18V Cordless Reciprocating Saw
68240 18V Reciprocating Saw
Read this material before using this product.
Failure to do so can result in serious injury.
Save this manual.
When unpacking, make sure that the product is intact and undamaged.
If any parts are missing or broken, please call 1-800-444-3353 as soon as possible.
©
®
Copyright 2010 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.
Manual Revised 11a
or a key left attached to a moving part of the
5. Battery tool use and care
power tool may result in personal injury.
a. Recharge only with the charger specified by
the manufacturer. A charger that is suitable
for one type of battery pack may create a risk
of fire when used with another battery pack.
e. Do not overreach. Keep proper footing and
balance at all times. This enables better control
of the power tool in unexpected situations.
f. 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.
b. Use power tools only with specifically
designated battery packs. Use of any other
battery packs may create a risk of injury and fire.
c. When battery pack is not in use, keep it away
from other metal objects, like paper clips,
coins, keys, nails, screws or other small metal
objects, that can make a connection from
one terminal to another. Shorting the battery
terminals together may cause burns or a fire.
g. If devices are provided for the connection of
dust extraction and collection facilities, ensure
these are connected and properly used. Use of
these devices can reduce dust-related hazards.
h. 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.
d. Under abusive conditions, liquid may be
ejected from the battery; avoid contact.
If contact accidentally occurs, flush with
water. If liquid contacts eyes, additionally
seek medical help. Liquid ejected from the
battery may cause irritation or burns.
4. Power tool use and care
6. Service
a. 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.
a. 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.
b. Do not use the power tool if the switch
does not turn it on and off. Any power
tool that cannot be controlled with the switch
is dangerous and must be repaired.
Reciprocating Saw
Safety Warnings
1. Hold power tools by insulated gripping surfaces
when performing an operation where the 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.
c. Disconnect the plug from the power source
and/or the battery pack from the power tool
before making any adjustments, changing
accessories, or storing power tools. Such
preventive safety measures reduce the risk
of starting the power tool accidentally.
d. 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.
2. Do not cut material that is thicker than the Saw
Blade is long. Always allow for blade stroke.
3. Use clamps or another practical way to secure
and support the work piece to a stable platform.
Do not hold the workpiece by hand or against your
body. Doing so can lead to loss of control.
e. 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.
4. Maintain labels and nameplates on the tool.
These carry important safety information.
If unreadable or missing, contact Harbor
Freight Tools for a replacement.
f. Keep cutting tools sharp and clean. Properly
maintained cutting tools with sharp cutting edges
are less likely to bind and are easier to control.
5. Avoid unintentional starting. Prepare to
begin work before turning on the tool.
g. 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.
6. 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.
7. When using a handheld power tool, maintain a firm grip
on the tool with both hands to resist starting torque.
SKU 68240
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Page 3
8. 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.
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.
9.
The battery charger gets hot during use.
The charger’s heat can build up to unsafe
Vibration Safety
levels and create a fire hazard if it does not
receive adequate ventilation, due to an
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:
electrical fault, or if it is used in a hot environment.
Do not place the charger on a flammable surface. Do
not obstruct any vents on the charger. Especially
avoid placing the charger on carpets and rugs; they
are not only flammable, but they also obstruct
vents under the charger.
Place the charger on a stable, solid, nonflammable
surface (such as a stable metal workbench or concrete
floor) at least 1 foot away from all flammable objects,
such as drapes or walls. Keep a fire extinguisher and a
smoke detector in the area. Frequently monitor the
charger and battery while charging.
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.
10. This product is not a toy. Keep it
out of reach of children.
11. 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:
2. Do not smoke during use. Nicotine reduces
the blood supply to the hands and fingers,
increasing the risk of vibration-related injury.
• Avoid operating alone.
• Do not use with power switch locked on.
• Properly maintain and inspect
3. Wear suitable gloves to reduce the
vibration effects on the user.
4. Use tools with the lowest vibration
when there is a choice.
to avoid electrical shock.
12. 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, birth defects or
other reproductive harm. Some examples of these
chemicals are:
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.
• 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.
SAVE THESE
INSTRUCTIONS.
Grounding
(California Health & Safety Code § 25249.5, et seq.)
13. WARNING: Handling the cord on this product’s charger
will expose you to lead, a chemical known to the State
of California to cause cancer, and birth defects or other
reproductive harm. Wash hands after handling.
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
(California Health & Safety Code § 25249.5, et seq.)
14. The warnings, precautions, and instructions discussed
in this instruction manual cannot cover all possible
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SKU 68240
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.
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.
Double Insulated Tools:
Tools with Two Prong Plugs
Do not cover ventilation ducts.
Keep flammable objects away.
WARNING marking concerning Risk of
Electric Shock.
Properly connect power cord
to appropriate outlet.
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 Outlets for 2-Prong Plug.)
Extension Cords
Note: Extension cords must not be used with this
item’s charger.
Symbology
Double Insulated
Canadian Standards Association
Underwriters Laboratories, Inc.
Volts Alternating Current
V~
Amperes
A
SKU 68240
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Page 5
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:
Unlock and release the Trigger and disconnect Battery Pack before
assembling or making any adjustments to the tool.
Note: For additional information regarding the parts listed in the following
pages, refer to Parts List and Assembly Diagram on page 1011.
Lock Button
Trigger
Blade Plate
Blade
Battery Button
Battery Pack
Page 6
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SKU 68240
9. Store the Charger and Battery Pack indoors, out
of reach of children. WARNING! Do NOT use a
different Charger or Battery to power this Saw.
Operating Instructions
Read the ENTIRE IMPORTANT SAFETY
General Operating Instructions
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:
Always make sure the Trigger Switch of the Cordless
Reciprocating Saw is in its “OFF” position, the Battery
Pack is disconnected prior to making any adjustments
to the tool.
Tool Set Up
TO PREVENT SERIOUS INJURY FROM
ACCIDENTAL OPERATION:
Unlock and release the Trigger and disconnect Battery
Pack before adjusting tool or installing accessories.
• DO NOT install the Battery Pack until
AFTER you complete the following
steps to set up the Saw for use.
• Refer to page 6 for the location of the parts
of the Saw for the following steps.
Charging
1. Place the Battery Pack on a dry fireproof surface in
a room where the temperature is from 50–104° F.
Installing the Saw Blade
Note: If recharging a newly spent Battery Pack, allow it to
cool completely before charging.
Make sure the Battery Pack is undamaged; do
not charge a cracked or leaking battery pack.
Note: Use only proper blades, otherwise the
blade will not lock into the blade holder.
1. Choose the correct Saw Blade (Wood or
Metal) for the material being cut.
2. Disconnect the Cord from the Battery Charger. Attach
the Adapter plug to a grounded, 120 V~, 60 Hz outlet.
2. Use the included Hex Wrench to loosen the Blade
Clamp Screw located on the side of the Blade Holder.
3. Plug the Charger into the power supply and
the green charging light will activate, showing
that power is supplied to the Charger.
3. Slide the Blade’s mounting edge into the Blade Plate
and into the Blade Holder until it slides all the way in.
4. Slide the Battery Pack onto the Charger’s base.
The red charging indicator light will activate
to show that charging is taking place.
4. Use the Hex Screw to tighten the Blade Clamp Screw
until blade is fastened securely into place.
Blade Clamp
Note: The Battery Pack’s capacity will increase
somewhat during the first few charging cycles. A fully
discharged battery will take about 3 to 5 hours to fully
charge. CAUTION! Recharging the Battery Pack for
more than 5 hours can damage the battery cells.
Screw
Blade Plate
5. While charging, the Battery Pack and Charger,
and Adapter may become warm to the touch. This
is normal, and does not indicate a problem.
6. Unplug the Charger and disconnect it from
the Battery Pack when finished.
7. Allow the Battery Pack to cool
completely before using it.
8. Press the Battery Button to release Battery Pack from
the Charger (or when removing it from the Saw).
SKU 68240
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Page 7
CAUTION! Check the Blade Clamp Screw regularly;
Blade may become loose after use. Before
tightening, make sure Balde Clamp Screw is free
of sawdust. Then retighten until secure.
Metal Cutting
1. For ferrous metals, use a finer-tooth blade. Use
a coarse-tooth blade for non-ferrous metals.
2. Make sure to clamp thin sheet metals to prevent
vibration during cut. Keeping the sheet metal
clamped will also keep the sheet metal from tearing.
Operating the Reciprocating Saw
1. Firmly hold the Reciprocating Saw, positioning
the Blade near the work piece. Place the
Base Plate on the surface to be cut. Align the
Saw Blade with the direction of the cut.
3. Add a couple drops of lubricant to sheet metal being
cutting. This will help reduce heat during cut.
WARNING! Do not force the cutting blade when
thin sheet metal or sheet steel. These materials
will take longer to cut. Excessive blade force can
damage the blade and lead to personal injury.
2. To activate the Reciprocating Saw, press the
Lock Button. The Trigger will not activate
unless the Lock Button is pressed.
CAUTION! Make sure the Blade Plate is set
firmly against the material to be cut before
use. This will prevent vibration, which can lead
to blade jumping and/or blade damage.
Pocket Cutting
WARNING! Do not cut into areas where
you cannot identify any possible hazards
behind or inside the surface being cut.
3. Press the Trigger. Allow the Saw to come up to full
speed before contacting the work piece with the blade.
1. Mark the pocket or internal hole to be cut out.
IMPORTANT: Do not start the Saw if the Saw Blade is in
contact with anything before operation. If necessary, lift
the tool from the work piece before squeezing the Trigger.
2. Insert cutting blade with teeth facing
down in Saw and secure into place.
4. Slowly slide the saw blade onto the
cut line to begin the cut.
3. Angle the Saw so that the back edge of Blade
Plate is resting on the work surface.
Note: If the blade becomes jammed in the workpiece,
turn off the tool and lift the blade away from the cut.
4. Activate the Saw, using a slow speed at first.
Increase speed once cut has started.
5. To increase the Reciprocating Saw’s speed,
apply more pressure to the Trigger. To decrease
speed, lessen pressure on the Trigger.
5. With Blade Plate set firmly against work surface, swing
the Saw upward in a slow but controlled motion. The
blade should cut into and then through the material.
6. When finished cutting, release the Trigger to stop the
tool. The Lock Button will automatically release.
6. Verify blade is completely through the material
before cutting the remainder of the pocket.
7. Press Battery Button and remove the Battery Pack.
8. Clean, then store the Saw indoors
and out of children’s reach.
Maintenance and Servicing
Procedures not specifically explained
in this manual must be performed
only by a qualified technician.
Flush Cutting
1. To make close cuts to floors and walls, insert
the blade into the Blade Holder with the teeth
facing UP (opposite normal working position.)
TO PREVENT SERIOUS INJURY FROM
ACCIDENTAL OPERATION:
2. For flush pipe cutting, insert more flexible blades with
the blade teeth facing DOWN (normal working position).
Unlock and release the Trigger and disconnect
Battery Pack before performing any inspection,
maintenance, or cleaning procedures.
Wood Cutting
Verify workpiece is firmly clamped to prevent movement.
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.
For easier control, start cut with a low speed
and increase the speed as you cut.
Page 8
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SKU 68240
NOTE: Ni-Cd BATTERY MUST BE RECYCLED
OR DISPOSED OF PROPERLY. Do not
short, incinerate or open Battery Pack.
Cleaning, Maintenance,
and Lubrication
3. When storing, always store in clean, dry and
safe location out of reach of children.
1. BEFORE EACH USE, inspect the general condition
of the tool. Check for loose hardware, misalignment
or binding of moving parts, cracked or broken
parts, damaged electrical wiring, and any other
condition that may affect its safe operation.
4.
WARNING! If the supply cord of the
charger is damaged, it must be replaced
only by a qualified service technician.
2. AFTER USE, wipe external surfaces of the tool with
clean cloth.
Troubleshooting
Problem
Tool will not start.
Possible Causes
Likely Solutions
1. Make sure that the battery pack (sold separately)
is securely inserted into the tool.
1. Battery pack not
properly connected.
2. Discharged Battery Pack.
2. Charge the Battery Pack.
3. No power at outlet during
charging.
3. Check power at outlet. If outlet has no power,
disconnect charger and check circuit breaker. If
breaker is tripped, make sure circuit is right capacity
for charger and circuit has no other loads.
4. Internal damage or
wear. (Carbon brushes or
switch, for example.)
4. Have technician service tool.
Trigger will not
turn off.
Tool needs service check.
Immediately remove battery pack from tool. Do
not use tool until a qualified service technician
checks out tool for damage or defects.
Performance
1. Accessory dull or damaged.
1. Keep cutting accessories sharp. Replace as needed.
decreases over time.
2. Carbon brushes worn
or damaged.
2. Have qualified technician replace brushes.
Cut line is irregular. 1. Bent, cracked, or
broken saw blade.
1. Replace saw blade.
2. Loose saw blade.
1. Dull Saw Blade.
2. Make sure blade is securely installed in tool.
1. Replace saw blade.
Saw doesn’t cut or
doesn’t cut properly.
2. Improper Saw Blade used.
2. Use metal saw blades for cutting metal and
wood saw blades for cutting wood.
3. Tool speed too slow.
3. Increase tool speed by squeezing Trigger harder.
Have technician service tool.
Excessive noise
or rattling.
Overheating.
Internal damage or wear. (Carbon
brushes or bearings, for example.)
1. Forcing tool to work too fast.
1. Allow tool to work at its own rate.
2. Accessory misaligned.
2. Check and correct accessory to fence
and/or table alignment.
3. Accessory dull or damaged.
4. Blocked motor housing vents.
3. Keep cutting accessories sharp. Replace as needed.
4. Wear ANSI-approved safety goggles and NIOSH-
approved dust mask/respirator while blowing
dust out of motor using compressed air.
Follow all safety precautions whenever diagnosing or servicing the tool. Disconnect power supply
before service.
SKU 68240
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Page 9
Parts List and Assembly Diagram
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM
IN THIS MANUAL 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.
Parts List
Part
Description
Qty.
1
1
1
1
1
1
1
1
2
14
1
9
1
Part
Description
Qty.
1
1
1
1
1
1
2
1
1
1
5
1
1
1
1
1
2
3
4
5
6
7
8
9
Right Housing
18 Connecting Bar
Lock Button
Spring
19 Cotter Pin
20 Shaft
21 Roll Pin
22 Gear
23 Washer
Gear
Trigger
Battery Terminal
Battery Pack
Left Housing
Rubber Damper
24 Rivet
25 Guard Plate
26 Blade Holding Plate
27 Blade Clamp Screw
28 Circlip
29 Gear Housing
30 Ball Bearing
31 Ball Bearing
32 Motor
10 Screw
11 Blade Plate
12 Screw
13 Reciprocating Lever
14 Cover Plate
15 Roll Pin
1
2
16 Shaft Housing
17 Attachment Bracket
2
1
33 Motor Gear
34 Shaft
1
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.
Page 10
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SKU 68240
SKU 68240
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Page 11
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 • (800) 444-3353
Page 12
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SKU 68240
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