each cord contains at least the minimum wire size required. (See Table A.)
If you are using one extension cord for more than one tool, add the nameplate
amperes and use the sum to determine the required minimum cord size.
(See Table A.)
If you are using an extension cord outdoors, make sure it is marked with the
sufx “W-A” (“W” in Canada) to indicate it is acceptable for outdoor use.
Make sure the extension cord is properly wired and in good electrical condition.
Always replace a damaged extension cord or have it repaired by a qualied
electrician before using it.
Protect the extension cords from sharp objects, excessive heat, and damp or wet
areas.
Page 9SKU 97009 For technical questions, please call 1-800-444-3353.
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS* (120/240 VOLT)
NAMEPLATE
EXTENSION CORD LENGTH
AMPERES
(at full load)
0 – 2.0 18 18 18 18 16
2.1 – 3.4 18 18 18 16 14
3.5 – 5.0 18 18 16 14 12
5.1 – 7.0 18 16 14 12 12
7.1 – 12.0 18 14 12 10 -
12.1 – 16.0 14 12 10 - -
16.1 – 20.0 12 10 - - -
TABLE A
25 Feet 50 Feet 75 Feet 100 Feet 150 Feet
* Based on limiting the line voltage drop to ve volts at 150% of the rated amperes.
SYMBOLOGY
Double Insulated
Canadian Standards Association
V~
A
Volts Alternating Current
Amperes
Underwriters Laboratories, Inc.
n0 xxxx/min.
No Load Revolutions per Minute
(RPM)
SPECIFICATIONS
Electrical Requirements 120 V~ / 60 Hz / 16 Amps
1 HP Single Phase Motor / 1720 RPM
Power Switch Type: Toggle
Circuit Breaker: 18 Amps (Resettable)
Power Cord Type: 14 AWG x 3C
Plug Type: 120 Volt / 3-Prong / Grounded
Stock Capacity at 90° 7” (Round) / 7” x 12” (Rectangle)
Blade Speeds
(Feet Per Minute)
Blade Size
Teeth Per Inch
Belt Type 3V-270
Miter Slot Width / Depth 11/16” Wide / 9/16” Deep
Hydraulic Ram Travel 5-5/8”
Base Mounting Holes 3/8” Diameter (Qty. 4)
Wheel Dimensions 5” Diameter x 1” Wide
90 FPM / 135 FPM / 195 FPM / 255 FPM
0.75” x 0.031” x 93” (Carbon Steel Blade)
6 TPI
Page 10SKU 97009 For technical questions, please call 1-800-444-3353.
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
on the cover of this manual as soon as possible.
SET UP 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.
WARNINGWARNING
Note: For additional information regarding the parts listed in the following pages, refer
to the Assembly Diagrams near the end of this manual.
Risk of accidental starting; resulting in serious personal
injury. Turn the Power Switch of the tool to its “OFF”
position and unplug the tool from its electrical outlet before
assembling or making any adjustments to the tool.
Assembly
1.
2.
3.
NOTE: To assemble and locate the Bandsaw will require additional assistance
and a proper lifting device.
After the Bandsaw and its accessories are unpacked, make sure its Head is
lowered to its horizontal position. (See Figure A.)
With a proper lifting device, raise the Bandsaw approximately six inches off the
oor surface. (See Figure A.)
FIGURE A
4.
Once the Bandsaw is lifted, insert the Wheel Rod (92-4) through the two holes
located at the bottom/right side of the Stand (77S). Slide one Wheel (92-2) on
each end of the Wheel Rod. Place one Washer (92-1) on each end of the Wheel
Page 11SKU 97009 For technical questions, please call 1-800-444-3353.
Rod. Insert one Cotter Pin (92-3) through the hole in each end of the Wheel Rod.
Make sure to bend the Cotter Pins to secure the Wheels in place.
(See Figure B.)
5.
6.
7.
Screw in the two Levelers (93) into the two threaded mounting holes located
underneath the bottom/left side of the Stand (77S). (See Figure B.)
Carefully lower the Bandsaw to the oor surface. Then turn the two Levelers (93)
clockwise or counterclockwise to properly level the Stand (77S).
(See Figure B.)
Attach the Hand Rod (98-1) to the Stand Assembly (77S) using Screw (98-2),
washer (98-3) and Hex Nut (98-4). See Diagram on page 39.
FIGURE B
STAND (77S)
WHEEL ROD (92-4)
WHEEL (92-2)
LEVELER (93)
WASHER (92-1)
COTTER PIN (92-3)
8.
NOTE: The Bandsaw is factory pre-wired to operate on a grounded, 120 volt
system. However, if rewired, the Bandsaw is also designed to operate on a
grounded, 240 volt system. For information about how to switch the electrical
system from 120 volt to 240 volt, refer to the “Electrical Schematics” toward the
end of this manual. WARNING! Only a qualied electrician should attempt
to rewire the Bandsaw.
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.
Caution: Even though the unit is equipped with wheels and a carrying handle,
always seek help when wheeling the unit around the shop.
TO USE THE QUICK VISE
1.
2.
Place the workpiece between the Vise Jaws (9, 22) with the amount to be cut off
extending out past the Saw Blade (251). (See Figure C, next page.)
The Bandsaw is equipped with a quick action Vise Jaw mechanism which allows
you to instantly position the moveable Front Vise Jaw (9). (See Figure C.)
Page 12SKU 97009 For technical questions, please call 1-800-444-3353.
3.
To operate, turn the Hand Wheel (5S) counterclockwise 1/2 turn and move the
Front Vise Jaw (9) to the desired position. Then tighten the Front Vise Jaw
against the workpiece by turning the Hand Wheel clockwise. (See Figure C.)
HAND WHEEL (5S)
FIGURE C
HAND WHEEL (5S)
4.
Setting up the Quick Vise for a straight (0°) cut:
Loosen the Screws (H) and (G) of Front Vise Jaw (F).
•
Turn the Hand Wheel (5S) counterclockwise by half a turn and slide back the
•
Front Vise Jaw (9).
Loosen Screw (A and B) and note that Screw (A) should be in the slot which is
•
parallel with the Rear Vise Jaw.
Rear Vise Jaw at the scale side should be aligned with the zero (0) on the rule.
•
Tighten Screws (A and B). (See Figure D.)
FRONT VISE JAW (9)
FIGURE D
BASE (1)
REAR VISE JAW (22)
22
Note: Make
C
A
D
sure “C” slot is
free of casting
ush so the
vise can be
positioned in
all angles.
5.
B
G
9
H
ORIGINAL POSITION (FOR 0° CUTTING)
Setting up the Quick Vise an angle:
Remove Screws (A and B) from base of the Rear Vise Jaw (22).
•
Position (D) over (B) and attach the Screw and Washer (19 and 22) and attach Screw
•
(B).
Attach Carriage Screw (17) onto Slot (C) through the curved slot in the Base (1).
•
Align edge of the Rear Vise Jaw with the indexing rule and tighten Screws at (B and
•
C). (See Figure E.)
Page 13SKU 97009 For technical questions, please call 1-800-444-3353.
FIGURE E
THE POSITION FOR AN ANGLE (90°) CUT.
A
D
B
6.
Setting up the Quick Vise for cutting a 12” workpiece:
Remove both fasteners from the Rear Vise Jaw (22).
•
Position (B) over the outer threaded hole on the Base (1).
•
Position Slot (A) over the small rectangular opening across the Base (1).
•
Attach Screws (A and B). Align the lower edge of the Rear Vise Jaw (22) with
•
the “0” index mark adjacent to the 16° degree setting. Tighten the screws.
(See Figure F)
FIGURE F
A
D
B
TO ADJUST THE STOP BLOCK
For repeated cuts of pre-set lengths
1.
2.
Loosen the Thumb Screw (38) that holds the Stop Block (41) to the Stock Stop
Rod (40). (See Figure G)
Adjust the Stop Block (41) to the desired length position. Then re-tighten the
Thumb Screw (38). (See Figure G)
Page 14SKU 97009 For technical questions, please call 1-800-444-3353.
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