Jarvis 444 Wellsaw User manual

Model 444 Wellsaw
Electric Powered
Reciprocating Saw
TABLE OF
CONTENTS Page.........................
EQUIPMENT
SELECTION Ordering No..............
Model 444 (115V)
End Cutting with 8 inch Blade 4005254..
End Cutting with 16 inch Blade 4005256.
Heavy Duty with 8 inch Blade 4005250...
Heavy Duty with 16 inch Blade 4005252.
Model 444 (230V)
End Cutting with 8 inch Blade 4005255..
End Cutting with 16 inch Blade 4005257.
Heavy Duty with 8 inch Blade 4005251...
Heavy Duty with 16 inch Blade 4005253.
Accessories
Balancer 4042037.....................
•Safety Messages to Employer and
Safety Director 2...................
•Safety Messages to Operators,
Maintenance and Cleanup Personnel 3
•Parts Diagram 4....................
•Parts List 6........................
•Specifications 7....................
•Installation Instructions 7............
•Operation Instructions 8.............
•Maintenance Instructions 9..........
®
JARVIS
6205004;:.
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA E--MAIL. jarvis.produc[email protected]
FAX. [phone] TEL. [phone] WWW. jarvisproducts.com

page 2 of 12
MODEL 444
®
JARVIS
6205004;:.
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA E--MAIL. jarvis.produc[email protected]
FAX. [phone] TEL. [phone] WWW. jarvisproducts.com
1. Ensure that all employees who use this tool are trained in the proper use of this tool and are aware
of the dangers that may arise if they do not follow the procedures outlined in this brochure.
2. Follow our installation and maintenance instructions for proper installation and care of the tool.
3. Enclosed are four (4) copies of “NOTICE TO OPERATORS AND MAINTENANCE AND
CLEANUP PERSONNEL.” Post one copy on the employees’ bulletin board; give one copy to
operator(s); give one copy to the maintenance foreman; and give one copy to the sub-contract clean-
up / internal cleanup foreman. Additional copies will be provided upon request.
4. The tool is designed and intended to be powerful. That fact should be obvious to your employees,
but you must emphasize it to them.
5. Always disconnect the tool from its power supply when it is not in use.
6. Ensure that employees wear eye protection in accordance with OSHA’s eye and face protection re-
quirements (29 CFR 1910.133) when using the tool.
7. Hand/Wrist/Arm injury and other Cumulative Trauma Disorders may result from repetitive work,
motion or vibration. You must make your employees aware of hazards, symptoms of injury and ap-
propriate prevention. See OSHA’s “Ergonomics Program Management Guidelines for Meatpack-
ing Plants.”
8. Remove and repair any tool that malfunctions. All personnel must be instructed to remove any
malfunctioning equipment.
9. Never make modifications or alterations to the tool. Replace any missing or illegible labels.
10. Avoid injury. Do not permit the tool to be misused.
11. If you resell or distribute a Jarvis product, you must provide the purchaser with the appropriate safe-
ty sheets and tool brochure. Additional copies of safety sheets and tool brochures will be provided
upon request.
SAFETY MESSAGES TO EMPLOYER AND SAFETY DIRECTOR
AVOID INJURY
Keep hands clear.
safety messages to employer
and safety director

page 3 of 12 MODEL 444
®
JARVIS
6205004;:.
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA E--MAIL. jarvis.produc[email protected]
FAX. [phone] TEL. [phone] WWW. jarvisproducts.com
1. Disconnect the power supply in accordance with OSHA’s lockout/tagout procedures (29 CFR
1910.147) before changing the blade.
2. Disconnect the power supply in accordance with OSHA’s lockout/tagout procedures (29 CFR
1910.147) before performing any repair or maintenance.
3. Disconnect the power supply -- or have the power supply disconnected - in accordance with OSHA’s
lockout/tagout procedures (29 CFR 1910.147) before performing any cleanup.
4. Disconnect the power supply when the tool is not in use.
5. Always wear eye protection in accordance with OSHA’s eye and face protection requirements (29 CFR
1910.133) and when needed, a dust mask.
6. Do not operate near flammable liquids or in gaseous atmospheres.
7. Do not operate in outdoor locations or in damp or wet locations.
8. Do not overreach; keep proper footing and balance when using the tool.
9. Never put fingers, hands or other parts of the body on the cutting edge of the blade or in the cutting
path.
10. Always use both hands when starting and operating the tool to avoid the risk of possible “kick back”
or “recoil.” Continue holding the tool with both hands until the saw blade comes to a complete stop.
11. Test the tool prior to use or daily. Depress the trigger and the tool should start. Release the trigger
and the tool should stop. If the tool malfunctions, remove it from service and report or repair it immedi-
ately.
12. Never depress the trigger unless you are going to use or test the tool.
13. Never make any alterations to the tool. Report or replace any missing or illegible labels.
SAFETY MESSAGES TO OPERATORS, MAINTENANCE AND CLEANUP
PERSONNEL
REMOVE ANY MALFUNCTIONING TOOL FROM SERVICE
REPORT ANY PROBLEMS TO YOUR SUPERVISOR
Keep hands clear.
safety messages to operators,
maintenance and cleanup personnel

page 4 of 12
MODEL 444
®
JARVIS
6205004;:.
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA E--MAIL. jarvis.produc[email protected]
FAX. [phone] TEL. [phone] WWW. jarvisproducts.com
parts diagram

page 5 of 12 MODEL 444
®
JARVIS
6205004;:.
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA E--MAIL. jarvis.produc[email protected]
FAX. [phone] TEL. [phone] WWW. jarvisproducts.com
install bearing with sealed
side facing fan on armature
parts diagram

page 6 of 12
MODEL 444
®
JARVIS
6205004;:.
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA E--MAIL. jarvis.produc[email protected]
FAX. [phone] TEL. [phone] WWW. jarvisproducts.com
blades and blade supports
replacement kits
assembly tools
1 1055948 Socket Head Cap Screw 4
2 1024095 Guard 1
3 1055439 Oval Head Screw 7
4 1061188 Tie Bar 1
5 1002198 Cover Plate 1
6 1055454 Round Head Screw 2
1055438 Set of 12 Screws
7 1055434 Button Head Screw 1
8 1055431 Oval Head Screw 6
9 1002194 Bearing Cap 1
10 1035198 Gasket 1
11 1016200 Gear Housing 1
12 1063121 Strain Relief 1
13 1012048 Clamp Bar 1
14 1001028 Power Cord Set, 115v 1
1001029 Power Cord Set, 230v 1
3001016 European Line Cord 1
3063091 Control Box 42v, includes: 1
1001111 Switch Cord 1
1063537 Fuse 1
1063601 Relay 1
15 1055430 Fillister Head Screw 2
16 1035194 Seal 1
17 1055436 Set Screw 3
18 1005038 Switch 1
19 1073190 Round Head Screw 2
20 1063124 Insulator 1
21 1002195 Handle Cover 1
22 1055452 Flat Head Screw 11
1055426 Set of 12 Screws
23 1002196 Bottom Plate 1
24 1035196 Bottom Plate Gasket 1
25 1035195 Seal 2
26 1036118 Bushing 1
35 1024060 Blade Guard 1
36 3063009 Brush and Spring Assy 2
37 1063122 Brush Holder 2
38 1017035 Information Label, 115v 1
1017036 Information Label, 230v 1
39 1055425 Label Mounting Screw 4
40 1016201 Motor Housing and Label 1
41 1035203 Gasket 1
42 1002199 Brush Cap 2
43 1007163 Cap Nut 4
44 1004150 Flat Washer 4
45 1027046 Stud 2
46 1036119 Insert 2
47 1063123 Grommet 1
48 1012047 “U” Clip 1
49 1012046 “S” Clip 1
50 1001027 Hanging Ring 1
51 1002197 Shroud 1
52 1019079 Handle (incls. items 52--53) 1
53 1004049 Lock Washer 4
54 1055069 Button Head Screw 4
55 1055100 Set Screw 3
56 1007165 Lock Nut 1
57 1004127 Thrust Bearing Race 2
58 1028059 Connecting Rod 1
59 1021221 Needle Bearing 1
60 1021223 Inner Race 1
61 1061189 Crank Arm 1
ITEM PART NO. PART NAME QTY
62 1021230 Ball Bearing 1
63 1020130 Drive Shaft 1.
64 1026070 Spiral Bevel Gear 1
65 1021210 Ball Bearing 1
66 1030100 Woodruff Key 1
67 1027044 Drive Stud 1
68 1021222 Inner Race 1
69 1021220 Needle Bearing 1
70 1027045 Rod Stud 1
71 8030032 Hex Key 1
72 1055423 Set Screw 1
73 1065026 Push Rod 1
74 1026071 Spiral Bevel Pinion Gear 1
75 1021211 Ball Bearing 1
76 1063603 Armature, 42v 1
1063113 Armature, 115v
1063114 Armature, 230v
77 1021209 Ball Bearing 1
78 1007164 Lock Nut 2
79 1012049 Clamp 1
80 1027047 Stator Stud 2
81 1063602 Stator, 42v 1
1063115 Stator, 115v
1063116 Stator, 230v
ITEM PART NO. PART NAME QTY
27 1023121 Blade 16”, End Cutting 1
28 1023124 Blade 16” 4 tpi, Heavy Duty 1
29 1058072 Blade Support 16” Hvy. Duty 1
30 1058077 Blade Support 16” End Cut 1
31 1023122 Blade 8”, End Cutting 1
32 1023123 Blade 8” 4 tpi, Heavy Duty 1
33 1058076 Blade Support 8” End Cut 1
34 1058073 Blade Support 8” Heavy Duty 1
ITEM PART NO. PART NAME QTY
8039105 Brush Alignment Bar 1
8039106 “T” Handle Stator Studs 1
8039107 “T” Handle Hex Key 1
8039108 Brush Wiring Tool 1
8039109 Brush Alignment Shaft 1
8039110 All Tools Listed Above
ITEM PART NO. PART NAME QTY
3016120 Gear Housing & Seal Assy 1
3016121 Motor Housing & Seal Assy 1
3061069 Drive Shaft Assembly 1
3061070 Crank Arm Assembly 1
3028031 Connecting Rod & Bearing 1
3063092 Armature & Brg. Assy, 42v 1
3063005 Armature & Brg. Assy, 115v 1
3063006 Armature & Brg. Assy, 230v 1
1062003 Gear Grease, 1 Pound 1
1017083 Danger Label 1
ITEM PART NO. PART NAME QTY
parts list

page 7 of 12 MODEL 444
®
JARVIS
6205004;:.
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA E--MAIL. jarvis.produc[email protected]
FAX. [phone] TEL. [phone] WWW. jarvisproducts.com
SPECIFICATIONS
Model 444 Wellsaw
Motor Power 2 hp 1491 W
Voltage 115V, 1 phase, 50/60 Hz
230V, 1 phase, 50/60 Hz
Full Load Amperes at 115V 15 A
at 230V 7.5 A
at 42V 41 A
Blade Speed 6300 cycles per minute
Stroke 1.5 in 38 mm
Control Handle single trigger electric
Blade Lengths 8 in 203 mm
16 in 406 mm
Overall Length (with 16 in / 400 mm blade)
38 in 965 mm
Weight 23 lbs 10.5 kg
INSTALLATION INSTRUCTIONS
These instructions have been prepared to assure you of
satisfactory operation through proper use of your Jarvis
Wellsaw. Read them carefully and keep them for future
reference.
OPTIONAL BALANCER:
Install the Model 444 above the work station from a ba-
lancer. Jarvis part number 4042037 is available.
POWER SUPPLY:
Your Jarvis Wellsaw operates on 50 or 60 Hz., single
phase alternating current. Its voltage rating is indicated
on the name plate (42 volt, 115 volt or 230 volt). If an
extension cord is to be used, be sure that the wire size is
adequate to maintain full line voltage to the tool. For the
115 and 230 volt tools, be sure that it is a three conductor
cord with a three prong grounding-type plug (with the
grounding blade intact).
GROUNDING: 115 volt and 230 volt tools only.
Your Jarvis Wellsaw should be grounded to protect the
user from electric shock or ELECTROCUTION. The
Jarvis Wellsaw is equipped with an approved three con-
ductor cord and three-prong grounding-type plug to fit
the proper grounding-type receptacle. The green con-
ductor in the cord is the grounding wire. Never connect
the green wire to a live terminal. If your Jarvis Wellsaw
is the 115 volt model, it has a plug that looks like figure
“A”. If your Jarvis Wellsaw is the 230 volt model, it has
a plug that looks like figure “B”.
figure A figure B
grounding blade grounding blade
Do not use any adapters with the Jarvis Wellsaw.
CONTROL BOX: 42 volt tool only.
Your Jarvis Wellsaw must be connected to the electrical
control box (3063091) as shown in figure “C”.
figure C
specifications and
installation instructions

page 8 of 12
MODEL 444
®
JARVIS
6205004;:.
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA E--MAIL. jarvis.produc[email protected]
FAX. [phone] TEL. [phone] WWW. jarvisproducts.com
EXTENSION CORDS:
Make sure your extension cord is in good condition.
When using an extension cord, be sure to use one heavy
enough to carry the current your Jarvis Wellsaw will
draw. An undersized cord will cause a drop in line volt-
age resulting in loss of power and overheating. The table
below shows the correct size to use depending on cord
length and nameplate ampere rating. If in doubt, use the
next heavier gage. The smaller the gage number, the
heavier the cord.
Minimum Wire Gage for Extension Cords
Volts TotalLengthofCordinFeet
120 0--25 26--50 51--100 101--150
240 0--50 51--100 101--200 201--300
Amp Rating Wire Size (AWG)
6--1018161412
12--16 14 12 not recommended
When tool is used outdoors, use only extension cords la-
beled for outdoor use.
OPERATION INSTRUCTIONS
Before starting regular operation of the Jarvis Wellsaw
we recommend that you make a few cuts with a fine pitch
blade to acquaint yourself with the operation of the tool
before using any of the coarser blades.
A. AVERAGE CUTTING AND RIPPING:
1 Place your work piece on a solid support at a
convenient working height.
2 Adjust the material so that the line of cut will be
close to the support. Secure it firmly.
3 To prevent the starting torque of the motor from
pulling the saw away from the line of the cut,
make a few short strokes until the blade has cut
into the material about 1/4 inch. Then squeeze
the trigger.
4Both hands should be on the saw at all times
when cutting. Continue holding the tool with
both hands until the saw blade comes to a
complete stop.
5 The saw should be kept at a 90 degree angle to
the work piece while cutting material that is
thicker than 1 inch.
6 The saw should be pushed firmly into the mate-
rial while cutting.
7 Do not allow the saw blade or the blade support
to leave the work piece while cutting.
8 Never permit any part of the saw, except the
blade and the blade support, to contact the work
piece during the cut.
B. SINKING THE BLADE THROUGH A SUR-
FACE:
1 Your power hand saw is not designed for regular
use in starting its own hole by sinking the blade
through a surface, commonly called “plunge
cutting”. If attempted, you must:
a. Keep the saw blade as parallel to your work
as possible.
b. As the blade makes contact with work piece,
immediately start to draw the saw back
slowly from your starting point.
c. Repeat the operation outlined in “b”, if nec-
essary.
d. Have room to draw the saw at least 4-6 in-
ches before cutting through a 1 inch thick-
ness.
e. Do not force the saw blade, but keep it mov-
ing slowly on the draw back from the start-
ing point. After a break through cut has
been made and the end of the blade support
extends through material at least 1-1/2 in-
ches, the saw may be tipped to a normal cut-
ting angle.
installation and
operation instructions

page 9 of 12 MODEL 444
®
JARVIS
6205004;:.
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA E--MAIL. jarvis.produc[email protected]
FAX. [phone] TEL. [phone] WWW. jarvisproducts.com
C. NOT FOR CUTTING SMALL RADII
D. ALWAYS KEEP A SHARP BLADE ON THE
SAW:
1 Cutting with a dull or badly worn blade can
overload the saw and cause damage from over-
heating.
2 New blades can be purchased from Jarvis
Products Corporation.
MAINTENANCE INSTRUCTIONS
Always disconnect the saw from its power supply
before performing any maintenance.
Item numbers: refer to the parts diagrams on pages 4-5.
A. LUBRICATION:
1 The gear case should be kept 1/3 full of grease.
To check the grease level remove the bottom
plate and its gasket (items 23 and 24). It should
be checked every 30 days for saws that are used
moderately and every two weeks for saws that
are used daily. If replacement grease is required
it should be obtained from Jarvis Products
Corporation.
B. BLADE INSTALLATION:
NOTE: Your Jarvis Wellsaw is equipped with
a hex key wrench(item 71) for removing and in-
stalling the blade. This wrench is located in the
motor housing.
1 Insert hex key (item 71) into set screw (item 72).
2 Fasten the set screw into the hole in the end of
push rod (item 73). Do not tighten.
3STANDARD BLADE SUPPORT (End Cutting):
a. Align blade (items 27 or 31) with blade sup-
port (item 30 or 33). The blade should ex-
tend approximately 3 inches from the end of
the blade support.
b. Slide the blade onto the blade support until
the crimp in the blade is touching the end of
the blade support.
c. Use a rubber hammer and tap the end of
blade towards the body of the saw until the
crimp in the blade slides into the slot in the
blade support.
HEAVY DUTY BLADE SUPPORT (Heavy Duty):
a. Place the grooved end of blade (item 28 or
32) into the guide in the blade support (item
29 or 34).
b. Slide the blade over the blade support to-
wards the body of the saw. Make sure that
the tabs on the blade extend over each side
of the blade support.
4 Slide the blade into the push rod (item 73) as far
as it will go.
5 Tighten the set screw (item 72) with the hex key
(item 71).
C. BLADE SUPPORT INSTALLATION:
1 Remove cap nuts (item 43) and flat washers
(item 44) from threaded stud (item 45).
2 Slide the blade support over inserts (item 46) un-
til the blade support is against the housing.
3 Replace flat washers (item 44) and cap nuts
(item 43) and tighten firmly.
D. DISASSEMBLY OF MOTOR:
1 Remove blade and set screw (item 72).
2 Remove handle cover (item 21).
3 Disconnect the two wires from the stator (item
81) and the two wires from the power cord (item
14) attached to switch (item 18). Remove
switch (item 18).
4 Remove tie bar (item 4) and cover plate (item 5).
5 Remove shroud (item 51), brush cap (item 42)
and brush and spring assembly (item 36).
6 Remove bottom plate (item 23) and bottom plate
gasket (item 24).
operation and
maintenance instructions

page 10 of 12
MODEL 444
®
JARVIS
6205004;:.
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA E--MAIL. jarvis.produc[email protected]
FAX. [phone] TEL. [phone] WWW. jarvisproducts.com
7 Insert a small block of wood between the con-
necting rod and the housing to stop rotation of
the crank arm (item 61). Remove locknut (item
56) and rod stud (item 70). Remove connecting
rod (item 58).
8 Remove push rod (item 73) by pulling it toward
the center of the saw. If the outer end of the push
rod is deformed, grinding may be necessary to
allow it to pass through the bushing (item 26).
9 Reinsert the small block of wood to stop rotation
of the crank arm (item 61). Insert 5/16 inch hex
key wrench into the drive shaft (item 63) and
turn clockwise to loosen and remove crank arm
(item 61).
10 Remove drive shaft (item 63).
11 Remove (4) screws (item 1).
12 Rotate gear housing (item 11), approximately 90
degrees relative to the motor housing (item 40).
Separate the housings by pulling or tapping
lightly with a rubber hammer.
13 Back off, but do not remove, (3) set screws (item
17).
14 Remove armature (item 76) by inserting two
screwdrivers between the gear housing and the
armature fan and gently prying.
15 Clean the gear housing cavity and the drive shaft
assembly to remove any contaminated lubri-
cant.
16 Remove (4) screws (item 8) and (1) screw (item
7).
17 Insert screw (item 1) into the center tapped hole
of the bearing cap (item 9) and tighten to remove
the bearing cap.
18 Turn the bottom up and push or tap it lightly to
remove drive shaft assembly (items 62-66).
19 Remove stator wires (item 81) from brush hold-
ers (item 37).
20 Remove (2) locknuts (item 78). Pull the stator
lead wires through the grommet hole and re-
move the stator (item 81).
21 Using an arbor press remove the bushing (item
26) and the (2) seals (item 25). New seals will
be required after removing the bushing.
22 Assembly may be accomplished by reversing
these steps.
23 Caution: the armature must turn counter--clock-
wise as viewed from behind the handle looking
toward the blade. To reverse rotation, put stator
leads on opposite brush holders.
E. DRIVE SHAFT ASSEMBLY:
1 Place the drive shaft assembly assembly (items
62--66) into the gear housing (item 11). Make
sure that the sub-assembly is completely bot-
tomed out in the bearing bore.
2 Place the armature sub-assembly (items 74--77)
into the gear housing. Make sure that the sub-
assembly is completely bottomed out in the
bearing bore .
3 Grease the gear housing until it is 1/4 full.
4 Fasten the gasket (item 10) and bearing cap
(item 9) to the gear housing.
5 Lock the armature sub-assembly in place with
(3) set screws (item 17). Do not over tighten the
screws as they may distort the bearing and cause
uneven rotation.
6 Assemble the motor housing (item 40) and the
remaining parts of the saw assembly to the gear
housing with the exception of:
- crank arm and stud assembly (items 61 and
67)
- connecting rod and bearing assembly (items
58, 59 and 69)
- push rod (item 73)
- (3) set screws (items 55)
- (1) screw (item 7)
7 Place the saw on its back with connecting rod
cavity facing up.
maintenance instructions

page 11 of 12 MODEL 444
®
JARVIS
6205004;:.
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA E--MAIL. jarvis.produc[email protected]
FAX. [phone] TEL. [phone] WWW. jarvisproducts.com
8 Screw in each of (3) set screws (items 55) to a
depth of approximately two complete turns.
9 Connect the saw to a power source and turn on
the saw.
10 With the saw running, turn each set screw (item
55) - slowly and equally - until the saw starts to
slow down (there may be a change in pitch of the
motor). It is very important that the set screws
are drawn down equally. Failure to do so can re-
sult in misalignment of gears.
11 Back off each set screw in equal amounts until
the full speed of the saw is reached.
12 Turn off the saw and disconnect it from the pow-
er source.
13 Check to see that there is very little back lash be-
tween the bevel and the pinion gears. If there
seems to be too much backlash, back off set
screws (items 55) and repeat steps 7-13.
14 Assemble the remainder of the saw.
maintenance instructions

page 12 of 12
MODEL 444
®
JARVIS
6205004;:.
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA E--MAIL. [e-mail]
FAX. [phone] TEL. [phone] WWW. jarvisproducts.com
PRODUCTS CORPORATION
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457--4926
UNITED STATES OF AMERICA E--MAIL jarvis.produc[email protected]
TEL. [phone] •FAX. [phone] •WWW.jarvisproducts.com
®
JARVIS
6205004;:.