Harbor Freight Tools 4095 User's Manual
Contents
1. 27 Roller Shaft 60 Metal Saw Blade not shown 28 Gear Wheel 61 Replacement Brushes not shown 29 Washer 62 4MM Hex Key not shown 30 Center Column 63 Rotor Assembly Includes 51 56 B ee Only available as part of Rotor Assy 63 32 Carbon Brush 33 Brush Holder e4 Stator Lift Body Assembly 34 Screw Includes 18 46 39 40 49 57 35 __ Washer Only available as part of Stator Lift Body 36 Screw Nut Assy 64 NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts SKU 4095 For technical questions please call 1 800 444 3353 REV 10 05 PAGE 13 ASSEMBLY DIAGRAM WOOD SAW BLADE 59 NOT SHOWN METAL SAW BLADE 60 NOT SHOWN REV 10 05 SKU 4095 For technical questions please call 1 800 444 3353 PAGE 14 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 pro2. plugged from its electrical outlet prior to making any adjustments to the tool To Install A Saw Blade Select the Saw Blade 59 60 best suited for your application The Wood Blade 59 has a coarser tooth pitch The Metal Blade 60 has a finer tooth pitch Make sure to use each Blade only for its specified material See Figure B 2 With the Hex Key 62 loosen but do not remove the Hex Screw 6B See Figure B 3 Slide the selected Saw Blade 58 60 teeth down into the Guard Plate 2 as far as possible 4 Then firmly retighten the Hex Screw 6B to secure the Saw Blade 59 60 in place See Figure B WOOD SAW HEX SCREW 6B TRIGGER 37 BLADE 59 ADJUSTABLE SHOE PLATE 1 GUARD PLATE 2 7 HEX KEY 62 AEN METAL SAW BLADE 60 FIGURE B POWER CORD 44 REV 10 05 SKU 4095 For technical questions please call 1 800 444 3353 PAGE 10 To Adjust The Depth Of Cut 1 To Adjust the depth of cut loosen but do not remove the two Hex Screws 58 located on the underside of the Reciprocating Saw See Figure C 2 For a deeper cut slide the Adjustable Shoe Plate 1 close to the Guard Plate 2 For a shallower cut slide the Adjustable Shoe Plate further away from the Guard Plate See Figure C 3 Then retighten the two Hex Screws 58 See Figure C BOTTOM VIEW GUARD PLATE 2 ADJUSTABLE HEX SCREW SHOE PLATE FIGURE C 58 1 Operating Instructions 1 The
3. 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 LICENSEDTECHNICIANS 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 SKU 4095 For technical questions please call 1 800 444 3353 PAGE 12 PARTS LIST Part Description Part Description 1 Adjustable Shoe Plate 37 Trigger 2 Guard Plate 38 Right Body 3 Rubber Sleeve 39 Washer 4 Screw 40 Retaining Washer 5 Cover 41 Screw 6A _ Hex Screw 42 Power Cord Support 6B Hex Screw 43 Screw 7 Blade Holder 44 Power Cord 8 Felt Retainer 44B Cord Guard 8B Felt Pad 45 Racing Plate 9 Shock Absorber 46 Inducer 10 Small Cover Sheet A 47 Screw 11 Screw 48 Screw 12 Retaining Washer 49 Screw 14 Reciprocating Bar 50 Wingshield Ring 15 Sliding Bearing 51 Ball Bearing 80018 15B Felt Pad 52 Rotor 18 Left Body 53 Screw 19 Speed Control 54 Bearing Cover 20 Small Cover Sheet B 55 Ball Bearing 80200 23 Large Washer 57 Stator 24 Roller Bearing HKH1216 58 Screw 26 Roller 59 Wood Saw Blade not shown
4. loose clothing or jewelry Contain long hair Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts Avoid accidental starting Be sure the Trigger is off before plugging in Carrying power tools with your finger on the Trigger or plugging in power tools with the Trigger on invites accidents Remove adjusting keys or wrenches before turning the power tool on A wrench or a key that is left attached to a moving part of the power tool may result in personal injury Do not overreach Keep proper footing and balance at all times Proper footing and balance enables better control of the power tool in unexpected situations SKU 4095 For technical questions please call 1 800 444 3353 PAGE 3 15 16 17 18 19 20 2 22 23 24 25 Use safety equipment Always wear eye protection Dust mask nonskid safety shoes hard hat or hearing protection must be used for appropriate conditions TOOL USE AND CARE Use clamps not included or other practical ways to secure and support the workpiece to a stable platform Holding the work by hand or against your body is unstable and may lead to loss of control Do not force the tool Use the correct tool for your application The correct tool will do the job better and safer at the rate for which it is designed Do not use the power tool if the Trigger does not turn it on or off Any tool that ca
5. 095 For technical questions please call 1 800 444 3353 PAGE 7 DOUBLE INSULATED TOOLS TOOLS WITH TWO PRONG PLUGS Tools marked Double Insulated do not require grounding They have a special double insulation system which satisfies OSHA requirements and complies with the applicable standards of Underwriters Laboratories Inc the Canadian Standard Association and the National Electrical Code See Figure B Double insulated tools may be used in either of the 120 volt outlets shown in the following illustration See Figure B FIGURE B EXTENSION CORDS 1 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 Figure C next page 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 Figure C 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 Figure C If you are using one extension cord for more than one tool add the nameplate am peres and use the sum to determine the required minimum cord size See Figure C
6. 353 PAGE 6 WARNING Improperly connecting the grounding wire can result in the risk of electric shock Check with a qualified 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 fit the outlet have a proper outlet installed by a qualified electrician GROUNDED TOOLS TOOLS WITH THREE PRONG PLUGS 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 elec tric shock See Figure A 2 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 Figure A 3 Your 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 Figure A FIGURE A SKU 4
7. CHICAGO 3I YenifePower Tools RECIPROCATING SAW 4 5 AMP Model 04095 ASSEMBLY 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 2003 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 Manual Revised 02 05 PRODUCT SPECIFICATIONS ITEM DESCRIPTION U Electrical Requirements 120 Volt 60 Hz 4 5 Amps JL J LISTED Variable Speed 6 Positions 0 2300 SPM Strokes Per Minute E194601 Blade Stroke 1 3 16 Shoe Plate Tilt Pin Type Chuck Capacity 1 2 Standard Shank Overall Dimensions 16 1 2 L x 3 1 4 W x 5 3 4 H 6 70 Pounds SAVE THIS MANUAL You will need this manual for the safety warnings and precautions assembly operating inspection maintenance and cleaning procedures parts list and assem bly diagram Keep your invoice with this manual Write the invoice number on the inside of
8. Reciprocating Saw is equipped with a Trigger Lock mechanism To operate the tool for extended periods of time squeeze and hold the Trigger 37 then press the Trigger Lock To unlock the Trigger Lock mechanism squeeze and release the Trigger once See Figure B 2 Before plugging the Reciprocating Saw into its 120 Volt grounded electrical outlet check to make sure the Trigger 37 is not locked in its ON position Press and release the Trigger once to make sure the Trigger is unlocked and OFF See Figure B Plug the Reciprocating Saw into its 120 Volt grounded electrical outlet NOTE The Reciprocating Saw has a variable speed setting from 0 to 2300 SPM strokes per minute When cutting softer materials use a faster speed When cutting harder materials use a slower speed See Figure B 5 Hold the Reciprocating Saw firmly with both hands then squeeze the Trigger 37 to start the Saw NOTE Do not start the Reciprocating Saw if the Saw Blade 59 60 is in contact with anything before operation If necessary lift the Reciprocating Saw to free the Saw Blade before squeezing the Trigger See Figure B 6 If operating the Reciprocating Saw for an extended period of time you may wish to lock the Trigger 37 in position as described in Step 1 See Figure B 7 With the Reciprocating Saw ON place the Saw Blade 59 60 against the material to be cut Press down slightly on the Reciprocating Saw to help it cut Se
9. SKU 4095 For technical questions please call 1 800 444 3353 PAGE 8 6 If you are using an extension cord outdoors make sure it is marked with the suf fix W A W in Canada to indicate it is acceptable for outdoor use T Make sure your extension cord is properly wired and in good electrical condition Always replace a damaged extension cord or have it repaired by a qualified elec trician before using it 8 Protect your extension cords from sharp objects excessive heat and damp or wet areas RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS 120 VOLT NAMEPLATE EXTENSION CORD LENGTH AMPERES at full load 25 50 7 1 12 0 321 160 14 12 10 1361 200 12 10 J SYMBOLOGY Double Insulated Canadian Standards Association Underwriters Laboratories Inc Volts Alternating Current n J No Load Revolutions i per Minute RPM SKU 4095 For technical questions please call 1 800 444 3353 PAGE 9 UNPACKING When unpacking check to make sure that the tool 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 ASSEMBLY AND OPERATING INSTRUCTIONS NOTE For additional information regarding the parts listed in the following pages refer to the Assembly Diagram on page 14 WARNING Always make sure the Power Cord 44 of the Reciprocating Saw is un
10. e Figure B SKU 4095 For technical questions please call 1 800 444 3353 PAGE 11 8 Once the cutting procedure is completed release pressure on the Trigger 37 to stop the Reciprocating Saw If the Trigger Lock was used squeeze and release the Trigger once to stop the Saw Then unplug the Saw from its electrical outlet See Figure B INSPECTION MAINTENANCE AND CLEANING 1 WARNING Make sure the Trigger of the Reciprocating Saw is in its OFF position and that the tool is unplugged from its electrical outlet before performing any inspection maintenance or cleaning procedures 2 BEFORE EACH USE inspect the general condition of the Reciprocating Saw Check for loose screws misalignment or binding of moving parts cracked or broken parts damaged electrical wiring cracked or broken Saw Blades and any other condition that may affect its safe operation If abnormal noise or vibration occurs have the problem corrected before further use Do not use damaged equipment 3 TO CLEAN use a clean cloth or vacuum to remove all dust and debris from the Reciprocating Saw Do not use any solvents 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 MANU FACTURER 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
11. es contain chemicals known to the State of California to cause cancer birth defects or other reproductive harm Some examples of these chemicals are e Lead from lead based paints e Crystalline silica from bricks and cement or other masonry products e 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 filter out microscopic particles California Health amp Safety Code 25249 5 et seq Always check the Saw Blade 59 60 to make sure it does not have missing teeth cracks or is bent Do not use a damaged Saw Blade Check that there is enough space under and behind the workpiece for the reciprocating Saw Blade 59 60 Make sure you will not be cutting through any electrical wires or your workbench Never attempt to remove material stuck in the moving parts of the Reciprocating Saw while the Saw is ON or plugged in to its electrical outlet Never cut material that is thicker than the length of the Saw Blade 59 60 Do not exert side to side pressure on the Saw Blade 59 60 or attempt to cut curves Doing so will break the Saw Blade and possibly cause pieces of the blade to fly outward causing injury SKU 4095 For technical questions please call 1 800 444 3
12. k of electric shock or injury SKU 4095 For technical questions please call 1 800 444 3353 PAGE 4 10 11 12 SPECIFIC SAFETY RULES Hold tool by insulated gripping surfaces when performing an operation where the cutting tools may contact hidden wiring or its own cord Contact with a live wire will make exposed metal parts of the tool live and shock the operator Industrial applications must follow OSHA requirements Maintain labels and nameplates on the Saw These carry important information If unreadable or missing contact Harbor Freight Tools for a replacement Always wear ANSI approved safety impact eye goggles and heavy work gloves when using the Saw Using personal safety devices reduce the risk for injury Safety impact eye goggles and heavy work gloves are available from Harbor Freight Tools Maintain a safe working environment Make sure there is adequate surrounding workspace Always keep the work area free of obstructions grease oil trash and other debris Do not use a power tool in areas near flammable chemicals dusts and vapors Do not use this product in a damp or wet location When using a handheld power tool always maintain a firm grip on the tool with both hands to resist starting torque Avoid unintentional starting Make sure you are prepared to begin work before turning on the Saw Do not force the Saw This tool will do the work better and safer at the speed and capacity for which i
13. nnot be controlled with the Trigger is dangerous and must be replaced Disconnect the Power Cord Plug from the power source before making any adjustments changing accessories or storing the tool Such preventive safety measures reduce the risk of starting the tool accidentally Store idle tools out of reach of children and other untrained persons Tools are dangerous in the hands of untrained users Maintain tools with care Keep cutting tools sharp and clean Properly maintained tools with a sharp cutting edge are less likely to bind and are easier to control Do not use a damaged tool Tag damaged tools Do not use until repaired Check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the tool s operation If damaged have the tool serviced before using Many accidents are caused by poorly maintained tools Use only accessories that are recommended by the manufacturer for your model Accessories that may be suitable for one tool may become hazardous when used on another tool SERVICE Tool service must be performed only by qualified repair personnel Service or maintenance performed by unqualified personnel could result in a risk of injury When servicing a tool use only identical replacement parts Follow instructions in the Inspection Maintenance And Cleaning section of this manual Use of unauthorized parts or failure to follow maintenance instructions may create a ris
14. perty 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 com plaint 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 REV 09e SKU 4095 For technical questions please call 1 800 444 3353 PAGE 15
15. t was designed Do not force the tool and do not use the tool for a purpose for which it is not intended Always keep the extension cord away from moving parts on the tool WARNING People with pacemakers should consult their physician s before using this product Electromagnetic fields in close proximity to a heart pacemaker could cause interference to or failure of the pacemaker In addition people with pacemakers should adhere to the following Avoid operating power tools alone e Don t use a power tool with the Trigger locked on e f powered via a power cord be certain that the tool is properly grounded A ground fault interrupt GFCI system is also a good precaution This inexpensive device is a good safety measure because it prevents a sustained electrical shock Properly maintain and inspect all tools before use to avoid electrical shock Never 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 Never leave the saw unattended when it is plugged into an electrical outlet Turn off the tool and unplug it from its electrical outlet before leaving SKU 4095 For technical questions please call 1 800 444 3353 PAGE 5 18 19 Always unplug the Saw from its electrical outlet before performing any inspection maintenance or cleaning procedures WARNING Some dust created by power sanding sawing grinding drilling and other construction activiti
16. the front cover Keep this manual and invoice in a safe and dry place for future reference GENERAL SAFETY RULES WARNING READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions listed below may result in electric shock fire and or serious injury SAVE THESE INSTRUCTIONS WORK AREA 1 Keep your work area clean and well lit Cluttered benches and dark areas invite accidents N Do not operate power tools in explosive atmospheres such as in the presence of flammable liquids gases or dust Power tools create sparks which may ignite the dust or fumes e Keep bystanders children and visitors away while operating a power tool Distractions can cause you to lose control Protect others in the work area from debris such as chips and sparks Provide barriers or shields as needed ELECTRICAL SAFETY Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances Never remove the grounding gt A SKU 4095 For technical questions please call 1 800 444 3353 PAGE 2 10 11 ie 13 14 prong or modify the plug in any way Do not use any adapter plugs Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded If the tools should electrically malfunction or break down grounding provides a low resistance path to carry electricity away from the user Double insulated tools are equipped with a polari
17. zed plug one blade is wider than the other This plug will fit in a polarized outlet only one way If the plug does not fit fully in the outlet reverse the plug If it still does not fit contact a qualified electrician to install a polarized outlet Do not change the plug in any way Double insulation E eliminates the need for the three wire grounded power cord and grounded power supply system Avoid body contact with grounded surfaces such as pipes radiators ranges 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 tool will increase the risk of electric shock Do not abuse the Power Cord Never use the Power Cord to carry the tools or pull the Plug from an outlet Keep the Power Cord away from heat oil sharp edges or moving parts Replace damaged Power Cords immediately Damaged Power Cords increase the risk of electric shock When operating a power tool outside use an outdoor extension cord marked W A or W These extension cords are rated for outdoor use and reduce the risk of electric shock PERSONAL SAFETY Stay alert Watch what you are doing and use common sense when operating a power tool Do not use a power tool while tired or under the influence of drugs alcohol or medication A moment of inattention while operating power tools may result in serious personal injury Dress properly Do not wear
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