Skil 4540, 4480, 4580 User Manual

IMPORTANT: IMPORTANT : IMPORTANTE:

Read Before Using Lire avant usage Leer antes de usar

Operating/Safety Instructions Consignes de fonctionnement/sécurité

Instrucciones de funcionamiento y seguridad

4480 4540 4580

Call Toll Free

for Consumer Information

& Service Locations

Pour renseignement des

consommateurs et centres

de service, appelez au

numéro gratuit :

Llame gratis para obtener información para el consumidor y

ubicaciones de servicio

1-877-SKIL999 (1-877-754-5999) www.skil.com

For English Parlez-vous français? ¿Habla español? See page 2 Voir page 14 Ver página 26

Power Tool Safety Rules

WARNING

Read and understand all instructions. Failure to follow all instructions listed below, may result in electric shock, fire and/or serious personal 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 presence of flammable liquids, gases, or dust.

tools create sparks which may ignite the dust or fumes.

Keep by-standers, children, and visitors away while operating a power tool.

Distractions can cause you to lose control.

Power

Electrical Safety

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.

certain the outlet voltage supplied is within the voltage marked on the nameplate. Do not use “AC only” rated tools with a DC power supply.

Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators

of electric shock if your body is grounded.

operating the power tool in damp locations is unavoidable, a Ground Fault Circuit Interrupter must be used to supply the power to your tool. Electrician’s rubber gloves and footwear will further enhance your personal safety.

Don't expose power tools to rain or wet conditions

increase the risk of electric shock.

Do not abuse the cord. Never use the cord to carry the tools or pull the plug from an outlet. Keep cord away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately.

the risk of electric shock.

When operating a power tool outside, use an outdoor extension cord marked "W-A"

Before plugging in the tool, be

. There is an increased risk

. Water entering a power tool will

Damaged cords increase

or "W."

and reduce the risk of electric shock. Refer to “Recommended sizes of Extension Cords” in the Accessory section of this manual.

These cords are rated for outdoor use

Personal Safety

Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use tool while tired or under the influence of drugs, alcohol, or medication.

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.

hair can be caught in moving parts. Keep handles dry, clean and free from oil and grease.

Avoid accidental starting. Be sure switch is “OFF” before plugging in

with your finger on the switch or plugging in tools that have the switch “ON” invites accidents.

Remove adjusting keys or wrenches before turning the tool “ON”

that is left attached to a rotating part of the tool may result in personal injury.

Do not overreach. Keep proper footing and balance at all times

balance enables better control of the tool in unexpected situations.

Use safety equipment. Always wear eye protection

shoes, hard hat, or hearing protection must be used for appropriate conditions.

A moment of inattention while

Loose clothes, jewelry, or long

. Carrying tools

. A wrench or a key

. Proper footing and

. Dust mask, non-skid safety

Tool Use and Care

Use clamps or other practical way to secure and support the workpiece to a stable platform.

against your body is unstable and may lead to loss of control.

Do not force tool. Use the correct tool for your application

job better and safer at the rate for which it is designed.

-2-

Holding the work by hand or

. The correct tool will do the

Do not use tool if switch does not turn it “ON” or “OFF”.

controlled with the switch is dangerous and must be repaired.

Disconnect the 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.

Store idle tools out of reach of children and other untrained persons.

dangerous in the hands of untrained users.

Maintain tools with care. Keep cutting tools sharp and clean.

tools, with sharp cutting edges are less likely to bind and are easier to control. Any alteration or modification is a misuse and may result in a dangerous condition.

Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tools operation. If damaged, have the tool serviced before using.

caused by poorly maintained tools. Develop

Any tool that cannot be

Tools are

Properly maintained

Many accidents are

a periodic maintenance schedule for your tool.

Use only accessories that are recommended by the manufacturer for your model.

suitable for one tool, may become hazardous when used on another tool.

Accessories that may be

Service

Tool service must be performed only by qualified repair personnel.

maintenance performed by unqualified personnel could result in a risk of injury. For example: internal wires may be misplaced or pinched, safety guard return springs may be improperly mounted.

When servicing a tool, use only identical replacement parts. Follow instructions in the Maintenance section of this manual.

Use of unauthorized parts or failure to follow Maintenance Instructions may create a risk of electric shock or injury. Certain cleaning agents such as gasoline, carbon tetrachloride, ammonia, etc. may damage plastic parts.

Service or

Safety Rules for Jigsaws

Hold tool by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord.

make exposed metal parts of the tool "live" and shock the operator.

or break into existing walls or other blind areas where electrical wiring may exist. If this situation is unavoidable, disconnect all fuses or circuit breakers feeding this worksite.

Never leave the trigger locked "ON". Before plugging the tool in, check that the trigger lock is "OFF".

could cause injury.

Be aware of the location and setting of the switch "Lock-ON" button.

is locked "ON" during the use, be ready for emergency situations to switch it "OFF", by

Contact with a "live" wire will

Do not drill, fasten

Accidental start-ups

If the switch

first pulling the trigger then immediately releasing it without pressing the "Lock-ON" button.

Keep hands away from cutting area. Do not reach under the material being cut.

The proximity of the blade to your hand is hidden from your sight.

Keep hands from between the gear housing and saw blade holder.

reciprocating blade holder can pinch your fingers.

Do not use dull or damaged blades. Bent blade can break easily or cause kickback.

Before starting to cut, turn tool "ON" and allow the blade to come to full speed.

Tool can chatter or vibrate if blade speed is too slow at beginning of cut and possibly kickback.

The

Always wear safety goggles or eye protection when using this tool. Use a dust mask or respirator for applications which generate dust.

Secure material before cutting. Never hold it in your hand or across legs.

or thin material may flex or vibrate with the blade, causing loss of control.

Make certain all adjusting screws and the blade holder are tight before making a cut.

Loose adjusting screws and holders can cause the tool or blade to slip and loss of control may result.

When removing the blade from the tool avoid contact with skin and use proper protective gloves when grasping the blade or accessory.

hot after prolonged use.

Accessories may be

Small

WARNING

grinding, drilling, and other construction activities contains chemicals known 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 and other masonry products, and

• Arsenic and chromium from chemicallytreated 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.

Some dust created by power sanding, sawing,

-4-

Symbols

IMPORTANT: Some of the following symbols may be used on your tool. Please study them

and learn their meaning. Proper interpretation of these symbols will allow you to operate the tool better and safer.

Symbol Name Designation/Explanation

V Volts Voltage (potential)

A Amperes Current

Hz Hertz Frequency (cycles per second)

W Watt Power

kg Kilograms Weight

min Minutes Time

s Seconds Time

Diameter Size of drill bits, grinding wheels, etc.

.../min Revolutions or reciprocation per minute Revolutions, strokes, surface speed,

0 Off position Zero speed, zero torque...

1, 2, 3, ... Selector settings Speed, torque or position settings.

I, II, III, Higher number means greater speed

No load speed Rotational speed, at no load

orbits etc. per minute

Infinitely variable selector with off Speed is increasing from 0 setting

Arrow Action in the direction of arrow

Alternating current Type or a characteristic of current

Direct current Type or a characteristic of current

Alternating or direct current Type or a characteristic of current

Class II construction Designates Double Insulated

Construction tools.

Earthing terminal Grounding terminal

Warning symbol Alerts user to warning messages

Ni-Cad RBRC seal Designates Ni-Cad battery recycling

program

This symbol designates that this tool is listed by Underwriters Laboratories.

This symbol designates that this tool is listed by the Canadian Standards Association.

This symbol designates that this tool is listed to Canadian Standards by Underwriters Laboratories.

This symbol designates that this tool is listed by Underwriters Laboratories, and listed to Canadian Standards by Underwriters Laboratories.

This symbol

designates that this tool complies to NOM Mexican Standards.

Functional Description and Specifications

WARNING

Disconnect the plug from the power source before making any assembly, adjustments or changing accessories

measures reduce the risk of starting the tool accidentally.

Jigsaws

FIG. 1

TOP OF FRONT

HOUSING

“LOCK-ON”

BUTTON

ORBIT CONTROL

LEVER

TOOL-LESS BLADE

CHANGE COVER

SCROLLING KNOB

(Models 4540 &4580 only)

. Such preventive safety

RUBBERIZED GRIP

DUST BLOWER

SWITCH

VARIABLE SPEED

CONTROL DIAL

(Model 4580 only)

RUBBERIZED GRIP

TRIGGER

SWITCH

VENTILATION

OPENINGS

DUST PORT /BLADE

STORAGE

COMPARTMENT

FOOT

FIG. 2

“LOCK-ON”

BUTTON

ORBIT/SCROLLING

CONTROL LEVER

SITE-LIGHT™

(Model 4580 only)

TOOL-LESS BLADE

CHANGE COVER

Model Blade

No. Thickness

4480 Minimum .7mm - Maximum 1.7mm 4540 Minimum .7mm - Maximum 1.7mm 4580 Minimum .7mm - Maximum 1.7mm

NOTE: For tool specifications refer to the nameplate on your tool.

Blade

Action

Orbital

Scroll

Orbital/Scroll

-6-

TRIGGER SWITCH

VENTILATION

OPENINGS

DUST PORT /BLADE

STORAGE

COMPARTMENT

FOOT

DUST BLOWER

SWITCH

MAXIMUM CAPACITIES

Stroke

Length Wood Aluminum Steel

13/16" 3-1/8" 1/2" 1/4" 13/16" 3-1/8" 1/2" 1/4" 13/16" 3-1/8" 1/2" 1/4"

Assembly

Attaching the Blade

WARNING

power source before assembling parts, making adjustments, or changing blades.

1. Insert the saw blade (teeth in cutting direction) until it latches in the plunger (Fig. 3).

FIG. 3

TOOL-LESS

BLADE CHANGE

COVER

To prevent personal injury, always disconnect plug from

ROLLER GUIDE

(Models 4480 & 4580 only)

Operating Instructions

TRIGGER "ON-OFF" SWITCH

TO TURN THE TOOL "ON" squeeze the trigger switch. TO TURN THE TOOL "OFF", release the trigger switch, which is spring loaded and will return to the "OFF" position automatically.

VARIABLE SPEED CONTROLLED

Your tool is equipped with a variable speed trigger switch. The tool can be turned "ON" or "OFF" by squeezing or releasing the trigger. The speed can be adjusted from the minimum to maximum nameplate SPM by the pressure you apply to the trigger. Apply more pressure to increase the speed and release pressure to decrease speed (Fig. 1).

The "Lock-ON" button, located in the handle of your tool allows for continuous operation at maximum SPM without holding the trigger (Fig. 1).

TO LOCK TRIGGER "ON": squeeze trigger, depress button and release trigger.

TO UNLOCK THE TRIGGER: squeeze trigger and release it without depressing the "LockON" button.

(Model 4580 only)

TRIGGER SWITCH

(Model 4480 & 4540 only)

"LOCK-ON" BUTTON

When inserting the saw blade, the back of the blade must rest in the groove of the guide roller (Fig. 4).

2. To remove blade, lift tool-less blade change

cover up with index finger and thumb and remove blade.

For use with both T or U shank jigsaw blades.

FIG. 4

BLADE

WARNING

the trigger can not be released.

Your tool is equipped with a variable speed dial. The blade stroke rate may be adjusted during cutting operation by presetting the dial on or between any one of the six numbers.

Setting SPM rating (strokes per minute)

1-2 Low stroke 3-4 Medium stroke

5 High stroke

Max. Override

ELECTRONIC FEEDBACK CIRCUITRY (EFC)

The internal electronic feedback system helps to keep the no load speed virtually constant between no-load and load conditions.

The stroke rate may be adjusted as described earlier under “Variable Speed Dial”. The best results for a particular application is determined by experience, though as a general rule, slower speeds are for denser materials and faster speeds are for soft materials.

If the “Lock-ON” button is continuously being depressed,

VARIABLE SPEED DIAL

(Model 4580 only)

PLUNGER SPEED

BLADE STORAGE COMPARTMENT

OFF

Your Jigsaw is equipped with a blade storage compartment in the dust port of your saw (Fig. 5) . To remove, pull compartment out of dust port in direction of arrow.

Always make sure the blade storage compartment is securely in the dust port to prevent blades from falling out.

FIG. 5

DUST PORT

BLADE

STORAGE

COMPARTMENT

Your jigsaw is equipped with a dust port for

DUST EXTRACTION

dust and chip extraction. To use this feature, remove blade storage

compartment and move dust blower switch to the “OFF” position “O” (Fig. 6).

Attach vacuum hose (optional accessory) to the dust port, and connect opposite end of the hose to a shop vacuum cleaner.

SITE-LIGHT™ (Model 4580 only)

Your tool is also equipped with a light that turns on automatically when the switch is activated, for better visibility when cutting (Fig. 7).

ORBITAL ACTION MODELS

Orbital Action models, have a lever (Fig. 8) that will regulate the orbital action from "Smooth" position for normal up and down motion to maximum orbital action for faster cutting in softer materials.

FIG. 8

ORBIT

CONTROL

LEVER

To increase orbital action, turn the lever to a higher setting. To decrease orbital action turn ever to a lower setting. When minimal splintering is desired we recommend using "Smooth" position.

SMOOTH LOW / MED FAST

MILD STEEL / SOFT METALS METAL PLASTIC SOFT WOODS

ALL MATERIALS HARD WOODS PLYWOOD

FIG. 6

DUST PORT

DUST

BLOWER

SWITCH

FIG. 7

foot must be all the way in the forward position. To adjust foot, lift foot adjustment lever and flip lever completely over, then push foot forward as far as possible and lower foot adjustment lever to maintain adjustment (Fig. 9).

Orbital cut control is not observable when jigsaw is free running. Jigsaw must be cutting for orbital action to occur. The speed of cut is much more apparent in thicker materials such as 2 by lumber.

FIG. 9

FOOT

BLADE

ROLLER

GUIDE

ATTENTION: In order to achieve orbital action, the blade must be facing STRAIGHT FORWARD and the back of the blade must rest in the groove of the guide roller, and the

FOOT

ADJUSTMENT

LEVER

SCROLL MODELS (4540 & 4580 ONLY)

Scrolling saws permit 360˚ rotation of the saw blade without turning the saw, so intricate designs may be cut with minimum effort. To permit rotation of plunger turn lever, (Fig. 10)

FIG. 10

SCROLLING

KNOB

LEVER

HANDLE

to scrolling. The plunger of your scrolling saw can also be locked in (4) positions, 90˚ apart. ATTENTION: When scroll cutting the blade must be moved away from the guide rollers. (Always move foot completely back). To adjust foot, lift foot adjustment lever and flip lever completely over, then push foot backwards as far as possible to engage

Cutting Tips

Face the good side of the material down and secure it in a bench vise or clamp it down. Draw cutting lines or designs on the side of the material facing up towards you. Then place the front edge of the saw foot on the work and line up the blade with the line to be cut. Hold the jigsaw firmly, turn it on, and press down (to keep the saw foot flat against the work) as you slowly push the saw in the direction of the cut.

Build up cutting rate gradually, cutting close to the line (unless you want to leave stock for finish sanding). As you cut you may have to adjust or relocate the vise or clamps to keep the work stable. Do not force the saw or the blade teeth may rub and wear without cutting and the blade may break. Let the saw do most of the work. When following curves, cut slowly so the blade can cut through cross grain. This will give you an accurate cut and will prevent the blade from wandering.

CUTTING WITH A STRAIGHTEDGE

Always use a rough cut blade when possible. Clamp a straightedge on the work parallel to the line of cut and flush with the side of the saw foot. (Either first mark the line of cut and

locking tab, then lower the foot adjustment lever to maintain adjustment (Fig. 11).

Note: It may be necessary to turn scrolling knob slightly back and forth to be sure the plunger is locked in the desired position.

When manually scroll cutting, operate saw by holding the handle with one hand and rotating the scrolling knob manually with your free hand.

CAUTION

Excessive side pressure to

the blade could result in broken blades and/or damage to the material being cut.

Note: When scroll cutting intricate designs, we recommend using a scroll cutting blade. However, a standard blade can be used.

BLADE

ROLLER

GUIDE

then position the straightedge parallel and at the same distance as between the blade and the side edge of the foot or first mark the side edge of the foot and then clamp the straightedge on the mark and parallel to the cut line Fig. 12).

On models with the scroll feature, it is advised to lock scroller knob.

As you cut, keep the saw foot edge flush against the straightedge and flat on the workpiece (Fig. 12).

FIG. 12

LINE

CUT

CLAMPS

FOOT

AGAINST

STRAIGHT-

EDGE

FIG. 11

FOOT

Plunge cutting is useful and time-saving in

PLUNGE CUTTING

making rough openings in softer materials. It is not necessary to drill a hole for an inside or pocket cut. Draw lines for the opening, hold the saw firmly, tilt it forward so that the toe of the saw foot rests on the work, but with the blade well clear of the work. Start the motor, and then very gradually lower the blade. When it touches, continue pressing down on the toe of the saw foot slowly pivoting the saw like a hinge until the blade cuts through and the foot rests flat on the work. Then saw ahead on the line of cut line. We do not recommend plunge cutting with a scroll blade (Fig. 13).

To make sharp corners, cut up to the corner, then back up slightly before rounding the

corner. After the opening is complete, go back to each corner and cut it from the opposite direction to square it off. Do not try to plunge cut into hard materials such as steel.

FIG. 13

TOE OF FOOT

BEVEL OR ANGLE CUTTING

WARNING

To prevent damage to the

tool when bevel or angle cutting, the scroll mechanism must be locked in place with the cutting edge of the blade facing the front of the tool.

Disconnect the cord from the power source. The foot can be adjusted to cut any angle from 0˚ to 45,˚ and is equipped with quick reference detent stops at 0˚, 15˚, 30˚, and 45˚.

TO ADJUST: Lift foot adjustment lever in the bottom of foot as shown, move foot slightly backward to disengage the locking tab (Fig. 14).

Position foot to desired angle, then push forward to engage locking tab and lower adjustment lever to maintain adjustment. After adjusting foot make a sample cut to check the angle, (Fig. 14).

METAL CUTTING

When cutting metal clamp material down. Be extra certain that you move the saw along slowly. Use lower speeds. Do not twist, bend, or force the blade. If the saw jumps or bounces, use a blade with finer teeth. If the blade seems clogged when cutting soft metal, use a blade with coarser teeth.

For easier cutting, lubricate the blade with a stick of cutting wax, if available, or cutting oil when cutting steel. Thin metal should be

Note: If the foot becomes loose you can use a screwdriver to tighten screw located on the foot adjustment lever, then re-adjust the foot adjustment lever.

FIG. 14

FOOT

LOCKING

TAB

SCREW

FOOT

ADJUSTMENT

LEVER

sandwiched between two pieces of wood or tightly clamped on a single piece of wood (wood on top of the metal). Draw the cut lines or design on the top piece of wood.

When cutting aluminum extrusion or angle iron, clamp the work in a bench vise and saw close to the vise jaws.

When sawing tubing and the diameter is larger than the blade is deep, cut through the wall of the tubing and then insert the blade into the cut rotating the tube as you saw.

-10-

RIP FENCE AND CIRCLE CUTTING GUIDE

This accessory is available at an extra cost. It is used for fast and accurate straight and circle cutting (Fig. 15).

ATTACHING RIP FENCE

1. Insert bar of rip fence through the slots provided in foot, from either side of foot with the edge guide facing down (Fig. 15).

2. Thread the clamp screw from under the foot through the threaded hole in the clamp on left side of foot, and securely tighten clamp screw with a screwdriver, to clamp the rip fence bar in place.

STRAIGHT CUTTING

Once the rip fence is attached, measure from the edge of work to the line of cut, and set edge guide of rip fence to the same distance and then securely tighten clamp screw (Fig. 16).

FIG. 15

CLAMP

SCREW

EDGE GUIDE DOWN

FIG. 16

CLAMP

SCREW

LINE

OF CUT

SLOT

BAR

1. Before attaching the rip fence, draw a circle

CIRCLE CUTTING

and drive a finishing nail in the center of circle.

2. Drill or plunge cut near the circles edge, turn saw off and disconnect the plug from power source (Fig. 17).

3. Attach rip fence to saw with the edge guide facing UP. In order for the rip fence to cut a circle, the nail must be in alignment with the blade, as shown in (Fig. 18).

4. Measure the distance from the selected hole to the blade to be equal to the circle radius.

5. Insert plug into power source, hold the saw firmly, squeeze trigger and slowly push the

11-

FIG. 17

WEDGE

EDGE

GUIDE UP

DESIRED

WIDTH

FINISHING

NAIL

saw forward. To make a hole, cut from inside the circle; To make wheels or discs, cut from the outside.

Cutting Tip: Cut slowly so the blade will stay straight in the cut. Place small wedges in the cut as shown in Fig. 17, to keep the inner circle from spreading when near the end of the cut.

FIG. 18

NAIL

BLADE MUST BE IN

ALIGNMENT WITH NAIL

-12-

+ 28 hidden pages