Harbor Freight Tools 66755 User Manual

Page 1
POWER TOOL SET
Model
66755
SET UP AND OPERATING INSTRUCTIONS
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
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
Page 2
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
Page 3
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
Page 4
inuence 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 specic 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
Page 5
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 specically 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.
qualied 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
Page 6
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
Page 7
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
Page 8
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-
magneticeldsincloseproximityto
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.
maintainarmgriponthetoolwithboth
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 levelsandcreatearehaz-
ard if it does not receive adequate venti­lation, due to an electrical fault, or if it is used in a hot environment.
Donotplacethechargeronaammable
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,
nonammablesurface(suchasastable metalworkbenchorconcreteoor)at least1footawayfromallammable
objects, such as drapes or walls. Keep a
reextinguisherandasmokedetectorin
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
thatarespeciallydesignedtolterout
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
Page 9
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.
orforanextendedperiodshouldrst
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),seekmedicaladviceassoonas
possible.
Do not smoke during use. Nicotine re-2.
duces the blood supply to the hands and
ngers,increasingtheriskofvibration-
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 qualied 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 qualied
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
Page 10
doubleinsulationsystemwhichsatises
OSHA requirements and complies with the applicable standards of Underwriters Laboratories, Inc., the Canadian Stan­dard Association, and the National Elec­trical Code. (See Outlets for 2-Prong
Plug.)
Double insulated tools may be used in 2. 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
V~
A
n0 xxxx/min.
Canadian Standards Association
Underwriters Laboratories, Inc.
Volts Alternating Current
Amperes
No Load Revolutions per Minute (RPM)
Page 10 For technical questions, please call 1-800-444-3353. SKU 66755
Page 11
SPECIFICATIONS
UNPACKING
Battery Specications
Type 18VDC, NiCd, 1.3Ah
Circular Saw Specications
Max. RPM 4000 RPM Blade 5-1/2” Dia. / 6,000 RPM Arbor 10MM
Max Cutting Depth
Cutting Angle 0 to 45°
1-1/2” at 90°, 1-1/16” at 45°
Reciprocating Saw Specications
Blades Two 4-3/4” / 3,300 SPM Stroke Length 7/8”
Drill Specications
Max. RPM 600 RPM Chuck 3/8” Keyless Type
Torque Settings
23 Torque Settings/ 1 Drill Setting
When unpacking, check to make sure
that the item is intact and undamaged. If any parts are missing or broken, please call Har­bor Freight Tools at the number shown on the cover of this manual as soon as possible.
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: Turn the Power Switch of the tool to its “OFF” position and unplug the tool from its Battery Pack (1) before assembling or making any adjustments to the tool.
Flashlight Specications
Switch Push Button On/Off Bulb Type 9 LEDs Head Positions 7
Charger Specications
Input Power 120V/60Hz Output Power 22VDC (max.) / 400mA
LED Indicator Light
Charge Time 3 - 5 hours
Red when charging; Green when fully charged,
TO PREVENT SERIOUS INJURY FROM FLYING SHRAPNEL: Do not use any abrasive wheels on the circular saw. The saw and its guards are not designed to accommodate abrasive wheels.
Note: For additional information regarding the
parts listed in the following pages, refer to the Assembly Diagram near the end of this manual.
Page 11For technical questions, please call 1-800-444-3353.SKU 66755
Page 12
The Battery Packs
Two Battery Packs (1) are included • with this tool kit. They can be used in combination with the Work Light and any of the other tools at the same time, or you can have an extra fully charged stand-by Battery Pack available for use when needed.
Charge both Battery Packs before us-• ing the tools.
Charge the Battery Pack (1) only with • the 18V Charger (3) provided.
Charge indoors only. • If the Battery Pack is hot from use in •
a tool, allow time for it to cool down before Charging.
If the Battery Pack is hot after charging, • allow time for it to cool down before us­ing in a tool.
To Charge the Battery Pack:
Battery Socket (3)
Charger (2)
Battery Pack (1)
moved from the Battery Socket/Charger assembly.
Note: When the Charger is plugged into a
power outlet and connected to the Bat­tery Socket without a Battery Pack at-
tached,theLEDwillashfromgreen
to red, and then off. When the Battery Pack is inserted into the Battery Socket the LED changes to a solid red. The light changes to green when the Battery Pack is fully charged. Do not charge for over 5 hours. Do not place the Charger on
carpetingornearammables.
After each subsequent use, 3 hours of 4. charging time is needed for the Battery Pack to be fully charged. However, the Battery Pack can be left to charge for 5 hours to ensure longer running time in the tools.
If the Battery Pack will not hold a full 5. charge, discharge batteries by keeping the tool in the “ON” position until tool slows or the light begins to dim. Do not completely discharge batteries. Remove Battery Pack from tool, allow it to cool, and charge for 3-5 hours, making sure not to exceed 5 hours of charging time.
connect here
LED Light
Figure 1
1. Insert the Battery Pack (1) into the Bat­tery Socket (3).
Release Button
outlet and store in secure location. The batteries contained in the Battery 7.
Pack are nickel-cadmium (Ni-Cd). Do not dispose of Ni-Cd batteries in house­hold waste.
Plug the Charger (2) cord into the Bat-2.
When not charging, unplug Charger from 6.
tery Socket (3), then plug the Charger
intoanappropriateAC120V,60Hz
power outlet. The red LED light on the Battery Socket will activate, indicating the Battery Pack is charging.
Follow all local regulations regarding the 8. proper disposal of Ni-Cd batteries.
9. WARNING! If the Charger cord is
damaged, it must be replaced only by
a qualied service technician.
The initial charge time is 3-5 hours, after 3. which the Battery Pack should be re-
Page 12 For technical questions, please call 1-800-444-3353. SKU 66755
Page 13
SET UP AND OPERATING
INSTRUCTIONS
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.
Tool Set Up
TO PREVENT
SERIOUS INJURY FROM ACCIDENTAL OPERATION: Turn the Power Switch of the tool to its “OFF” position and remove the Battery Pack (1)from the tool before performing any inspection, maintenance, or cleaning procedures.
ciprocating Saw or the Circular Saw. Ensure you will not be cutting through any electrical wires, pipes, or your work­bench.
Work Piece and Work Area Set Up
Designate a work area that is clean and 1. well-lit. The work area must not allow access by children or pets to prevent injury and distraction.
Route the charger cord for the Charger/2. Battery Socket assembly along a safe route to reach the charger location with­outcreatingatrippinghazardorexpos­ing the cord to possible damage.
Secure loose workpieces using a vise or 3. clamps (not included) to prevent move­ment while working.
Verify that there are no utility lines, for-4.
eignobjectsorotherhazardousobjects nearbythatwillpresentahazardwhile
working. Check to make sure there is enough 5.
space under and behind the workpiece for the Saw Blade when using the Re-
Page 13For technical questions, please call 1-800-444-3353.SKU 66755
Page 14
Circular Saw Set Up and Operating
Instructions
TO PREVENT
SERIOUS INJURY FROM FLYING SHRAPNEL: Do not use any abrasive wheels on the circular saw. The saw and its guards are not designed to accommodate abrasive wheels.
DO NOT• install the Battery Pack (1)
until AFTER you complete the follow­ing steps to set up the Circular Saw for use.
Refer to Figure A1 for the location of • the parts of the saw for the following steps.
Safety
Button (A15)
Trigger (A19-1)
Changing the Circular Saw Blade
The Blade comes installed on the Cir­cular Saw, but replacement Blades will need to be installed when the blade gets dull or is damaged. To replace the Blade:
Placetheunitonaat,hardhorizontal1. bench or table.
Secure the Blade in place by depressing 2. the Self-Locking Button (A28-1). Use the Hex Wrench (A45) (not shown in Figure A1) to remove the Bolt (A1), unthreading in a clockwise direction.
Move the Lower Guard (A7) out of the 3. way, remove the Washer (A2) and Saw Blade (A3) and replace with a new 5-1/2” blade rated to at least 4,000 RPM. Blade rotation must match up with the direction arrow on the Lower Guard (A7) of the Saw. The Blade’s teeth must be facing upwards.
Base Plate (A36)
Lower Guard (A7)
Battery Pack (1)
Depth Guide
Depth Adjustment Knob (A46)
Figure A1
Saw Blade (A3)
Bolt (A1) & Washer (A2)
Self Locking Button (A28-1)
Angle Plate
Rip Fence Knob (A42)
Angle Adjustment Knob (A38)
Replace the Washer (A2) and Bolt (A1) 4. and tighten securely, rethreading in a counterclockwise direction.
Set the Cutting Angle
The cutting angle of the saw can be adjusted from a standard vertical cut, up to a 50° angled left cut. To adjust the cut­ting angle of the Saw:
Loosen the Angle Adjustment Knob 1. (A38).
Pivot the Base Plate (A36) to the desired 2. cutting angle, using the measurements on the Angle Plate as a guide.
Tighten the Angle Adjustment Knob 3. (A38) to hold the Base Plate (A36) at the desired angle.
Page 14 For technical questions, please call 1-800-444-3353. SKU 66755
Page 15
Set the Cutting Depth
The cutting depth of the Saw Blade (A3) can be adjusted up to a 1-1/2” depth when the cutting angle is set to 90°, or up to 1-1/16” when the cutting angle is set to 45°.
The cut should be deep enough to cut all the way through the material but not deep enough to bite into a surface be­neath. Adding about 1/8” cut greater than the thickness of the material is advised. To adjust the cutting depth of the Saw:
Loosen the Depth Adjustment Knob 1. (A46).
To prevent accidents, turn off the tool 6. and disconnect its power supply after use. Clean, then store the tool indoors out of children’s reach.
Operating the Circular Saw
Mark the line to be cut on the workpiece.1. Adjust the depth and angle of the cut as 2.
needed. Slide a fully charged Battery Pack (1) 3.
into the end of the handle of the Circular Saw, making sure that it clicks into place securely. Be sure the Battery Pack (1) is securely seated into the Saw Handle so it will not fall off during use.
Pivot the Base Plate (A36) to the desired 2. cutting depth, using the measurements on the Depth Guide as a guide.
Tighten the Depth Adjustment Knob 3. (A46) to hold the Base Plate (A36) at the desired cutting depth.
Using the Rip Fence
The Rip Fence can be used to make a long uniform cut of a piece of material to the same width, or to make repeated cuts of the same width. To position the Rip Fence for use:
Loosen the Rip Fence Knob (A42).1. Position the Rip Fence (A35) (not shown 2.
in Figure A1) so that the top of the “T” shape is facing down.
Slide the arm of the Rip Fence through 3. the mounting slots (not shown) at the front of the Base Plate (A36).
Position the Blade near the workpiece, 4. depress the Safety Button (A15) and hold the Trigger (A19-1)down. Release the Safety Button once the tool has power. Allow the Saw to come up to full speed before addressing it to the workpiece.
Hold the Circular Saw with both hands 5. and allow it to cut through the workpiece at it’s own pace.
When the cut is complete, release the 6. Trigger. Allow the Saw to coast to a stop before setting it down.
Remove the Battery Pack (1). 7. Clean then store the Circular Saw in-8.
doors and out of children’s reach.
Adjust the Rip Fence to the desired cut-4. ting width.
Tighten the Rip Fence Knob (A42).5.
Page 15For technical questions, please call 1-800-444-3353.SKU 66755
Page 16
Reciprocating Saw Set Up and
Operating Instructions
DO NOT• install the Battery Pack (1)
until AFTER you complete the following steps to set up the Reciprocating Saw for use.
Refer to Figure B1 for the location of • the parts of the saw for the following steps.
Outer Ring & Clutch
Guard
Figure B1
Installing the Saw Blade
Safety Button (B18)
Trigger (B19-1)
Slide a fully charged Battery Pack (1) 5. into the bottom of the Handle of the Reciprocating Saw, making sure that it clicks into place securely. Be sure the Battery Pack (1) is securely seated into the Saw Handle so it will not fall off dur­ing use.
Firmly hold the Reciprocating Saw with 6. both hands. Position the Blade near the work piece, depress the Safety Button (B18) and hold the Trigger down. Release the Safety Button once the tool has power. Allow the Saw to come up to full speed before addressing it to the work piece.
IMPORTANT: Do not start the Saw if the
Saw Blade (B15/B16) is in contact with anything before operation. If necessary, lift the tool from the work piece before
squeezingtheTrigger.
Choose the correct Saw Blade (B15/1. B16) for the material being cut. Fine tooth Saw Blades (B16) are generally used for cutting metal. Saw Blades (B15) with larger teeth are generally used for cutting wood.
To avoid accidental injury, make sure 2. to wear heavy duty work gloves when installing the Saw Blade.
Open the Outer Ring of the Clutch by 3. turning it counterclockwise. Insert the shank of the Saw Blade (B15/B16) fully into the Chuck, making sure the teeth of the Saw Blade face downward, away from the tool. Then release the Outer Ring and make sure it locks the Saw Blade in place.
Operating the Reciprocating Saw
NEVER cut into areas where you cannot 7.
identifyanypossiblehazardsbehindor
inside the surface being cut. In preparation to making a cut, place the 8.
Guard on the surface to be cut. Align the Saw Blade with the direction of the cut and slowly lower the saw blade onto the cut line to begin the cut. Do not attempt to cut with the tip of the blade; kickback and damage to the blade could result. Note: When cutting hard woods, a hole
shouldbedrilledrsttoinsertthesaw
blade (see Plunge Cutting on next page). Whennishedcutting,releasetheTrig-9.
ger to stop the tool. Remove the Battery Pack (1). 10. Clean, then store the Saw indoors and 11.
out of children’s reach.
WiththeSawBladeinstalled,squeeze,4. then release the Trigger (B19-1) to make sure it is locked. It should not move.
Page 16 For technical questions, please call 1-800-444-3353. SKU 66755
Page 17
Plunge Cutting
Note: Before Plunge Cutting, drill a hole or
opening for inserting the saw blade.
Never allow the tip of the saw blade to contact the workpiece.
Clearly mark the line of cut on the work 1. piece.
From a convenient starting point within 2. the cut out area, place the blade tip into the hole or opening. The saw should be positioned vertically at a 90° angle to the workpiece.
Slowly lower the Saw until the lower 3. edge of the Guard rests on the work piece - See Figure B2.
Drill/Driver Set Up and Operating
Instructions
DO NOT• install the Battery Pack (1)
until AFTER you complete the following steps to set up the Drill/Driver for use.
Refer to Figure C1 for the location of • the parts of the Drill/Driver for the fol­lowing steps.
Forward/Lock/Reverse Button (C10)
Clutch Cap
Chuck Jaws
Tighten Chuck (C2)
Start the Saw and allow it to reach full 4. speed.
With the Saw resting on the Guard, 5. slowly lower the Saw Blade (B15/B16) onto the cut line. Continue this motion until the Saw Blade is perpendicular to the work piece.
Metal Cutting
When cutting metal materials with the 1. Saw, make sure to use the metal Saw Blade (B16).
Lubricate the cutting surface with cut-2. ting oil to avoid heat build-up. Follow the
“Operating the Reciprocating Saw”
section on page 17 of this manual.
Trigger Switch (C4)
Light Switch (C11)
LED Light (C12)
Battery Pack (1)
Figure C1
1. Center the Forward/Lock/Reverse Button (C10) to “lock” the trigger mechanism as a safety measure, so the drill does not turn on accidentally.
Loosen the Chuck (C2) if needed and 2. place the desired drill bit or screw driver bit into the drill between the Chuck Jaws.
Tighten the Chuck until the bit is held 3. securely in place, centered between the Chuck Jaws.
Page 17For technical questions, please call 1-800-444-3353.SKU 66755
Page 18
Torque Setting
Indicator
Clutch Cap Set to Drill
Be sure the Battery Pack (1) is securely seated into the Drill/Driver Handle so it does not fall off during use.
Slide the Forward/Lock/Reverse Button 2. (C10) (which should initially be centered in the “lock” position) to either Forward or Reverse as required.
If using the Drill to insert or remove 3. screws, position the driver tip in the item to insert or remove.
Figure C2
4. Set the desired torque setting by rotating the Clutch Cap.
To drill holes, turn the torque Clutch Cap a. so that the drill icon is lined up with the torque setting indicator.
The numbered settings from 1 to 23 are b. for driving screws, bolts and nuts.
It is recommended that a very low •
torquesettingbeusedfortherst
drive, and adjust the setting as the proper force required is determined.
The torque setting required depends • on the item being driven. In the case of
screws,considerthesize,length,and
type of material. If a pilot hole has been drilled into the •
material, the torque setting required will be less to drive the screw.
If drilling a hole, hold the Drill Driver 4. above the area to drill.
Depress the Trigger Switch (C4) to start 5. the drill.
When inserting or removing a screw or 6.
bolt,useslightpressureatrsttokeep
the screw driver bit in the head of the screw or bolt and cause the screw or bolt to thread into or unthread from the mate­rial.
When drilling a hole, let the Drill/Driver 7. do the work, using only enough pressure to follow the drill as it cuts the hole in the material.
WhennishedusingtheDrill/Driver,re-8. lease the Trigger Switch (C4), and center the Forward/Lock/Reverse Button (C10) to lock the trigger mechanism as a safety measure.
In addition to single or double-ended c.
Remove the Battery Pack (1). 9.
screwdriver bits, adapters with hexago­nal shafts with matching socket heads can also be used.
Clean then store the Drill/Driver indoors 10. and out of children’s reach.
Fix the torque setting low enough to al-• low a safety margin.
Operating the Drill/Driver
Insert the fully charged Battery Pack (1) 1. into the base of the Drill/Driver, making sure that it clicks into place securely.
Page 18 For technical questions, please call 1-800-444-3353. SKU 66755
Page 19
Work Light Set Up and Operating
Instructions
Insert the fully charged Battery Pack (1) 1. into the base of the Work Light, making sure that it clicks into place securely.
Seven Position
Rotation
Power Switch (D17)
Battery Pack (1)
Figure D1
2. Adjust the Head position of the Work Light by rotating it to click in place at any of the seven locking positions.
Press the Power Switch (D17) to turn the 3. light on.
WhennishedusingtheWorkLight,4. press the Power Button again to turn the light off.
Disconnect the Battery Pack after use. 5. Clean, then store the tool indoors out of children’s reach.
Page 19For technical questions, please call 1-800-444-3353.SKU 66755
Page 20
MAINTENANCE AND
SERVICING
Procedures not specically
explained in this manual must
be performed only by a qualied
technician.
TO PREVENT
SERIOUS INJURY FROM ACCIDENTAL OPERATION: Turn the Power Switch of the tool to its “OFF” position and unplug the tool from its Battery Pack (1) before performing any inspection, maintenance, or cleaning procedures.
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.
Cleaning, Maintenance, and
Lubrication
BEFORE EACH USE,1. inspect the gen-
eral condition of the tool. Check for loose screws, misalignment or binding of moving parts, cracked or broken parts, damaged electrical wiring, and any other condition that may affect its safe opera­tion.
AFTER USE,2. clean external surfaces of the tool with clean, moist cloth.
Store indoors, out of reach of children.3.
Page 20 For technical questions, please call 1-800-444-3353. SKU 66755
Page 21
Troubleshooting
Problem Possible Causes Likely Solutions
Charger will not turn on.
Battery Pack will not charge.
Tool will not start Battery Pack not fully 1.
Tool does not run at full power.
Power Switch will not turn off tool.
When using Circular Saw, cut quality is poor.
When using Reciprocating Saw, cut line is irregular.
When using Reciprocating Saw, undesirable cutting action.
When using Drill as a screwdriver, unable to remove screw
No power to Charger (2) Make sure the Charger is plugged into a working, 120
volt, grounded, electrical outlet.
Components not connected. 1.
Battery Pack damaged.2.
connected. Battery Pack not fully charged.2. Tool is damaged or defective.3.
Battery Pack not fully charged. 1.
Low torque setting.2.
Tool needs service check. Immediately remove Battery Pack (1) from tool. Do not
Blade damaged or dull.1. Blade not installed properly.2. Blade being forced into 3.
workpiece. Blade mounted in incorrect 4.
direction of rotation. Bent, cracked, or broken Saw 1. Blade.
Loose Saw Blade. 2.
Improperly exerting side-to-3. side pressure on Saw Blade. Dull Saw Blade.1.
Improper Saw Blade used. 2.
Tool speed too slow. 3.
Attempting to cut curves with 4. tool Not enough torque.1.
Wrongsizebit.2.
Make sure Battery Pack (1), Charger (2), and Battery 1. Socket (3) are all connected securely.
Check for leaking or damaged Battery. Do not attempt 2. to charge a leaking or damaged Battery. Make sure that the Battery Pack (1) is securely 1. inserted into the tool.
Make sure the Battery Pack (1) is fully charged.2. Haveaqualiedservicetechnicianchecktoolfor3.
damage or defects. Remove Battery Pack (1) and replace with fully 1. charged Battery Pack (1).
Adjust to higher torque setting.2.
usetooluntilaqualiedservicetechnicianchecksout
tool for damage or defects.
Replace Blade (A3).1. Check that Blade (A3) is properly secured in place.2. Cut more slowly. Do not force tool. 3.
Reinstall blade correctly.4.
Replace Saw Blade (B15/B16). 1.
Make sure Blade (B15/B16) is securely installed in 2. tool.
Make sure Blade (B15/B16) is held at 90° angle to 3. workpiece. Replace Saw Blade (B15/B16).1.
Use metal Saw Blades (B16) for cutting metal and 2. wood Saw Blades (B15) for cutting wood.
IncreasetoolspeedbysqueezingTrigger(B19-1)3. harder.
Use tool only to cut straight lines.4.
Use a tool with greater torque.1. Usecorrectsizebit.2.
Follow all safety precautions whenever diagnosing or servicing the tool.
Disconnect power supply before service.
Page 21For technical questions, please call 1-800-444-3353.SKU 66755
Page 22
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.
Page 22 For technical questions, please call 1-800-444-3353. SKU 66755
Page 23
PARTS LISTS AND ASSEMBLY DIAGRAMS
Accessory Parts List and Diagram
Part Description Qty
1 Battery Pack 2 2 Charger 1 3 Battery Socket 1
2
3
1
Page 23For technical questions, please call 1-800-444-3353.SKU 66755
Page 24
Parts List A - Circular Saw
Part Description Qty
A1 Bolt 1 A2 Washer 1 A3 Saw Blade 1 A4 Inside Clamping Plate 1 A5 Screw 4 A6 Clamping Board 1 A7 Lower Guard 1 A8 Bolt 1
A9 Spring 1 A10 Screw 3 A11 Label 1 A12 Upper Safety Cover 1 A13 Left Motor Housing 1 A14 Label 1 A15 Safety Button 1 A16 Compression Spring 1 A17 Phillips Head Screw 2 A18 Spring Shim 2 A19 Trigger Module 1
A19-1 Trigger 1 A19-2 Connecting Wire 1 1 A19-3 Connecting Wire 2 1 A19-4 Contact Plate 1 A19-5 Contact Plate Socket 1 A19-6 Connecting Wire 3 1
A20 Screw 2 A21 Screw 7 A22 Screw 2 A23 Rear Cover 1 A24 Right Motor Housing 1 A25 Motor Assembly 1
A25-1 Motor 1
Part Description Qty
A25-2 Motor Gear 1
A26 Screw 4
A27 Output Assembly 1 A27-1 Screw 4 A27-2 Gear Box 1 A27-3 Axle Sleeve 1 A27-4 Output Gear 1 A27-5 Self-Locking Plate 1 A27-6 Output Shaft 1 A27-7 Big Axle Sleeve 1 A27-8 Gear Box Cover 1
A28 Self-Locking Module 1 A28-1 Self-Locking Button 1 A28-2 Spring 1 A28-3 Self-Locking Board 1
A29 Clamp 1
A30 Seal 1
A31 Nut 1
A32 Retaining Ring 1
A33 Bolt 1
A34 Bolt 1
A35 Rip Fence 1
A36 Base Plate 1
A37 Washer 3
A38 Angle Adjustment Knob 1
A39 Impacting Spring 1
A40 Hex Nut 1
A41 Bolt 1
A42 Rip Fence Knob 1
A43 Phillips Head Screw 1
A45 Hex Wrench 1
Page 24 For technical questions, please call 1-800-444-3353. SKU 66755
Page 25
Assembly Diagram A - Circular Saw
Note: Some parts are listed and shown for illustration purposes only, and are not avail-
able individually as replacement parts.
Page 25For technical questions, please call 1-800-444-3353.SKU 66755
Page 26
Parts List and Diagram B - Reciprocating Saw
Part Description Qty
B1 Phillips Head Screw 4 B2 Phillips Head Screw 2 B3 Label 1 B4 Right Housing Cover 1 B5 Phillips Head Screw 7 B6 Right Motor Housing 1 B7 Hacked-Type Rubber 1 B8 Square Rubber 1
B9 Motor Module 1 B10 Impacting Spring 1 B11 Left Motor Housing 1 B12 Left Motor Housing 1
Part Description Qty
B14 Label 1 B15 Saw Blade 1 1 B16 Saw Blade 2 1 B17 Rubber Molded Cover 1 B18 Safety Button 1
B19 Trigger Module 1 B19-1 Trigger 1 B19-2 Contact Plate 1 B19-3 Contact Plate Socket 1 B19-4 Connecting Wire 1 1 B19-5 Connecting Wire 2 1
Note: Some parts are listed
and shown for illustration purposes only, and are not available individually as replacement parts.
Page 26 For technical questions, please call 1-800-444-3353. SKU 66755
Page 27
Parts List and Diagram C - Drill
Part Description Qty
C1 Screw 1 C2 Chuck 1 C3 Motor and Gear Box Module 1 C4 Trigger Switch 1 C5 Contact Plate Socket 1 C6 Contact Plate 1 C7 Left Motor Housing 1 C8 Left Rear Cover 1
C9 Left Front Cover 1 C10 Forward/Lock/Reverse Button 1 C11 Light Switch 1
Part Description Qty
C12 LED Light 1 C13 Right Motor Housing 1 C14 Screw 6 C15 Right Rear Cover 1 C16 Right Front Cover 1 C17 Screw 2 C18 Screw 2 C20 Connecting Wire 2 1 C21 Connecting Wire 1 1 C22 Connecting Wire 3 1 C23 Connecting Wire 4 1
Note: Some parts are listed and shown for
illustration purposes only, and are not available individually as replacement parts.
Page 27For technical questions, please call 1-800-444-3353.SKU 66755
Page 28
Parts List D - Flashlight
Part Description Qty
D4 Screw 1 D5 Screw 4 D6 Screw 2 D7 Contact Plate Socket 1 D8 Contact Plate 1
D9 Connecting Wire 1 D10 Switch 1 D11 Left Housing 1 D12 Right Front Cover 1 D13 Right Lamp Holder 1 D14 O-Ring 1 D15 Right Housing 1 D16 PCB 1 D17 Power Switch 1 D18 Spring 1 D19 Screw 1 D20 Lamp Holder Orientation 1 D21 Orientation Pin 1 D22 Spring 1 D23 Lamp Shade 1 D24 Lens 1 D25 Reector 1 D26 Left Lamp Holder 1 D27 Left Front Cover 1
Page 28 For technical questions, please call 1-800-444-3353. SKU 66755
Page 29
Assembly Diagram D - Flashlight
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 29For technical questions, please call 1-800-444-3353.SKU 66755
Page 30
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veries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specic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 30 For technical questions, please call 1-800-444-3353. SKU 66755
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