Harbor Freight Tools 120 Volt Electric Body Saw Product manual
Contents
1. DANGER will result in death or serious injury Indicates a hazardous situation which if not avoided AWARNING could result in death or serious injury Indicates a hazardous situation which if not avoided ACAUTION could result in minor or moderate injury NOTICE CAUTION Addresses practices not related to personal injury IMPORTANT SAFETY INFORMATION General Power Tool Safety Warnings AWARNING Read all safety warnings and all instructions Failure to follow the warnings and instructions may result in electric shock fire and or serious injury Save all warnings and instructions for future reference The term power tool in the warnings refers to your mains operated corded power tool Work Area Safety 1 Keep work area clean and well 3 Keep children and bystanders lit Cluttered or dark areas invite away while operating a power tool accidents Distractions can cause you to lose control 2 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 Item 65766 For technical questions please call 1 888 866 5797 Page 2 Electrical Safety 1 Power tool plugs must match the outlet Never modify the plug in any way Do not use any adapter plugs with grounded power tools Unmodified plugs and matching outlets will reduce risk of electric shock Avoid body contact with grounded su2. out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool Power Service replacement parts This will ensure that the safety of the power tool is maintained Item 65766 5 For technical questions please call 1 888 866 5797 Unapproved safety equipment may not provide adequate protection Eye protection must be ANSI approved and breathing protection must be NIOSH approved for the specific hazards in the work area tools are dangerous in the hands of untrained users Maintain power tools Check for misalignment or binding of moving parts 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 sharp cutting edges are less likely to bind and are easier to control Use the power tool accessories and tool bits etc in accordance with these instructions 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 Have your power tool serviced by a qualified repair person using only identical Page 4 Reciprocating Saw Safety Warnings 1 Item 65766 Hold power tool by insulated 9 gripping sur
3. questions please call 1 888 866 5797 Page 11 General Operating Instructions 4 When the cut is finished remove the Blade from the workpiece 1 Plug the Body Saw into a and release the Throttle Do grounded 120V electrical outlet not set the Saw down until the 2 With one hand holding the casing Plade pas stopped moving of the Body Saw push the Safety 5 To prevent accidents turn off the 36 forward and squeeze the tool and disconnect its power supply Throttle 20 to power the Blade after use Clean then store the tool l i i h 3 Contact the workpiece and make MeoOrSsQUC OT C MIJE Me TEAL the desired cut Do not push on the Saw allow it to make the cut at its intended pace CHICAGOG ELECTRIC POWER TOOLS Item 65766 For technical questions please call 1 888 866 5797 Page 12 MAINTENANCE AND Cleaning Maintenance and SERVICING Lubrication Procedures not specifically 1 BEFORE EACH USE inspect the A explained in this manual general condition of the tool Check must be performed only by a for loose screws misalignment or qualified technician binding of moving parts cracked or broken parts damaged electrical TO PREVENT wiring and any other condition that AWARNING SERIOUS INJURY may affect its safe operation FROM ACCIDENTAL OPERATION 2 AFTER USE clean external surfaces Turn the Power Switch of the of the tool with clean cloth tool to its OFF position and 3 WARNING If the supply cord of unplug th
4. Owner s Manual amp Safety Instructions 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 ITEM 65766 ELECTRIC BODY SAW Sea When unpacking make sure that the product is intact and undamaged If any parts are missing or broken AWARNING please call 1 888 866 5797 as soon as possible Copyright 2008 by Harbor Freight Tools All rights reserved No portion of this manual or any artwork contained herein may be reproduced in Read this material before using this product any shape or form without the express written consent of Harbor Freight Tools Failure to do so can result in serious injury Diagrams within this manual may not be drawn proportionally Due to continuing SAVE THIS MANUAL improvements actual product may differ slightly from the product described herein Tools required for assembly and service may not be included WARNING SYMBOLS AND DEFINITIONS 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 Indicates a hazardous situation which if not avoided A
5. 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 PARTS LIST PARTS LIST Part __ Description Qty 21 RightHousing 1 22 Screw _ _ y O 8i Screw S l i Blade Holder Carbon Brush 2 Stator tL 2 2 26 27_ HexScrew 1 28 29 30 Part ____ Description Qty 1 Carbon Brush Holder 2 2 3 4 LeftHousing 1 5 PowerCord _ 1 6 Guard O l 7 Bot a 8 Nut o d 9 BladeGuard 1 10 1 1 Screw o y 12 13 14 15 16 ete Screw 1 Main Shaft S 1 i Bearing o 1 Ring o i GearBracket_ 18 GearHousing 19 GearBoxCover 20 Throtte 1 2 3 4 5 T 10 11 12 13 14 15 16 17 18 19 0 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 Item 65766 For technical ques
6. e outlet CHICAGOG ELECTRIC POWER TOOLS Item 65766 For technical questions please call 1 888 866 5797 Page 9 SPECIFICATIONS Electrical Requirements 120 VAC 60 Hz 150W loaded Blade Speed 2600 SPM Maximum Cutting Capacity eta SLOR Chuck Capacity 1 2 M Listed Blade Stroke 3 8 Intertek 4010157 INSTRUCTIONS FOR PUTTING INTO USE 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 TO PREVENT AWARNING SERIOUS INJURY FROM ACCIDENTAL OPERATION 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 Note For additional information regarding the parts listed in the following pages refer to the Assembly Diagram near the end of this manual Assembly 1 Use the Hex Wrench 40 to loosen the Hex Screw 27 See picture below Hex Screw 27 2 Wearing work gloves insert the shank of the Blade 39 into the front of the Body Saw with the blade pointed downward Tighten the Hex Screw to secure the Blade in place CHICAGOG ELECTRIC Item 65766 For technical questions please call 1 888 866 5797 POWER TOOLS Page 10 OPERATING INSTRUCTIONS Read the ENTIRE IMPORTANT A SAFETY INFORMATION section at the beginning of this manual incl
7. e tool from its this power tool is damaged it must Sleenic ar outlet petere be replaced only by a qualified performing any inspection service technician maintenance or cleaning procedures TO PREVENT SERIOUS INJURY FROM TOOL FAILURE Do not use damaged equipment If abnormal noise or vibration occurs have the problem corrected before further use Troubleshooting Possible Causes Likely Solutions Tool will not start 1 No power at outlet 1 Check power at outlet 2 Cord not connected 2 Check that cord is plugged in 3 Carbon Brushes may be worn 3 Have Carbon Brushes replaced by a qualified or damaged technician Tool operates Carbon Brushes may be worn or Have Carbon Brushes replaced by a qualified slowly or damaged technician sporadically 1 Blade may be damaged worn 1 Check condition and type of blade Use only or wrong type for the material proper type of blade in good condition blade jams in work 2 Too much pressure 2 Ease off pressure on blade material Follow all safety precautions whenever diagnosing or servicing the tool Disconnect power supply before service Item 65766 For technical questions please call 1 888 866 5797 Page 13 PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS DOCUMENT AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND
8. ed in either of the 120 volt outlets shown in the preceding illustration See 3 Prong Plug and Outlet 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 suffix 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 qualified electrician before using it Protect the extension cords from sharp objects excessive heat and damp or wet areas Page 8 TABLE A RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS 120 240 VOLT AMPERES LENGTH full oad 25 50 75 100 150 aeo aa pe ol 61 200 n fo Based on limiting the line voltage drop to five volts at 150 of the rated amperes Symbology o Double Insulated a Revolutions per Minute WARNING marking e Canadian Standards Association concerning Risk of Eye Injury Wear ANSI approved safety EON Underwriters Laboratories Inc godg es will side shields Read the manual before set up WARNING marking concerning Do not cover ventilation ducts Keep flammable objects away Risk of Electric Shock Properly connect power cord to appropriat
9. 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 CHICAGOG ELECTRIC POWER TOOLS 3491 Mission Oaks Blvd e PO Box 6009 Camarillo CA 93011 1 888 866 5797
10. faces when performing an operation where cutting tool 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 Use clamps or another practical way to secure and support the workpiece to a stable platform Holding the work by hand or against your body leaves it unstable and may lead to loss of control Maintain labels and nameplates on the tool 10 These carry important safety information If unreadable or missing contact Harbor Freight Tools for a replacement Avoid unintentional starting Prepare to begin work before turning on the tool 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 When using a handheld power tool maintain a firm grip on the tool with both hands to resist starting torque 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 This product is not a toy 11 Keep it out of reach of children For technical questions please call 1 888 866 5797 People with pacemakers should consult their physician s before use Electromagnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure In addition people with pacemakers should e Avoid operating alone e Do not use w
11. ith Trigger locked on e Properly maintain and inspect to avoid electrical shock e Properly ground power cord Ground Fault Circuit Interrupter GFCI should also be implemented it prevents sustained electrical shock WARNING Some dust created by power sanding sawing grinding drilling and other construction activities contains chemicals known to the State of California to cause cancer and 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 WARNING The cord of this product contains lead a chemical known to the State of California to cause cancer and birth defects or other Page 5 reproductive harm Wash hands after handling California Health amp Safety Code 25249 5 et seq The warnings precautions and instructions discussed in this instruction manual cannot cover all Vibration Safety This tool vibrates during use Repeated or long term exposure to vibration may ca
12. lustration break down grounding provides a See 3 Prong Plug and Outlet low resistance path to carry electricity away from the user reducing the risk of electric shock See 3 Prong Plug and Outlet Item 65766 For technical questions please call 1 888 866 5797 Page 7 Double Insulated Tools Tools with Two Prong Plugs 1 8 Outlets for 2 Prong Plug Tools marked Double Insulated do not require grounding They Extension Cords lg Item 65766 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 When using more than one extension cord to make up the total length make sure each cord contains at For technical questions please call 1 888 866 5797 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 Double insulated tools may be us
13. rfaces 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 Personal Safety 1 Item 65766 Stay alert watch what you are doing and use common sense when operating a power tool Do not use a power tool while you are tired or under the influence of drugs alcohol or medication A moment of inattention while operating power tools may result in serious personal injury Use personal protective equipment Always wear eye protection Protective equipment such as dust mask non skid safety shoes hard hat or hearing protection used for appropriate conditions will reduce personal injuries Prevent unintentional starting Ensure the Trigger is in the off position before connecting For technical questions please call 1 888 866 5797 Do not abuse the cord Never use the cord for carrying pulling or unplugging the power tool Keep cord away from heat oil sharp edges or moving parts Damaged or entangled cords increase the risk of electric shock When operating a power tool outdoors use an extension cord suitable for outdoor use Use ofa cord suitable for outdoor use reduces the risk of electric shock If operating a power tool in a damp location is unavoidable use a Ground Fault Circuit Interrupter GFCI protected suppl
14. tely A SAVE THESE INSTRUCTIONS CHICAGOG ELECTRIC For technical questions please call 1 888 866 5797 POWER TOOLS Page 6 AWARNING TO PREVENT ELECTRIC SHOCK AND DEATH FROM AN INCORRECT GROUNDING WIRE CONNECTION 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 2 The grounding prong in the plug is connected through the green wire inside the cord to the grounding S system in the tool The green wire in the cord must be the only wire DAE connected to the tool s grounding gt system and must never be attached to an electrically live terminal See 3 Prong Plug and Outlet 3 Prong Plug and Outlet 1 Tools marked with Grounding 3 The tool must be plugged into an Required have a three wire cord appropriate outlet properly installed and three prong grounding plug and grounded in accordance with all The plug must be connected to a codes and ordinances The plug and properly grounded outlet If the tool outlet should look like those in the should electrically malfunction or preceding il
15. tions please call 1 888 866 5797 Page 14 ASSEMBLY DIAGRAM Page 15 For technical questions please call 1 888 866 5797 Item 65766 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
16. uding all text under subheadings therein before set up or use of this product TO PREVENT AWARNING SERIOUS INJURY FROM ACCIDENTAL OPERATION Turn the Power Switch of the tool to its OFF position and unplug the tool from its electrical outlet before performing any inspection maintenance or cleaning procedures Work Piece and Work Area Set Up 1 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 2 Route the power cord along a safe route to reach the work area without creating a tripping hazard or exposing the power cord to possible damage The power cord must reach the work area with enough extra length to allow free movement while working Secure loose work pieces 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 This is especially critical for plunge cuts Using a glove push blade holder all the way back The workpiece must be thinner than minimum blade extension CAUTION To prevent injury do not use on workpieces thicker than the minimum blade extension at their maximum thickness Blade tip can strike workpiece and may shatter Properly Sized Workpieces Workpieces that are Too Thick Figure A Maximum Workpiece Thickness Item 65766 For technical
17. use temporary or permanent physical injury particularly to the hands arms and shoulders To reduce the risk of vibration related injury 1 Item 65766 Anyone using vibrating tools regularly or for an extended period should first be examined by a doctor and then have regular medical check ups 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 symptoms related to vibration Such as tingling numbness and white or blue fingers seek medical advice as soon as possible 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 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 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 To reduce vibration maintain the tool as explained in this manual If any abnormal vibration occurs stop use immedia
18. y Use of a GFCI reduces the risk of electric shock to power source picking up or carrying the tool Carrying power tools with your finger on the Trigger or energizing power tools that have the Trigger on invites accidents Do not overreach Keep proper footing and balance at all times This enables better control of the power tool in unexpected situations Dress properly Do not wear loose clothing or jewelry Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts If devices are provided for the connection of dust extraction and collection facilities ensure these Page 3 are connected and properly used Use of dust collection can reduce dust related hazards Only use safety equipment that has been approved by an appropriate standards agency Power Tool Use and Care 1 Do not force the power tool Use the correct power tool for your application 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 Trigger does not turn it on and off Any power tool that cannot be controlled with the Trigger is dangerous and must be repaired Disconnect the plug from the power source 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
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