Chicago Electric 40039 User manual

VARIABLE SPEED
JIG SAW
ASSEMBLY and OPERATING
INSTRUCTIONS
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit ourWeb site at http://www.harborfreight.com
For technical questions and replacement parts,please call 1-800-444-3353
Model 40039
®
Copyright © 2002 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 FreightTools.

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SKU 40039
Power 120V, 60 Hz, 540Watts, 4.5 Amps (Loaded)
Maximum Stroke 1-1/16”, 3100 per minute
Shoe Plate Angles 0 - 45 Degrees in 15 Degree Increments
Overall Dimensions 3.25”W x 9”L x 9”H
Shoe Plate Dimensions 2.75”W x 5.9”L
Weight 5.9 Lbs.
Cutting Capacities Wood:3-3/8”, Aluminum:9/16”,Steel 5/16”
Available Blades SKU # 6888 T-Shank Jigsaw Blades (5 pc.)
SKU # 8261 T-Shank Jigsaw Blades (10 pc.)
Accessory: Hex Key
Blade not included.
Specifications
Save This Manual
You will need the manual for the safety warnings and precautions, assembly instructions,
operating and maintenance procedures, parts list and diagram. Keep your invoice with this
manual. Write the invoice number on the inside of the front cover. Keep the manual and
invoice in a safe and dry place for future reference.
Safety Warnings and Precautions
WARNING:When using tool, basic safety precautions should always be followed to re-
duce the risk of personal injury and damage to equipment.
Read all instructions before using this tool!
1. Keep work area clean. Cluttered areas invite injuries.
2. Observe work area conditions. Do not use machines or power tools in damp or wet
locations. Don’t expose to rain. Keep work area well lighted. Do not use electrically
powered tools in the presence of flammable gases or liquids.
3. Keep children away. Children must never be allowed in the work area. Do not let
them handle machines, tools, or extension cords.
4. Store idle equipment. When not in use, tools must be stored in a dry location to
inhibit rust. Always lock up tools and keep out of reach of children.
5. Use the right tool for the job. Do not attempt to force a small tool or
attachment to do the work of a larger industrial tool. There are certain
applications for which this tool was designed. It will do the job better
and more safely at the rate for which it was intended. Do not modify this
tool and do not use this tool for a purpose for which it was not intended.
6. Dress properly. Do not wear loose clothing or jewelry as they can be caught in
moving parts. Protective, electrically non-conductive clothes and non-skid footwear
are recommended when working. Wear restrictive hair covering to contain long hair.
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SKU 40039
7. Use eye, face and ear protection. Always wear ANSI approved impact safety
goggles.Wear a full face shield if you are producing metal filings or wood chips.Wear
an ANSI approved dust mask or respirator when working around metal, wood, and
chemical dusts and mists.
8. Do not overreach. Keep proper footing and balance at all times. Do not reach over or
across running machines.
9. Maintain tools with care. Keep tools sharp and clean for better and safer
performance. Follow instructions for lubricating and changing accessories. Inspect
tool cords periodically and, if damaged, have them repaired by an authorized
technician.The handles must be kept clean, dry, and free from oil and grease at all
times.
10. Disconnect power. Unplug Jig Saw when not in use.
11. Remove adjusting keys and wrenches. Check that keys and adjusting wrenches
are removed from the tool or machine work surface before plugging it in.
12. Avoid unintentional starting. Be sure the switch is in the Off position when not in
use and before plugging in. Do not carry any tool with your finger on the trigger,
whether it is plugged in or not.
13. Stay alert. Watch what you are doing, use common sense. Do not operate any tool
when you are tired.
14. Take caution as some woods contain preservatives such as copper chromium
arsenate (CCA) which can be toxic.When cutting these materials extra care should
be taken to avoid inhalation and minimize skin contact.
15. Check for damaged parts. Before using any tool, any part that appears damaged
should be carefully checked to determine that it will operate properly and perform its
intended function. Check for alignment and binding of moving parts; any broken parts
or mounting fixtures; and any other condition that may affect proper operation. Any
part that is damaged should be properly repaired or replaced by a qualified
technician. Do not use the tool if any switch does not turn On and Off properly.
16. Guard against electric shock. Prevent body contact with grounded surfaces such as
pipes, radiators, ranges, and refrigerator enclosures.
17. Replacement parts and accessories. When servicing, use only identical
replacement parts. Use of any other parts will void the warranty. Only use accessories
intended for use with this tool. Approved accessories are available from Harbor
Freight Tools.
18. Do not operate tool if under the influence of alcohol or drugs. Read warning
labels on prescriptions to determine if your judgment or reflexes are impaired while
taking drugs. If there is any doubt, do not operate the tool.

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19. Use proper size and type extension cord. If an extension cord is required, it must be
of the proper size and type to supply the correct current to the tool without heating up.
Otherwise, the extension cord could melt and catch fire, or cause electrical damage to
the tool.This tool requires use of an extension cord of 0 to 10 amps capability (up to
50 feet), with wire size rated at 16 AWG.Longer extension cords require larger size
wire. If you are using the tool outdoors, use an extension cord rated for outdoor use.
(Signified by “WA” on the jacket).
20. Maintenance. For your safety, maintenance should be performed regularly by a
qualified technician.
Note: Performance of this tool (if powered by line voltage) may vary depending on
variations in local line voltage. Extension cord usage may also affect tool performance.
Warning:The warnings,cautions,and instructions discussed in this instruction manual
cannot cover all possible conditions and situations that may occur. It must be under-
stood by the operator that common sense and caution are factors which cannot be
built into this product, but must be supplied by the operator.
WARNING: Some dust created by power sanding, sawing, grinding, drilling, and
other construction activities, contain 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 spe-
cially designed to filter out microscopic particles.
(California Health & Safety Code 25249.5, et seq. )
Unpacking
When unpacking, check to make sure the parts listed on pages 5 and 8 are included. If any
parts are missing or broken, please call Harbor Freight Tools at the number on the cover of
this manual as soon as possible.
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Operation
General Jig Saw Overview
1a- Switch
2a - Trigger
3a - Lock Button
4a - Adjustment Nut
7a - Lever
8a - Nut
9a - Nut Slot
10a - Blade
11a - Rod
12a - Rod Slot
13a - Fixing Screw
14a - Anti-Skid Guard
Parts List “a”
Note: The accessory, Hex Key is not included on the parts list or assembly drawing.
Cover
Power Cord
Base
14
Note: Add an “a” suffix when
ordering parts shown on this page.

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Operation (continued)
Note: All operational part numbers refer to parts on the General Jig Saw Overview dia-
gram (Parts List“a”) on page 5 of this manual.
Attaching a blade
Warning! When attaching blades, make sure the Jig Saw is not plugged in to an outlet.
1. The Cover (#2) should be removed.
2. Turn the Nut (#8a) so that the slots on it align with the Rod Slot (#12a) on the Rod (#11a).
Caution: Do not twist the Nut (#8a) more than is necessary to line up the notches with the
groove on Rod Slot (#12a) of Rod (#11a). If the Nut (#8a) is separated from the Rod (#11A)
as the result of improper use, it will be necessary to carry out the following sequence when
repairing it:
Put the spring inside the Nut (#8a)
up to the stop, with the end of the
spring going into the square Nut’s
groove as shown in the illustration
to the near right .
Install the Nut with spring onto the
Rod (#11a) until the nut thread
presses against the Rod’s thread, so
that the spring end falls into the
square notch on the rod (see
illustration to the far right.
To install the Nut: Twist the Nut counterclockwise (click produced by the Nut and
Rod’s thread should be heard every 90 degrees) and let the nut go after 4 clicks.
Note: Only useT-Shank Blades, as shown in the above right illustration.
3. To install the Blade: Align the tang of the Blade with the slot in the Nut. Push the Blade in
and rotate the Nut 90 degrees. Make sure the teeth of the blade are facing out and down-
ward,away from the Jig Saw.
4. Wearing a thick leather glove, tug on the Blade (#10a) and make sure it is securely
fastened in the Rod (#11a).
5. Replace the Cover (#2).
6. Slide the Anti-Skid Guard (#14a) over the hooked end of the Base (#37) making sure the
flat side sits flush with the bottom of the Base (#37).
Note: Never use a dull or cracked blade. A damaged blade can break causing serious injury
and damage. Replacement blades are available at Harbor Freight Tools.
Note: If the Jig Saw comes from the factory with a protective lubricant coating, wipe it clean
using a cloth. Make sure no liquid enters the motor or sawing mechanisms.
Warning: Do not use the Jig Saw without the Cover (#2) in place.
REV 01/03
Slot in Nut
T-Shank
Blade
REV 04/04

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Operation
7. Checkagain to make sure yourworkpiece is secure anddraw a cutting line on it. Re-check
the condition of your blade.
8. Plug in the Jig Saw.
9. Test the Jig Saw without a load by gently squeezing the Trigger (#2a). Run it on high (fully
depressed) for a few minutes. Then, test the lock mechanism by starting the Jig Saw and
then engaging the Lock Button (#3a). To disengage the Lock Button (#3a) squeeze the
Trigger (#2a).
10. To begin cutting, first bring the blade up to speed by depressing the Trigger (#2a) before
contacting the workpiece.
11. Set the front of the Base (#37) on the beginning of your cutting line.
12. Slowly make contact letting the Jig Saw do the work. Just guide the saw. If the Jig Saw
is not cutting to your satisfaction try using the Adjustment Nut (#4a) to compensate.
If it still does not cut to satisfaction, make sure you have a straight, sharp blade with no
cracks.
Note: If the Jig Saw seizes in a workpiece, shut it off and unplug it. Try to work out the blade.
If necessary, remove the blade from the saw and remove the blade from the workpiece.
Before replacing the blade, make sure it is in satisfactory condition.
13. When finished cutting, release the Trigger (#2a) and unplug the Jig Saw.
1. Secure your workpiece in a vice or clamp it to a work bench. Make sure the blade path
below the workpiece is clear of obstacles.
2. Choose the appropriate blade for the material you will be cutting. Blades for cutting soft or
hard metals, and wood cutting blades are available at Harbor Freight Tools.
3. Attach the blade following the instructions above.
Note: This Jig Saw has three adjustment features.
4. The number of strokes per minute (0 - 3100) is determined by adjusting the Adjustment
Nut (#4a). Turning toward the + sign increases the strokes, and turning toward the - sign
decreases the strokes. Use the highest number of strokes possible for cutting soft materials
such as wood, and use a low number of strokes when cutting hard materials like metal.
Note: Steelrequires aliquid coolant while cutting. Practice onscrap piecesto learnthe stroke
adjustment appropriate to your needs.
Note:You may adjust when the Jig Saw is running or off.
Note: The Jig Saw heats up rapidly when cutting at a slow rate. Periodically, set the stroke
setting to high, and run the saw for a few minutes without a load to cool the saw.
5. There is also a pendulum adjustment Lever (#7a). It adjusts the movement of the blade
path according to the material you are cutting. For soft materials such as wood, set the
Lever (#7a) to number 3. For hard materials such as steel, set the Lever (#7a) to 0 or to 1.
Forthin-walled materialsset theLever (#7a) to 0. Always set theLever (#7a) adjustment after
the blade is attached. It takes practice to learn to skillfully use the pendulum
adjustments. Practice on scrap pieces.
6. You may also adjust the cutting angle of the Base (#37). Loosen the Fixing Screw (#13a).
TurntheBase (#37) to the requiredangle. Ithasstops for 15, 30, and 45degrees,butyoumay
set it anywhere in between. Tighten the Fixing Screw (#13a).
CAUTION: Keep fingers and hands a safe distance from blade at all times while cutting.
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1. Before each use visually inspect the Jig Saw for cracks or loose nuts or screws. Tighten if
necessary. If the unit is cracked, do not use it. Take it to an authorized service technician.
2. Keep the Rod Slot (#12a) and the Rod (#11a) clean and clear of any dirt or debris.
3. If the Jig Saw is used regularly, have an authorized service technician check the brushes
and change them every six months if they are too short. Also, have an authorized service
technician grease the internal parts when needed. Do not attempt to change brushes or
grease the internal parts yourself.
Maintenance
Rev 01/03

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NOTE: Some parts are listed and shown for illustration purposes only and are not available
individually as replacement parts.
PLEASE READTHE FOLLOWING CAREFULLY
THEMANUFACTURER AND/OR DISTRIBUTOR HASPROVIDEDTHEPARTS DIAGRAMINTHIS MANUAL
AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY
REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIEDTO
MAKE ANY REPAIRSTOTHE PRODUCT ORTHAT HE OR SHE IS QUALIFIEDTO REPLACE ANY PARTS
OFTHE PRODUCT. IN FACT,THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATESTHAT
ALLREPAIRS ANDPARTS REPLACEMENTSSHOULD BEUNDERTAKEN BY CERTIFIEDAND LICENSED
TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING
OUTOF HISOR HER REPAIRSTOTHEORIGINAL PRODUCTORREPLACEMENTPARTSTHERETO,OR
ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTSTHERETO.
Parts List
Part No. Description Qty. Part No. Description Qty.
2 Cover 1 38 Channel 1
3 Screw 2 39 Screw 2
4 Screw 2 40 Pin 1
5 Cover 1 41 Pin 1
6 Gasket 1 42 Rocker 1
7 Spring 2 43 Rivet 1
8 Frame 1 44 Bushing 1
9 Nut 1 45 Bearing 2
10 Spring 1 46 Pulley 1
11 Rod 1 47 Armature 1
12 Insert 1 48 Bearing 1
13 Plate 1 49 Ring 1
14 Plate 1 50 Membrane 1
15 Screw 4 51 Plug 2
16 Washer 4 52 Stator 1
17 Nut 4 53 Housing 1
18 Spring 1 54 Brush 2
19 Spring 2 55 Brush Holder 2
20 Screw 2 56 Spring 2
21 Washer 2 57 Washer 2
22 Bearing 1 58 Screw 2
23 Washer 1 59 Cover 1
24 Washer 1 60 Screw 2
25 Gear 1 61 Nameplate 1
26 Bearing 2 62 Nameplate 1
27 Counterweight 1 63 Screw 1
28 Lever 1 64 Screw 3
29 Plate 1 65 Plate 1
30 Screw 2 66 Frequency Filter 1
31 Washer 1 67 Block 1
32 Washer 1 68 Screw 2
33 Lever 1 69 Plate 1
34 Housing 1 70 Power Cord 1
35 Bearing 1 71 Unit 1
36 Nut 1 72 Key 1
37 Base 1 73 Handle 1
74 Plug 1
Note: The accessory, Hex Key is not included on the parts list..
Rev 01/03

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Assembly Drawing
Rev 01/03