Chicago Electric 94782 Parts list manual

ELECTRIC POWER NIBBLER
Model 94782
ASSEMBLY AND OPERATION INSTRUCTIONS
Due to continuing improvements, actual product may differ slightly from the product described herein.
®
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
TO PREVENT SERIOUS INJURY, READ AND UNDERSTAND
ALL WARNINGS AND INSTRUCTIONS BEFORE USE.
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.

Page 2SKU 94782 For technical questions, please call 1-800-444-3353.
SPECIFICATIONS
Electrical Requirements 120 V~
Motor No Load Speed 1000 RPM
Frequency 50-60 Hz
Rated Input Power 525 Watts
Cutter Dimensions 9” L x 12-1/8” W x 3-3/8” H
Cutter Width 1/4”
Cutter Capacity 14 gauge sheet steel/iron plate
Peak Amps 1.87 (no load), 4.4 (rated)
3/4 HP continuous operation in cutting steel plates up to 5/32”
thick and stainless steel up to 5/64” thick. 360 degree direction
during operation.
Save This Manual
You will need this manual for the safety warnings and precautions, assembly, oper-
ating, inspection, maintenance and cleaning procedures, parts list and assembly diagram.
Keep your invoice with this manual. Write the invoice number on the inside of the front
cover. Write the product’s serial number in the back of the manual near the assembly dia-
gram, or write month and year of purchase if product has no number. 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
Keep your work area clean and well lit. Cluttered benches and dark areas invite
accidents.
Do not operate power tools in explosive atmospheres, such as in the pres-
ence of flammable liquids, gases, or dust. Power tools create sparks which may
ignite the dust or fumes.
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.
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Page 3SKU 94782 For technical questions, please call 1-800-444-3353.
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
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 polarized 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 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. Dam-
aged 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 operat-
ing 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 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 Power Switch is off before plugging
in. Carrying power tools with your finger on the Power Switch, or plugging in power
tools with the Power Switch on, invites accidents.
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Page 4SKU 94782 For technical questions, please call 1-800-444-3353.
Remove adjusting keys or wrenches before turning the power tool on. A
wrench or a key that is 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. Proper footing
and balance enables better control of the power tool in unexpected situations.
Use safety equipment. Always wear eye protection. Dust mask, nonskid safety
shoes, hard hat, or hearing protection must be used for appropriate conditions. Al-
ways wear ANSI-approved safety goggles and a dust mask/respirator when using
or performing maintenance on this tool.
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 force
the tool and do not use the tool for a purpose for which it is not intended.
Do not use the power tool if the Power Switch does not turn it on or off. Any
tool that cannot be controlled with the Power Switch 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. Always unplug the tool
from its electrical outlet before performing any inspection, maintenance, or
cleaning procedures.
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 main-
tained 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.
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Page 5SKU 94782 For technical questions, please call 1-800-444-3353.
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 instruc-
tions in the “Inspection, Maintenance, And Cleaning” section of this manual.
Use of unauthorized parts or failure to follow maintenance instructions may create
a risk of electric shock or injury.
SPECIFIC SAFETY RULES
Maintain labels and nameplates on the tool. These carry important information.
If unreadable or missing, contact Harbor Freight Tools for a replacement.
Maintain a safe working environment. Make sure there is adequate surrounding
workspace. 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 tool.
Always keep the extension cord away from moving parts on the tool.
People with pacemakers should consult their physician(s) before use. Elec-
tromagnetic fields in close proximity to heart pacemaker could cause pacemaker
interference or pacemaker failure. In addition, people with pacemakers should:
• Avoid operating alone.
• Don’t 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.
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 tool unattended when it is plugged into an electrical outlet.
Turn off the tool, and unplug it from its electrical outlet before leaving.
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, 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
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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.)
WARNING: 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.)
GROUNDING
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 facil-
ity 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
Note: The Electric Power Nibbler has a 3-Prong Plug
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 resis-
tance 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.)
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 3-Prong Plug and Outlet.)
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Page 7SKU 94782 For technical questions, please call 1-800-444-3353.
3-Prong Plug and Outlet Outlets for 2-Prong Plug
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 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 seri-
ous 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 least the minimum wire size required. (See Table A.)
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 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 your extension cord is properly wired and in good electrical condition.
Always replace a damaged extension cord or have it repaired by a qualified electri-
cian before using it.
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Page 8SKU 94782 For technical questions, please call 1-800-444-3353.
Protect your extension cords from sharp objects, excessive heat, and damp or wet
areas.
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS*
(120 OR 240 VOLT)
NAMEPLATE
AMPERES
(at full load)
EXTENSION CORD LENGTH
25 Feet 50 Feet 75 Feet 100 Feet 150 Feet
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 * Based on limiting the line voltage drop to five volts at 150% of the rated amperes.
SYMBOLOGY
Double Insulated
Canadian Standards Association
Underwriters Laboratories, Inc.
V~ Volts Alternating Current
AAmperes
n0xxxx/min. No Load Revolutions per Minute (RPM)
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Page 9SKU 94782 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.
ASSEMBLY INSTRUCTIONS
Note: For additional information regarding the parts listed in the following pages, refer to
the Assembly Diagram near the end of this manual.
WARNING! Make sure the Power Switch of the tool is in its “OFF” position and
that the tool is unplugged from its electrical outlet before making any adjustments
to the tool.
Installing Handles
Both the Fixed Handle (21) and the Auxiliary Handle (25) can be installed on either
side of the Nibbler.
To attach the Auxiliary Handle (25) directly onto the Nibbler, select the desired
threaded hole on either side of the Housing (11). Thread the Auxiliary Handle (25)
into the hole.
To attach the Fixed Handle (21) onto the Nibbler, select the desired threaded hole
on either side of the Housing (11). Slide Flat Washer (22) onto External Hex Bolt
(23) and thread Fixed Handle (21) into threaded hole.
The Fixed Handle (21) and the Auxiliary Handle (25) can also be used together as
in the cover photo. Install the Fixed Handle (21) as in Step 3 above. Then thread
the Auxiliary Handle (25) into the Fixed Handle (21).
Replacing the Cutting Knife
Use extreme caution when handling and replacing the Cutting Knife (6) as it
is very sharp. Wear gloves and follow all safety warnings when handling and
replacing the Cutting Knife (6).
Insert the end prong of the Collar Wrench (63) into the Nut (7). Unscrew the Nut
(7) and pull the Nut straight off of the Housing (11).
Remove the Cutting Knife (6).
Insert a new Cutting Knife (6). Carefully insert the Cutting Knife (6) up through both
the Down-Blade Block (8) and Plunger Guide (9). Continue to slide the Cutting Knife
up into the shaft in the Piston (2).
Thread back on the Nut (7) using the Collar Wrench (63).
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Page 10SKU 94782 For technical questions, please call 1-800-444-3353.
OPERATION INSTRUCTIONS
Make certain that the material to be cut does not exceed the capacity for this Nib-
bler; steel plates up to 5/32” thick and stainless steel up to 5/64” thick.
Create a template of the shape to be cut; or mark the lines to be cut using a straight-
edge.
Grasp the Nibbler firmly with both hands. Press the On/Off Button (53).
Apply light and firm pressure to move the Nibbler through the material. If the Nib-
bler stalls while cutting, turn it OFF. Back it slightly out of the cut and restart the
cutting process.
NOTE: The Nibbler is designed for cutting gradual curves and not 90 degree cor-
ners.
Practice with the Nibbler on a scrap piece of steel plate before using it on the de-
sired workpiece.
When finished cutting, slide the ON/OFF Button to the OFF position to turn off the
tool. Disconnect it from the power source.
INSPECTION, MAINTENANCE, AND CLEANING
WARNING! Make sure the Power Switch of the tool is in its “OFF” position and
that the tool is unplugged from its electrical outlet before performing any inspection,
maintenance, or cleaning procedures.
BEFORE EACH USE, inspect the general condition of the tool. Check for loose
screws, misalignment or binding of moving parts, cracked or broken parts, dam-
aged electrical wiring, 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.
Periodically, inspect the condition of the Cutting Knife (6). If dull or damaged,
the Cutting Blade should be replaced. Follow instructions for replacing the
Cutting Knife on the previous page.
As necessary, wipe off the Nibbler with a damp cloth. You may use a mild detergent
or non-flammable solvent.
Once clean, lubricate all moving parts with a light oil.
When storing, keep the Nibbler in the case, out of the reach of children.
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Page 11SKU 94782 For technical questions, please call 1-800-444-3353.
Cleaning the Carbon Brushes
Replacement of the Carbon Brushes (44) must be done by a qualified technician.
Improper reassembly may damage the Nibbler.
Always change both Carbon Brushes (44) at the same time.
Remove both Adjustable Screws (42). When you remove the Adjustable Screws, the
Carbon Brushes may spring out. Do not lose the Carbon Brushes. If the brushes
do not spring out, gently remove them using the tip of a screwdriver.
Examine the Carbon Brush (44) surface. The surface should be smooth and clean.
If scratch marks appear, or if the Brushes are broken, replace the Brushes imme-
diately with approved replacement Carbon Brushes (44).
If the Carbon Brushes appear fine and only dirty, you may clean them off with a
pencil eraser. Gently rub with the eraser until the dirt has been removed. Remove
any eraser dust which may have occurred during cleaning.
Reinstall the Carbon Brushes back into the Brush Holders (43). Replace both Ad-
justable Screws (42).
TROUBLESHOOTING
Problem Possible Causes Probable Solutions
Tool will not start No power at outlet.
Cord not connected.
Defective switch.
Worn carbon brushes
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Check power at outlet.
Check that cord is plugged in.
Inspect/replace switch.
Inspect/replace brushes.
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Nibbler will not cut
smoothly; motor runs
slowly during cuts.
Cutting Knife needs replacing.
Material too thick.
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Follow directions for Replacing
Cutting Knife on page 9.
Cut only proper thickness and
materials.
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Page 12SKU 94782 For technical questions, please call 1-800-444-3353.
PARTS LIST
Part Description Q’ty
1 Piston Pin 1
2 Piston 1
3 Plunger 1
4 Piston Seat 1
5 Copper Washer 1
6 Cutting Knife 1
7 Nut 1
8 Down-Blade Block 1
9 Plunger Guide 1
10 M4 12 Hex Bolt 4
11 Housing 1
12 Needle Roller Bearing 1
13 Eccentric Axis 1
14 Bearing 1
15 Helical Gear 1
16 Connecting Bar 1
17 Needle Roller Bearing 1
18 Gear 1
19 Flat Washer 2
20 Needle Roller Bearing 2
21 Fixed Handle 1
22 Flat Washer 1
23 M12-25 External Hex Bolt 1
24 Positioned Pin 1
25 Auxiliary Handle 1
26 M5-50 Inner Hex Bolt 4
27 Elastic Washer 4
28 Flat Washer 4
29 Positioned Sleeve 1
30 Motor End Casing 1
31 Self-Tapping Screw 4
32 Plastic Sealing Washer 1
Part Description Q’ty
33 Ball Bearing 1
34 Helical Gear (right) 1
35 Fan 1
36 Rotor 1
37 Ball Bearing 1
38 Brass Washer 1
39 Air Shutter Cover 1
40 Stator 1
41 Motor Housing 1
42 Adjustable Screw 2
43 Carbon Brush Holder 2
44 Carbon Brush 2
45 Self-Tapping Screw 3.7/15 2
46 Flat Washer 4
47 Press Strip 2
48 Motor Switch 1
49 Capacitor 1
50 Capacitor Cover 1
51 Self-Tapping Screw-3.7/15 1
52 Flat Washer 2
53 On/Off Button 1
54 Switch Bar 1
55 Self-Tapping Screw 2
56 Press Strip 1
57 Flat Washer 2
58 Back Motor Cover 1
59 Plug Cable 1
60 Cable Sheath 1
61 Screw Rod 2
62 Flat Washer 2
63 Collar Wrench 1
64 Hex Wrench 1

Page 13SKU 94782 For technical questions, please call 1-800-444-3353.
Parts and Assembly Diagram continued on next page
Collar Wrench (63) and Hex Wrench (64) not shown
PARTS AND ASSEMBLY DIAGRAM

Page 14SKU 94782 For technical questions, please call 1-800-444-3353.
PARTS AND ASSEMBLY DIAGRAM

Page 15SKU 94782 For technical questions, please call 1-800-444-3353.
WARRANTY
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • [phone]
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 ninety 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, 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.
LIMITED 90 DAY
WARRANTY
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEM-
BLY 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.
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.