Harbor Freight Tools 66755 User Manual
POWER TOOL SET
Model
66755
SET UP AND OPERATING INSTRUCTIONS
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Copyright© 2009 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.
For technical questions or replacement parts, please call 1-800-444-3353.
Manual Revised 09l
CONTENTS
IMPORTANT SAFETY
INFORMATION .................................3
GENERAL POWER TOOL SAFETY
WARNINGS ........................................... 3
RECIPROCATING SAW SET UP AND
OPERATING INSTRUCTIONS ........... 16
INSTALLING THE SAW BLADE ...... 16
OPERATING THE
RECIPROCATING SAW ................ 16
PLUNGE CUTTING ............................... 17
CIRCULAR SAW SAFETY WARNINGS . 5
DRILL SAFETY WARNINGS ................... 7
RECIPROCATING SAW SAFETY
WARNINGS ........................................... 7
ADDITIONAL SAFETY WARNINGS ....... 8
VIBRATION SAFETY .............................. 9
GROUNDING ......................................9
DOUBLE INSULATED TOOLS:
TOOLS WITH TWO PRONG PLUGS ... 9
SYMBOLOGY ........................................ 10
SPECIFICATIONS .............................11
UNPACKING .....................................11
INSTRUCTIONS FOR PUTTING
INTO USE .......................................11
THE BATTERY PACKS ......................... 12
TO CHARGE THE BATTERY
PACK: ............................................ 12
SET UP AND OPERATING
INSTRUCTIONS .............................13
TOOL SET UP ....................................... 13
WORK PIECE AND WORK AREA
SET UP ............................................... 13
CIRCULAR SAW SET UP AND
OPERATING INSTRUCTIONS ........... 14
CHANGING THE CIRCULAR SAW
BLADE ........................................... 14
SET THE CUTTING ANGLE ............ 14
SET THE CUTTING DEPTH ............15
USING THE RIP FENCE .................. 15
OPERATING THE CIRCULAR SAW 15
METAL CUTTING .................................. 17
DRILL/DRIVER SET UP AND
OPERATING INSTRUCTIONS ........... 17
OPERATING THE DRILL/DRIVER .. 18
WORK LIGHT SET UP AND
OPERATING INSTRUCTIONS ........... 19
MAINTENANCE AND SERVICING ...20
CLEANING, MAINTENANCE, AND
LUBRICATION .................................... 20
TROUBLESHOOTING ........................... 21
PARTS LISTS AND ASSEMBLY
DIAGRAMS .....................................23
ACCESSORY PARTS LIST AND
DIAGRAM ........................................... 23
PARTS LIST A -
CIRCULAR SAW ................................ 24
ASSEMBLY DIAGRAM A -
CIRCULAR SAW ................................ 25
PARTS LIST AND DIAGRAM B -
RECIPROCATING SAW ..................... 26
PARTS LIST AND DIAGRAM C -
DRILL .................................................. 27
PARTS LIST D -
FLASHLIGHT ...................................... 28
ASSEMBLY DIAGRAM D -
FLASHLIGHT ...................................... 29
LIMITED 90 DAY WARRANTY .........30
Page 2 For technical questions, please call 1-800-444-3353. SKU 66755
SAVE THIS MANUAL
Keep this manual for the safety warnings
and precautions, assembly, operating, inspection, maintenance and cleaning procedures.
Write the serial number of the products in the
back of the manual near the assembly diagram (or month and year of purchase if product has no number). Keep this manual and
the receipt in a safe and dry place for future
reference.
IMPORTANT SAFETY
INFORMATION
In this manual, on the labeling, and
all other information provided with
this product:
This is the safety alert
symbol. It is used to alert
you to potential personal
injury hazards. Obey all
safety messages that follow
this symbol to avoid possible
injury or death.
DANGER indicates a
hazardous situation
which, if not avoided, will result
in death or serious injury.
WARNING indicates a
hazardous situation
which, if not avoided, could
result in death or serious injury.
CAUTION, used with
the safety alert
symbol, indicates a hazardous
situation which, if not avoided,
could result in minor or moderate
injury.
NOTICE is used to
address practices not
related to personal injury.
CAUTION, without the
safety alert symbol, is
used to address practices not
related to personal injury.
General Power Tool Safety Warnings
WARNING Read all safety warnings
and instructions. Failure to follow the
warnings and instructions may result
in electric shock, re and/or serious
injury.
Save all warnings and instructions
for future reference.
The term ″power tool″ in the warnings
refers to your mains-operated (corded)
power tool or battery-operated
(cordless) power tool.
Work area safety1.
Keep work area clean and well lit. a.
Cluttered or dark areas invite accidents.
Do not operate power tools in ex-b.
plosive atmospheres, such as in the
presence of ammable liquids, gases
or dust. Power tools create sparks
which may ignite the dust or fumes.
Keep children and bystanders away c.
while operating a power tool. Distrac-
tions can cause you to lose control.
Electrical safety2.
Do not expose power tools to rain or a.
wet conditions. Water entering a power
tool will increase the risk of electric
shock.
Personal safety3.
Stay alert, watch what you are doing a.
and use common sense when operating a power tool. Do not use a power
tool while you are tired or under the
Page 3For technical questions, please call 1-800-444-3353.SKU 66755
inuence of drugs, alcohol or medication. A moment of inattention while op-
erating power tools may result in serious
personal injury.
Use safety equipment. Always wear b.
eye protection. Safety equipment such
as a )dust mask, non-skid safety shoes,
hard hat, or hearing protection used for
appropriate conditions will reduce per-
sonal injuries.
Prevent unintentional starting. Ensure c.
the switch is in the off-position before
connecting to power source and/or
battery pack, picking up or carrying
the tool. Carrying power tools with your
nger on the switch or energizing power
tools that have the switch on invites accidents.
Remove any adjusting key or wrench d.
before turning the power tool on. A
wrench or a key left attached to a rotat-
ing part of the power tool may result in
personal injury.
Do not overreach. Keep proper foot-e.
ing and balance at all times. This
enables better control of the power tool
in unexpected situations.
Dress properly. Do not wear loose f.
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.
If devices are provided for the con-g.
nection of dust extraction and collection facilities, ensure these are
connected and properly used. Use of
these devices can reduce dust-related
hazards.
Only use safety equipment that has h.
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 specic
hazards in the work area.
Power tool use and care4.
Do not force the power tool. Use the a.
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.
Do not use the power tool if the b.
switch does not turn it on and off.
Any power tool that cannot be controlled
with the switch is dangerous and must
be repaired.
Disconnect the plug from the power c.
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 start-
ing the power tool accidentally.
Store idle power tools out of the reach d.
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.
Maintain power tools. Check for e.
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.
Keep cutting tools sharp and clean. f.
Properly maintained cutting tools with
sharp cutting edges are less likely to
bind and are easier to control.
Use the power tool, accessories and g.
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
Page 4 For technical questions, please call 1-800-444-3353. SKU 66755
operations different from those intended
could result in a hazardous situation.
Battery tool use and care5.
Recharge only with the charger speci-a.
ed by the manufacturer. A charger
that is suitable for one type of battery
pack may create a risk of re when used
with another battery pack.
Use power tools only with specically b.
designated battery packs. Use of any
other battery packs may create a risk of
injury and re.
When battery pack is not in use, keep c.
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 termi-
nals together may cause burns or a re.
Under abusive conditions, liquid may d.
be ejected from the battery; avoid
contact. If contact accidentally occurs, ush with water. If liquid contacts eyes, additionally seek medical
help. Liquid ejected from the battery may
cause irritation or burns.
Service6.
Have your power tool serviced by a a.
qualied repair person using only
identical replacement parts. This will
ensure that the safety of the power tool
is maintained.
Circular Saw Safety Warnings
1. DANGER: Keep hands away from
cutting area and the blade. Keep your
second hand on auxiliary handle, or
motor housing. If both hands are hold-
ing the saw, they cannot be cut by the
blade.
Do not reach underneath the work-2.
piece. The guard cannot protect you
from the blade below the workpiece.
Adjust the cutting depth to the thick-3.
ness of the workpiece. Less than a full
tooth of the blade teeth should be visible
below the workpiece.
Never hold piece being cut in your 4.
hands or across your leg. Secure the
workpiece to a stable platform. It is
important to support the work properly to
minimize body exposure, blade binding,
or loss of control.
Hold power tool by insulated gripping 5.
surfaces when performing an operation where the cutting tool may contact hidden wiring. Contact with a″ live″
wire will also make exposed metal parts
of the power tool ″ live″ and shock the
operator.
When ripping always use a rip fence 6.
or straight edge guide. This improves
the accuracy of cut and reduces the
chance of blade binding.
Always use blades with correct ar-7.
bor hole for the tool. Blades that do
not match the mounting hardware of the
saw will run eccentrically, causing loss of
control.
Never use damaged or incorrect blade 8.
washers or bolt. The blade washers
and bolt were specially designed for your
saw, for optimum performance and safe-
Page 5For technical questions, please call 1-800-444-3353.SKU 66755
ty of operation. Observe thread direction
of the bolt.
rective actions to eliminate the cause of
blade binding.
Causes and Operator Prevention of 9.
Kickback:
Kickback is a sudden reaction to a •
pinched, bound or misaligned saw
blade, causing an uncontrolled saw to
lift up and out of the workpiece toward
the operator;
When the blade is pinched or bound •
tightly by the kerf closing down, the
blade stalls and the motor reaction
drives the unit rapidly back toward the
operator;
If the blade becomes twisted or mis-•
aligned in the cut, the teeth at the back
edge of the blade can dig into the top
surface of the wood causing the blade
to climb out of the kerf and jump back
toward the operator.
Kickback is the result of saw misuse
and/or incorrect operating procedures or
conditions and can be avoided by taking
proper precautions as given below:
Maintain a rm grip with both hands a.
on the saw and position your arms to
resist kickback forces. Position your
body to either side of the blade, but
not in line with the blade. Kickback
could cause the saw to jump backwards,
but kickback forces can be controlled by
the operator, if proper precautions are
taken.
When blade is binding, or when inter-b.
rupting a cut for any reason, release
the trigger and hold the saw motionless in the material until the blade
comes to a complete stop. Never
attempt to remove the saw from the
work or pull the saw backward while
the blade is in motion or kickback
may occur. Investigate and take cor-
When restarting a saw in the work-c.
piece, center the saw blade in the cut
and check that saw teeth are not engaged into the material. If saw blade is
binding, it may walk up or kickback from
the workpiece as the saw is restarted.
Support large panels to minimize the d.
risk of blade pinching and kickback.
Large panels tend to sag under their own
weight. Supports must be placed under
the panel on both sides, near the line of
cut and near the edge of the panel.
Do not use dull or damaged blades. e.
Unsharpened or improperly set blades
produce narrow kerf causing excessive
friction, blade binding and kickback.
Blade depth and bevel adjusting lock-f.
ing levers must be tight and secure
before making cut. If blade adjustment
shifts while cutting, it may cause binding
and kickback.
Use extra caution when making a g.
″plunge cut″ into existing walls or
other blind areas. The protruding blade
may cut objects that can cause kickback.
Check Lower Guard (A7) on Circular 10.
Saw for proper closing before each
use. Do not operate the saw if Lower
Guard does not move freely and close
instantly. Never clamp or tie the Lower
Guard into the open position. If saw
is accidentally dropped, Lower Guard
may be bent. Raise the Lower Guard
with the retracting handle and make sure
it moves freely and does not touch the
blade or any other part, in all angles and
depths of cut.
Check the operation of the Lower 11.
Guard (A7) spring on the Circular
Saw. If the Guard and the spring are
not operating properly, they must
Page 6 For technical questions, please call 1-800-444-3353. SKU 66755
be serviced before use. Lower Guard
may operate sluggishly due to damaged
parts, gummy deposits, or a build-up of
debris.
Lower Guard (A7) on the Circular Saw 12.
should be retracted manually only for
special cuts such as ″plunge cuts″
and ″compound cuts.″ Raise Lower
Guard by retracting handle and as
soon as blade enters the material, the
Lower Guard must be released. For all
other sawing, the Lower Guard should
operate automatically.
Always observe that the Lower Guard 13.
(A7) on the Circular Saw is covering
the blade before placing saw down on
bench or oor. An unprotected, coasting
blade will cause the saw to walk backwards, cutting whatever is in its path. Be
aware of the time it takes for the blade to
stop after switch is released.
Reciprocating Saw Safety Warnings
Hold power tool by insulated gripping 1.
surfaces when performing an operation where cutting tool may contact
hidden wiring or its own cord. Con-
tact with a ″live″ wire will make exposed
metal parts of the tool ″live″ and shock
the operator.
Use clamps or another practical way 2.
to secure and support the work piece
to a stable platform. Holding the work
by hand or against your body leaves it
unstable and may lead to loss of control.
When using the Reciprocating Saw, 3.
do not cut material that is thicker than
the Saw Blade is long. Allow for blade
stroke.
The Circular Saw is designed for use 14.
only with a 5-1/2” diameter Saw Blade
having a 10mm arbor and rated to
4,000 RPM or greater. Do not use any
other rated blade.
To prevent serious injury from ying 15.
shrapnel, do not use any abrasive
wheels on the circular saw. The saw
and its guards are not designed to accommodate abrasive wheels.
Drill Safety Warnings
Hold power tools by insulated grip-1.
ping 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.
Page 7For technical questions, please call 1-800-444-3353.SKU 66755
Additional Safety Warnings
Maintain labels and nameplates on the 1.
tool. These carry important safety information. If unreadable or missing, contact Harbor Freight Tools for a replacement.
People with pacemakers should consult 8.
their physician(s) before use. Electro-
magneticeldsincloseproximityto
heart pacemaker could cause pacemaker interference or pacemaker failure.
In addition, people with pacemakers
should:
Avoid unintentional starting. Prepare to 2.
begin work before turning on the tool.
Do not lay the tool down until it has come 3.
to a complete stop. Moving parts can
grab the surface and pull the tool out of
your control.
When using a handheld power tool, 4.
maintainarmgriponthetoolwithboth
hands to resist starting torque.
Do not leave the Charger unattended 5.
when it is plugged into an electrical
outlet. Unplug it from its electrical outlet
before leaving.
6. The battery charger gets hot
during use. The charger’s
heat can build up to unsafe
levelsandcreatearehaz-
ard if it does not receive adequate ventilation, due to an electrical fault, or if it is
used in a hot environment.
Donotplacethechargeronaammable
surface. Do not obstruct any vents on
the charger. Especially avoid placing
the charger on carpets and rugs; they
are not only ammable, but they also
obstruct vents under the charger.
Place the charger on a stable, solid,
nonammablesurface(suchasastable
metalworkbenchorconcreteoor)at
least1footawayfromallammable
objects, such as drapes or walls. Keep a
reextinguisherandasmokedetectorin
the area. Frequently monitor the charger
and battery during use.
This product is not a toy. Keep it out of 7.
reach of children.
Avoid operating alone.•
Do not use with power switch locked •
on.
Properly maintain and inspect to avoid •
electrical shock.
Any power cord must be properly •
grounded. Ground Fault Circuit Interrupter (GFCI) should also be implemented – it prevents sustained electrical shock.
Some dust created by power sand-9.
ing, 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:
Lead from lead-based paints•
Crystalline silica from bricks and ce-•
ment 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
thatarespeciallydesignedtolterout
microscopic particles. (California Health
& Safety Code § 25249.5, et seq.)
The warnings, precautions, and instruc-10.
tions discussed in this instruction manual
cannot cover all possible conditions and
situations that may occur. It must be
Page 8 For technical questions, please call 1-800-444-3353. SKU 66755
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.
To reduce vibration, maintain the tool as 7.
explained in this manual. If any abnormal vibration occurs, stop use immediately.
Vibration Safety
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:
Anyone using vibrating tools regularly 1.
orforanextendedperiodshouldrst
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 cir-
culation to the hand, past hand injuries,
nervous system disorders, diabetes, or
Raynaud’s Disease should not use this
tool. If you feel any medical or physical
symptoms related to vibration (such as
tingling, numbness, and white or blue
ngers),seekmedicaladviceassoonas
possible.
Do not smoke during use. Nicotine re-2.
duces the blood supply to the hands and
ngers,increasingtheriskofvibration-
related injury.
Wear suitable gloves to reduce the vibra-3.
tion effects on the user.
SAVE THESE
INSTRUCTIONS.
GROUNDING
TO PREVENT
ELECTRIC SHOCK
AND DEATH FROM INCORRECT
GROUNDING WIRE
CONNECTION:
Check with a qualied electrician
if you are in doubt as to whether
the outlet is properly grounded.
Do not modify the 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
t the outlet, have a proper
outlet installed by a qualied
electrician.
Double Insulated Tools: Tools with
Two Prong Plugs
Use tools with the lowest vibration when 4.
there is a choice between different processes.
Include vibration-free periods each day 5.
of work.
Grip tool as lightly as possible (while still 6.
keeping safe control of it). Let the tool
do the work.
1. Tools marked “Double Insulated” do not
require grounding. They have a special
Page 9For technical questions, please call 1-800-444-3353.SKU 66755
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