Chicago Electric 65766 User manual

Visit our website at: http://www.harborfreight.com
Email our technical support at: [email protected]
ITEM 65766
REV 14g
Owner’s Manual & 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.
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
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
any shape or form without the express written consent of Harbor Freight Tools.
Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein.
Tools required for assembly and service may not be included.
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.

Item 65766 For technical questions, please call 1-888-866-5797. Page 2
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,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Addresses practices not related to personal injury.
IMPORTANT SAFETY INFORMATION
General Power Tool Safety Warnings
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
lit. Cluttered or 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 children and bystanders
away while operating a power tool.
Distractions can cause you to
lose control.

Item 65766 For technical questions, please call 1-888-866-5797. Page 3
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.
2. 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.
3. Do not expose power tools to rain
or wet conditions. Water entering
a power tool will increase the risk of
electric shock.
4. 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.
5. When operating a power tool
outdoors, use an extension cord
suitable for outdoor use. Use of a
cord suitable for outdoor use reduces
the risk of electric shock.
6. If operating a power tool in a damp
location is unavoidable, use a
Ground Fault Circuit Interrupter
(GFCI) protected supply.
Use of a GFCI reduces the risk of
electric shock.
Personal Safety
1. 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.
2. 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.
3. Prevent unintentional starting.
Ensure the Trigger is in the
off-position before connecting
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.
4. Do not overreach. Keep proper
footing and balance at all times.
This enables better control of the
power tool in unexpected situations.
5. 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.
6. If devices are provided for the
connection of dust extraction and
collection facilities, ensure these

Item 65766 For technical questions, please call 1-888-866-5797. Page 4
are connected and properly used.
Use of dust collection can reduce
dust-related hazards.
7. Only use safety equipment
that has been approved by an
appropriate standards agency.
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.
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.
2. 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.
3. 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.
4. Store idle power tools 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
tools are dangerous in the hands of
untrained users.
5. 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.
6. Keep cutting tools sharp and
clean. Properly maintained cutting
tools with sharp cutting edges are
less likely to bind and are easier to
control.
7. 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.
Service
Have your power tool serviced by a qualified repair person using only identical
replacement parts.
This will ensure that the safety of the power tool is maintained.

Item 65766 For technical questions, please call 1-888-866-5797. Page 5
Reciprocating Saw Safety Warnings
1. Hold power tool by insulated
gripping surfaces 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.
2. 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.
3. Maintain labels and nameplates on
the tool.
These carry important safety
information.
If unreadable or missing,
contact Harbor Freight Tools for
a replacement.
4. Avoid unintentional starting.
Prepare to begin work before turning
on the tool.
5. 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.
6. When using a handheld power tool,
maintain a firm grip on the tool with
both hands to resist starting torque.
7. 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.
8. This product is not a toy.
Keep it out of reach of children.
9. 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:
• Avoid operating alone.
• Do not use with Trigger locked on.
• Properly maintain and inspect to
avoid electrical shock.
• Properly ground power cord.
Ground Fault Circuit Interrupter
(GFCI) should also be implemented –
it prevents sustained electrical shock.
10. 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:
• 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.)
11. WARNING: The cord of this product
contains lead, a chemical known
to the State of California to cause
cancer, and birth defects or other

Item 65766 For technical questions, please call 1-888-866-5797. Page 6
reproductive harm. Wash hands
after handling. (California Health &
Safety Code § 25249.5, et seq.)
12. The warnings, precautions, and
instructions discussed in this
instruction manual cannot cover all
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.
Vibration Safety
This tool vibrates during use.
Repeated or long-term exposure to
vibration may cause temporary or
permanent physical injury, particularly to
the hands, arms and shoulders. To reduce
the risk of vibration-related injury:
1. 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.
2. Do not smoke during use. Nicotine
reduces the blood supply to the
hands and fingers, increasing the risk
of vibration-related injury.
3. Wear suitable gloves to reduce the
vibration effects on the user.
4. Use tools with the lowest vibration
when there is a choice.
5. Include vibration-free periods each
day of work.
6. Grip tool as lightly as possible (while
still keeping safe control of it). Let
the tool do the work.
7. To reduce vibration, maintain the
tool as explained in this manual.
If any abnormal vibration occurs, stop
use immediately.
SAVE THESE INSTRUCTIONS.

Item 65766 For technical questions, please call 1-888-866-5797. Page 7
Grounding
TO PREVENT ELECTRIC SHOCK AND DEATH FROM
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
3-Prong Plug and Outlet
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 electric shock. (See
“3-Prong Plug and Outlet”.)
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
“3-Prong Plug and Outlet”.)
3. The 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
preceding illustration.
(See “3-Prong Plug and Outlet”.)

Item 65766 For technical questions, please call 1-888-866-5797. Page 8
Double Insulated Tools: Tools with Two Prong Plugs
Outlets for 2-Prong Plug
1. 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.
2. Double insulated tools may be used
in either of the 120 volt outlets shown
in the preceding illustration.
(See “3-Prong Plug and Outlet”.)
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 Table A.)
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 Table A.)
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 Table A.)
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 Table A.)
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 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.
8. Protect the extension cords from
sharp objects, excessive heat, and
damp or wet areas.

Item 65766 For technical questions, please call 1-888-866-5797. Page 9
TABLE A: RECOMMENDED MINIMUM
WIRE GAUGE FOR EXTENSION CORDS*
(120/240 VOLT)
NAMEPLATE
AMPERES
(at full load)
EXTENSION CORD
LENGTH
25´ 50´ 75´ 100´ 150´
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.
Symbology
Double Insulated
Canadian Standards Association
Underwriters Laboratories, Inc.
VVolts
~Alternating Current
AAmperes
n0xxxx/min. No Load Revolutions per Minute
(RPM)
WARNING marking
concerning Risk of Eye Injury.
Wear ANSI-approved safety
goggles with side shields.
Read the manual before set-up
and/or use.
WARNING marking concerning
Risk of Fire.
Do not cover ventilation ducts.
Keepammableobjectsaway.
WARNING marking concerning
Risk of Electric Shock.
Properly connect power cord to
appropriate outlet.

Item 65766 For technical questions, please call 1-888-866-5797. Page 10
SPECIFICATIONS
Electrical Requirements 120 VAC / 60 Hz /
150W (loaded)
Blade Speed 2600 SPM
Blade Stroke 3/8”
Maximum Cutting Capacity 18 Gauge Steel
Sheet
Chuck Capacity 1/2”
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
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.
3. Tighten the Hex Screw to
secure the Blade in place.

Item 65766 For technical questions, please call 1-888-866-5797. Page 11
OPERATING INSTRUCTIONS
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
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.
3. Secure loose work pieces using
a vise or clamps (not included) to
prevent movement while working.
4. 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.
5. 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 questions, please call 1-888-866-5797. Page 12
General Operating Instructions
1. Plug the Body Saw into a
grounded 120V electrical outlet.
2. With one hand holding the casing
of the Body Saw; push the Safety
(36) forward and squeeze the
Throttle (20) to power the Blade.
3. Contact the workpiece and make
the desired cut. Do not push
on the Saw; allow it to make
the cut at its intended pace.
4. When the cut is finished; remove
the Blade from the workpiece
and release the Throttle. Do
not set the Saw down until the
Blade has stopped moving.
5. To prevent accidents, turn off the
tool and disconnect its power supply
after use. Clean, then store the tool
indoors out of children’s reach.

Item 65766 For technical questions, please call 1-888-866-5797. Page 13
MAINTENANCE AND
SERVICING
Procedures not specifically
explained in this manual
must be performed only by a
qualified technician.
TO PREVENT
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.
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.
Cleaning, Maintenance, and
Lubrication
1. BEFORE EACH USE, inspect the
general condition of the tool. Check
for loose screws, misalignment or
binding of moving parts, cracked or
broken parts, damaged electrical
wiring, and any other condition that
may affect its safe operation.
2. AFTER USE, clean external surfaces
of the tool with clean cloth.
3. WARNING! If the supply cord of
this power tool is damaged, it must
be replaced only by a qualified
service technician.
Troubleshooting
Problem Possible Causes Likely Solutions
Tool will not start 1. No power at outlet.
2. Cord not connected.
3. Carbon Brushes may be worn
or damaged.
1. Check power at outlet.
2. Check that cord is plugged in.
3. HaveCarbonBrushesreplacedbyaqualied
technician.
Tool operates
slowly or
sporadically.
Carbon Brushes may be worn or
damaged.
HaveCarbonBrushesreplacedbyaqualied
technician.
Tool does not
cut effectively or
blade jams in work
material
1. Blade may be damaged, worn
or wrong type for the material.
2. Too much pressure.
1. Check condition and type of blade. Use only
proper type of blade in good condition.
2. Ease off pressure on blade.
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 14
PARTS LIST
Part Description Qty
1 Carbon Brush Holder 2
2 Carbon Brush 2
3 Stator 1
4 Left Housing 1
5 Power Cord 1
6 Guard 1
7 Bolt 1
8 Nut 1
9 Blade Guard 1
10 Bushing 1
11 Nut 1
12 Rocker Shaft 1
13 Main Shaft 1
14 Bearing 1
15 Ring 1
16 Gear Bracket 1
17 Gear 3
18 Gear Housing 1
19 Gear Box Cover 1
20 Throttle 1
PARTS LIST
Part Description Qty
21 Right Housing 1
22 Screw 8
23 Screw 1
24 Drive Plate 1
25 Drive Plate Guard 2
26 Blade Holder 1
27 Hex Screw 1
28 Screw 2
29 Switch 1
30 Cord Holder 1
31 Screw 2
32 Bearing Sleeve 1
33 Bearing 1
34 Rotor 1
35 Bearing 1
36 Safety 1
37 Lock Pin 1
38 Spring 1
39 Blade 1
40 Hex Wrench (not shown) 1
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.
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 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.

Item 65766 For technical questions, please call 1-888-866-5797. Page 15
ASSEMBLY DIAGRAM

Item 65766 For technical questions, please call 1-888-866-5797. Page 16
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 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 • 1-888-866-5797