Jarvis WELLSAW 404 User manual

Model 404 Wellsaw
Air Powered Reciprocating
Saw
TABLE OF
CONTENTS Page.........................
EQUIPMENT
SELECTION Ordering No..............
Model 404 115V
End Cutting, 4TPI, 8 in Blade 4005220.....
Heavy Duty, 4TPI, 8 in Blade 4005221.....
End Cutting, 4TPI, 16 in Blade 4005224....
Heavy Duty, 4TPI, 16 in Blade 4005225....
Model 404 230V
End Cutting, 4TPI, 8 in Blade 4005222.....
Heavy Duty, 4TPI, 8 in Blade 4005223.....
End Cutting, 4TPI, 16 in Blade 4005226....
Heavy Duty, 4TPI, 16 in Blade 4005227....
Blades
4 TPI, 8 inch, End Cutting 1023122........
4 TPI, 8 inch, Heavy Duty 1023123........
4 TPI, 16 inch, End Cutting 1023121.......
4 TPI, 16 inch, Heavy Duty 1023124.......
Supports
8 inch blade, End Cutting 1058071........
8 inch blade, Heavy Duty 1058075........
16 inch blade, End Cutting 1058070.......
16 inch blade, Heavy Duty 1058074.......
Accessories
Jarvis Wellsaw Blade Lubricant 1062023...
Balancer 4042028.......................
•Safety Messages to Employer and
Safety Director 2...................
•Safety Messages to Operators,
Maintenance and Cleanup Personnel 3
•Parts Diagram and List 4............
•Specifications 6....................
•Installation Instructions 6............
•Operation Instructions 6.............
•Maintenance Instructions 7..........
NOT FOR HOME USE
JARVIS
6205006;:.
®
Cutlerymania.com is an authorized online parts distributor supplying
Original Jarvis Products. .
E-mail: [email protected]
FAX: [phone] Telf: 973-751-7775 www.cutlerymania.com

pg 2 of 8
MODEL 404
JARVIS®
6205006;:.
safety messages to employer
and safety director
1. Ensure that employees wear eye protection in accordance with OSHA’s eye and face protection re-
quirements (29 CFR 1910.133) at all times.
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, MAINTENANCE AND CLEAN-
UP 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 cleanup / 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 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.
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 Meat Pack-
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.
Cutlerymania.com is an authorized online parts distributor supplying
Original Jarvis Products. .
E-mail: [email protected]
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pg 3 of 8 MODEL 404
JARVIS
6205006;:.
®
safety messages to operators,
maintenance and cleanup personnel
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 im-
mediately.
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.
Cutlerymania.com is an authorized online parts distributor supplying
Original Jarvis Products. .
E-mail: [email protected]
FAX: [phone] Telf: 973-751-7775 www.cutlerymania.com

pg 4 of 8
MODEL 404
JARVIS®
6205006;:.
parts diagram
Cutlerymania.com is an authorized online parts distributor supplying
Original Jarvis Products. .
E-mail: [email protected]
FAX: [phone] Telf: 973-751-7775 www.cutlerymania.com

pg 5 of 8 MODEL 404
JARVIS
6205006;:.
®
blades, blade supports
and accessories
ITEM
OLD
PART NO.
JARVIS
PART NO. PART NAME QTY
1 1063112 501022--005 Brush Cap 2
2 1063111 501022--004 Brush and Spring 2
3 1063110 501022--003 Brush Holder 2
4 1015006 501174 Deflector 2
5 1002191 501002 Top Cap 1
6 1017083 Danger Label 1
7 1055428 100101--004 Screw, Flat Head 4
8 1021215 100403--003 Ball Bearing 1
9 1063119 501224--003 Stator, 115V 1
1063120 501224--004 Stator, 230V 1
10 1027040 501021 Stator Stud 2
11 1007164 100105--001 Lock Nut 4
12 1063117 501224--001 Armature, 115V 1
1063118 501224--002 Armature, 230V 1
13 1026072 501225 Pinion Gear 1
14 1021227 100422--004 Ball Bearing 1
15 1035193 501120--001 Seal 1
16 1035192 501103 Seal 2
17 1036116 501171 Bushing 1
18 1027041 501046 Rod Stud 1
19 3065010 501172 Push Rod and Stud 1
20 1012050 501350 Clamp Ring 1
21 1055422 100034--038 Set Screw, 1/4 inch 1
22 8030031 100099--001 Hex Key 1
23 1002206 501003--001 Blade Support Cover 1
24 1007162 100022--006 Cap Nut 6
25 1055439 100102--002 Screw, Oval Head Phil 2
26 1054076 501380 Screw, Coated 3
27 1002203 501004 Handle Cover 1
28 1005038 100739--001 Switch 1
29 1073190 Screw, Round Head 2
30 1012046 501042 “S” Clip 1
31 1012047 501043 “U” Clip (rubber) 1
32 1027048 501272 Stud 3
33 1036120 501273 Insert Bushing 3
34 1017033 501187 Info Label 115V, Eng. 1
1017034 501179 Info Label 230V, Eng.
1017054 Info Label 115V, French
1017234 Info Label 230V, French
35 1045013 Label Retaining Rivet 4
36 1004149 100426--001 Thrust Bearing Race 1
37 1021218 100425--001 Needle Thrust Bearing 1
38 1027043 501081 Drive Stud 1
39 3026024 501223 Gear and Stud (32) 1
40 1020133 501377 Gear Shaft 1
41 1021228 Needle Bearing 2
42 1035191 501008 Gasket 1
43 1002193 501005 Bottom Plate 1
44 1055426 100101--001 Screw (set of 12) 4
45 3028030 501053 Connecting Rod & Brg 1
46 1029185 501082 Spacer 1
47 1013310 100069--013 Snap Ring 1
48 1021216 100424--001 Needle Bearing 2
49 1055454 Screw, Round Head 1
50 3001008 501006 Cord, Plug & Molded
Strain Relief, 115V
3001010 501089 Cord, Plug & Molded
Strain Relief, 230V
51 3001011 501337 Cord w/o Strain Relief 1
52 1063125 501294 Strain Relief 1
ITEM
OLD
PART NO.
JARVIS
PART NO. PART NAME QTY
replacement kits
IT. OLD
PART NO.
JARVIS
PART NO. PART NAME
3063010 501351--001 Armature and Bearing
(no pinion gear) 115V
3063011 501351--002 Armature and Bearing
(no pinion gear) 230V
3063007 501235--001 Armature, Bearing
and Pinion Gear, 115V
3063008 501235--002 Armature, Bearing
and Pinion Gear, 230V
3063013 501232 Armature and Pinion,115V
3063014 501233 Armature and Pinion,230V
3026023 501088 Gear & Bearing Assembly
3016119 501169--001 Hsg, Seals & Bushing Assy
3061152 Service Kit (items 11, 13,
27, 33, 38 and 42)
ITEM
OLD
PART NO.
JARVIS
PART NO. PART NAME QTY
53 1013137 501295 Clamp Ring 1
54 1063109 100647 Grommet 1
55 1016199 501001--006 Housing 1
56 1007166 501376 Gear Stud Nut 1
57 1006021 501066 Knob 1
58 1055429 100102--003 Screw, Oval Head Phil 2
59 1027042 501065 Handle Stud 1
60 1058071 501175T Blade Support 8” End Cut 1
1058070 501128T Blade Sup. 16” End Cut
61 1023122 501246 Blade 8” End Cutting 1
1023121 501247 Blade 16” End Cutting
62 1058075 502077T Blade Sup. 8” Heavy Duty 1
1058074 502076T Blade Sup. 16” Heavy Duty
63 1023123 501319 Blade 8” Heavy Duty 1
1023124 501320 Blade 16” Heavy Duty
1062003 Gear Grease, 1 Lb Can 1
parts list
Cutlerymania.com is an authorized online parts distributor supplying
Original Jarvis Products. .
E-mail: [email protected]
FAX: [phone] Telf: 973-751-7775 www.cutlerymania.com

pg 6 of 8
MODEL 404
JARVIS®
6205006;:.
SPECIFICATIONS
Motor Power 1 hp 745 W
Operating Volt/Amp 230V/3.5A, 1 phase, 50/60 Hz
115V/7A, 1 phase, 50/60 Hz
Stroke 1.13 in 29 mm
Blade Speed 8000 strokes / min
Control Handle Single Trigger Electric
Blade Length 8 in 203 mm
16 in 406 mm
Overall Length (w/16 in blade) 32 in 813 mm
Weight (w/o blade) 9.8 lbs 4.5 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 refer-
ence.
POWER SUPPLY
Your Jarvis Wellsaw operates on 50 or 60 Hz., single
phase alternating current. Its voltage rating is indicated
on the name plate (either 115 or 230 Volt). If an exten-
sion cord is to be used, be sure that the wire size is ade-
quate to maintain full line voltage to the tool.
GROUNDING
Your Jarvis Wellsaw should be grounded to prevent the
user from electric shock or electrocution.TheJarvis
Wellsaw is equipped with an approved three conductor
cord and three prong grounding--type plug to fit the prop-
er grounding--type receptacle. The green conductor 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
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)
0--6 18 16 16 14
6--10 18 16 14 12
When tool is used outdoors, use only extension cords
labeled 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 starting torque of the motor from
pulling the saw away from line of cut, the opera-
tor should make a few short strokes until the
blade has cut into the material about 1/4 inch be-
fore squeezing trigger switch.
specifications, installation
and operation instructions
Cutlerymania.com is an authorized online parts distributor supplying
Original Jarvis Products. .
E-mail: [email protected]
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pg 7 of 8 MODEL 404
JARVIS
6205006;:.
®
4. Both hands should be on the saw at all times
while cutting. Continue holding the tool with
both hands until the saw blade comes to a com-
plete 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 allow the saw blade to float into the mate-
rial while cutting.
9. Never permit any part of the saw, except the
blade and the blade support, to contact the work
piece during the cut.
B. LARGE CROSS SECTIONS:
1. Rocking the saw in the cut will speed up the cut-
ting action.
C. 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 blades
through a surface, commonly called “plunge
cutting”. If attempted, the operator must:
a. Keep the saw blade as parallel to the work
as possible.
b. Immediately, as the blade makes contact
with the work piece, start to draw the saw
back slowly from the 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
moving slowly on the draw back from the
starting point. After a break through cut
has been made and the end of the blade sup-
port extends through the material at least
1--1/2 inches, the saw may be tipped to a
normal cutting angle.
D. NOT FOR CUTTING SMALL RADII:
E. 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.
MAINTENANCE INSTRUCTIONS
Always disconnect the saw from its power supply
before performing any maintenance.
Item numbers: refer to the parts diagram on page 4.
A. LUBRICATION:
1. The gear case should be kept 1/3 full of grease.
To check the grease level, remove the bottom
plate (item 43) and its gasket (item 42). It should
be checked every thirty days for saws that are
used moderately and every two weeks for saws
that are used daily. If replacement grease is re-
quired it should be obtained from Jarvis.
B. BLADE SUPPORT INSTALLATION:
1. Tap (3) inserts (item 33) gently into the bores on
blade support cover (item 23).
2. Align the blade support cover (item 23) onto saw
housing (item 55), making sure the inserts stay
in place.
3. Assemble (3) studs (item 32) with cap nuts (item
24) and place them through the saw housing and
the blade support cover.
4. Draw down all (3) cap nuts (item 24) evenly un-
til the inserts are bottomed out into the saw hous-
ing.
5. Remove the cap nuts (item 24) and the blade
support cover (item 23). (The inserts should
now be properly set into the saw housing).
6. Assemble blade support (item 60 or 62) over the
inserts on the saw housing. Place the blade sup-
port cover (item 23) on the saw housing and fas-
ten it with the studs (item 32), the cap nuts (item
24) and the oval head screws (item 25).
operation and
maintenance instructions
Cutlerymania.com is an authorized online parts distributor supplying
Original Jarvis Products. .
E-mail: [email protected]
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pg 8 of 8
MODEL 404
JARVIS®
6205006;:.
7. Install handle stud (item 59) using two larger
oval head screws (item 58).
C. BLADE REMOVAL:
NOTE: Your Jarvis Wellsaw is equipped with a
hex key (item 22) for removing the blade. This
wrench is located in the housing directly behind
the blade support knob (item 57).
1. Insert the hex key through the hole in the outer
end of blade (item 61 or 63) and pull the blade
to the outer end of stroke.
2. Loosen the blade holding set screw (item 21)
about 1/2 turn.
3. Reinsert the hex key in the hole at the outer end
of the blade and pull the blade out.
D. BLADE INSTALLATION:
1. Insert hex key (item 22) into set screw (item 21).
2. Thread the set screw (item 21) into the hole in
the end of push rod (item 19). Do not tighten.
3. STANDARD BLADE SUPPORT (End Cutting):
a. Align blade (item 61) with blade support
(item 60). The blade should extend approx-
imately three 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 the
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 63)
into the guide in the blade support (item
62).
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 as far as it will
go.
5. Tighten the set screw with the hex key.
E. GENERAL DISASSEMBLY:
1. Remove blade (item 61 or 63) and blade support
(item 60 or 62).
2. Remove handle cover (item 27).
3. Remove switch (item 28). Remove the two
wires from the stator (item 9) and the two wires
from the cord (item 51).
4. Remove brush cap (item 1) and brushes (item 2).
5. Remove deflectors (item 4).
6. Slide off top cap (item 5) -- stator (item 9) will
be attached.
7. Remove armature (item 12). Hold the armature
in one hand and tap housing (item 55) with a rub-
ber hammer with the other hand to loosen the ar-
mature. (Pinion gear -- item 13 -- on the arma-
ture has a left hand thread).
8. Remove bottom plate (item 43) and gasket (item
42).
9. Insert a small block of wood between the con-
necting rod (item 45) and the housing (item 55)
to stop the rotation of the connecting rod. Re-
move lock nuts (item 11). Remove the connect-
ing rod and bearings (item 45) and spacer (item
46).
10. Using a 5/16 inch hex key, loosen gear shaft
(item 40) -- left hand thread. Be sure not to spin
gear stud nut (item 56). Remove items 36--40,
47 and 48.
11. Remove the push rod and stud (item 19) through
the center of the housing.
12. Clean the gear housing cavity to remove any
contaminated lubricant.
13. Remove and replace any faulty parts and reas-
semble by reversing these steps.
NOTE (when reassembling):
a. Step 10: Use Loctite 271 on gear stud nut
(item 56) before fastening gear shaft (item
40).
b. Step 7: Reassemble armature (item 12) in
housing (item 55) by using a center punch
to tap the armature until its bearing is fully
seated.
maintenance instructions
Cutlerymania.com is an authorized online parts distributor supplying
Original Jarvis Products. .
E-mail: [email protected]
FAX: [phone] Telf: 973-751-7775 www.cutlerymania.com