Chicago Electric 4095 User manual

RECIPROCATING SAW - 4.5 AMP
Model 04095
ASSEMBLY AND OPERATING INSTRUCTIONS
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit ourWeb site at http://www.harborfreight.com
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 FreightTools.
For technical questions and replacement parts, please call 1-800-444-3353.
TO PREVENT SERIOUS INJURY,
READ AND UNDERSTAND ALL WARNINGS
AND INSTRUCTIONS BEFORE USE.
Manual Revised 02/05

SKU 4095 For technical questions, please call 1-800-444-3353. PAGE 2
PRODUCT SPECIFICATIONS
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 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.
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.
3. 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.
E194601
Item Description
Electrical Requirements 120 Volt / 60 Hz / 4.5 Amps
Variable Speed 6 Positions / 0-2300 SPM (Strokes Per Minute)
Blade Stroke 1-3/16”
Shoe Plate Tilt 0-15°
Chuck Pin Type
Chuck Capacity 1/2” Standard Shank
Overall Dimensions 16-1/2” L x 3-1/4” W x 5-3/4” H
Weight 6.70 Pounds

SKU 4095 For technical questions, please call 1-800-444-3353. PAGE 3
ELECTRICAL SAFETY
4. 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.
5. 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.
6. 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.
7. Do not expose power tools to rain or wet conditions. Water entering a power
tool will increase the risk of electric shock.
8. 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.
9. 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
10. 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.
11. 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.
12. Avoid accidental starting. Be sure theTrigger 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.
13. 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.

SKU 4095 For technical questions, please call 1-800-444-3353. PAGE 4
14. 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.
15. 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
16. 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.
17. 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.
18. Do not use the power tool if theTrigger does not turn it on or off. Any tool that
cannot be controlled with the Trigger is dangerous and must be replaced.
19. 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.
20. Store idle tools out of reach of children and other untrained persons. Tools are
dangerous in the hands of untrained users.
21. 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.
22. 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.
23. 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
24. Tool service must be performed only by qualified repair personnel. Service or
maintenance performed by unqualified personnel could result in a risk of injury.
25. 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 risk of
electric shock or injury.

SKU 4095 For technical questions, please call 1-800-444-3353. PAGE 5
SPECIFIC SAFETY RULES
1. 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.
2. Industrial applications must follow OSHA requirements.
3. Maintain labels and nameplates on the Saw. These carry important information.
If unreadable or missing, contact Harbor Freight Tools for a replacement.
4. 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.
5. 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.
6. When using a handheld power tool, always maintain a firm grip on the tool
with both hands to resist starting torque.
7. Avoid unintentional starting. Make sure you are prepared to begin work before
turning on the Saw.
8. Do not force the Saw. This tool will do the work better and safer at the speed and
capacity for which it was designed. Do not force the tool and do not use the tool for
a purpose for which it is not intended.
9. Always keep the extension cord away from moving parts on the tool.
10. 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.
• Don’t use a power tool with the Trigger locked on.
• If 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.
11. 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.
12. 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 6
13. Always unplug the Saw from its electrical outlet before performing any
inspection, maintenance, or cleaning procedures.
14. 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 specially
designed to filter out microscopic particles.
(California Health & Safety Code 25249.5, et seq.)
15. 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.
16. 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.
17. 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.
18. Never cut material that is thicker than the length of the Saw Blade (59, 60).
19. 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 1-800-444-3353. PAGE 7
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 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
1. 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 4095 For technical questions, please call 1-800-444-3353. PAGE 8
FIGURE B
DOUBLE INSULATED TOOLS: TOOLS WITH TWO PRONG PLUGS
4. 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.)
5. Double insulated tools may be used in either of the 120 volt outlets shown in the
following illustration. (See 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.
2. 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.)
3. 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.)
4. 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.)
5. 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 Figure C.)

SKU 4095 For technical questions, please call 1-800-444-3353. PAGE 9
6. 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.
7. 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
electrician 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)
NAMEPLAT
E
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 - - -
* Based on limiting the line voltage drop
to five volts at 150% of the rated amperes.
FIGURE C
SYMBOLOGY
Double Insulated
Canadian Standards
Association
Underwriters
Laboratories, Inc.
Volts Alternating Current
Amperes
No Load Revolutions
per Minute (RPM)
noxxxx/min.
A
V ~

SKU 4095 For technical questions, please call 1-800-444-3353. PAGE 10
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
unplugged from its electrical outlet
prior to making any adjustments to the tool.
To Install A Saw Blade:
1. 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 (6A).
(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 (6A) to secure the Saw Blade (59, 60) in place.
(See Figure B.)
HEX SCREW (6A)
WOOD
SAW
BLADE
(59)
METAL SAW BLADE (60)
HEX KEY (62)
TRIGGER (37)
TRIGGER
LOCK
POWER CORD (44)
GUARD PLATE (2)
FIGURE B
SPEED
CONTROL
(19)
ADJUSTABLE
SHOE PLATE
(1)
REV 10/05

SKU 4095 For technical questions, please call 1-800-444-3353. PAGE 11
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
HEX SCREW
(58)
GUARD PLATE (2)
ADJUSTABLE
SHOE PLATE
(1)
FIGURE C
Operating Instructions:
1. The 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.)
3. Plug the Reciprocating Saw into its 120 Volt, grounded, electrical outlet.
4. 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.
(See Figure B.)

SKU 4095 For technical questions, please call 1-800-444-3353. PAGE 12
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.
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.)
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDEDTHE PARTS LIST AND AS-
SEMBLY DIAGRAM INTHIS MANUAL AS A REFERENCE TOOL ONLY. NEITHERTHE MANUFACTURER
OR DISTRIBUTOR MAKES ANY REPRESENTATION ORWARRANTY OF ANY KIND TO THE BUYER
THAT HE OR SHE IS QUALIFIEDTO MAKE ANY REPAIRS TO THE PRODUCT, ORTHAT HE OR SHE
IS QUALIFIEDTO REPLACE ANY PARTS OFTHE PRODUCT. IN FACT,THE MANUFACTURER AND/
OR DISTRIBUTOR EXPRESSLY STATESTHAT 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 PARTSTHERETO.
PLEASE READ THE FOLLOWING CAREFULLY

SKU 4095 For technical questions, please call 1-800-444-3353. PAGE 13
NOTE: Some parts are listed and shown for illustration purposes only, and are
not available individually as replacement parts.
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PARTS LIST
REV 10/05

SKU 4095 For technical questions, please call 1-800-444-3353. PAGE 14
WOOD SAW BLADE (59) NOT SHOWN
METAL SAW BLADE (60) NOT SHOWN
REPLACEMENT BRUSHES (61) NOT SHOWN
4MM HEX KEY (62) NOT SHOWN
ASSEMBLY DIAGRAM
REV 10/05