Harbor Freight Tools Saw 68240 User Manual

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  
Page 4  
For technical questions, please call 1-800-444-3353.  
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  
For technical questions, please call 1-800-444-3353.  
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  
For technical questions, please call 1-800-444-3353.  
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  
For technical questions, please call 1-800-444-3353.  
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  
For technical questions, please call 1-800-444-3353.  
SKU 68240  
 
SKU 68240  
For technical questions, please call 1-800-444-3353.  
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  
For technical questions, please call 1-800-444-3353.  
SKU 68240  
 

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