RECIPROCATING SAW
HEAVY DUTY
42597
OPERATING AND MAINTENANCE
INSTRUCTIONS
3491 Mission Oaks Blvd., Camarillo, CA 93011
Copyright © 2000 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.
For technical questions and replacement parts, please call 1-800-444-3353
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6. Use the right tool for the job. Do not attempt to force a small tool or attachment to do
the work of a larger industrial tool. There are certain applications for which this tool
was designed. Do not modify this tool and do not use this tool for a purpose for which
it was not intended.
7. Dress properly. Do not wear loose clothing or jewelry as they can be caught in
moving parts. Protective, electrically non-conductive clothes and non-skid footwear
are recommended when working. Wear restrictive hair covering to contain long hair.
8. Use eye and ear protection. Always wear ANSI approved impact safety goggles.
Wear a full face shield if you are producing metal filings or wood chips. Wear an ANSI
approved dust mask or respirator when working around metal, wood, and chemical
dusts and mists.
9. Do not overreach. Keep proper footing and balance at all times. Do not reach over or
across running machines.
10. Maintain tools with care. Keep tools sharp and clean for better and safer
performance. Follow instructions for lubricating and changing accessories. Inspect tool
cords periodically and, if damaged, have them repaired by an authorized technician.
The handles must be kept clean, dry, and free from oil and grease at all times.
11. Disconnect power. Unplug when not in use.
12. Remove adjusting keys and wrenches. Check that keys and adjusting wrenches
are removed from the tool or machine work surface before plugging it in.
13. Avoid unintentional starting. Be sure the switch is in the Off position when not in use
and before plugging in. Do not carry any tool with your finger on the trigger, whether it
is plugged in or not.
14. Stay alert. Watch what you are doing, use common sense. Do not operate any tool
when you are tired.
15. Check for damaged parts. Before using any tool, any part that appears damaged
should be carefully checked to determine that it will operate properly and perform its
intended function. Check for alignment and binding of moving parts; any broken parts
or mounting fixtures; and any other condition that may affect proper operation. Any part
that is damaged should be properly repaired or replaced by a qualified technician. Do
not use the tool if any switch does not turn On and Off properly.
16. Guard against electric shock. Prevent body contact with grounded surfaces such as
pipes, radiators, ranges, and refrigerator enclosures.
17. Replacement parts and accessories. When servicing, use only identical
replacement parts. Use of any other parts will void the warranty. Only use accessories
intended for use with this tool. Approved accessories are available from Harbor Freight
Tools.
18. Do not operate tool if under the influence of alcohol or drugs. Read warning
labels on prescriptions to determine if your judgment or reflexes are impaired while
taking drugs. If there is any doubt, do not operate the tool.
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19. Don’t abuse the power cord. Never carry a tool by its cord. Do not yank on the cord
to disconnect it from the outlet. Do not move bench-mounted, or floor-standing
machines with the power cord in the outlet. Keep cord away from heat, oil and sharp
edges.
20. Examine blade before using. Before each use, examine blade for chips, cracks, or
other damage. Do not use if damaged.
21. Check for tightness on all saw blade adjustments before using.
22. Use proper size extension cord. If an extension cord is required, it must be of the
proper size to supply the correct current to the tool without heating up. Otherwise, the
extension cord could melt and catch file, or cause electrical damage to the tool. This
tool requires use of an extension cord of 0 to 10 amps capability (up to 50 feet), with
wire size rated at 18 AWG. Longer extension cords required larger size wire. If you are
using the tool outdoors, use an extension cord rated for outdoor use (signified by “WA”
on the jacket).
Note: Performance of this tool may vary depending on variations in local line voltage. Exten-
sion cord usage may also affect tool performance.
WARNING: THE WARNINGS, CAUTIONS, AND INSTRUCTIONS DISCUSSED IN THIS IN-
STRUCTION MANUAL CANNOT COVER ALL POSSIBLE 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 PROD-
UCT, BUT MUST BE SUPPLIED BY THE OPERATOR.
Unpacking
When unpacking, check to make sure the following parts are included: Reciprocating Saw,
Wood and Metal Blades, and Hex Key Wrench. If any parts are missing or broken, please
call Harbor Freight Tools at the number on the cover of this manual as soon as possible.
Assembly
Install Blade
Refer to the photo on the top of the next page.
1. Select the saw blade best suited for stock you are cutting.
Wood blades have a coarser tooth pitch. Metal blades have a finer tooth pitch. Use
each blade only for cutting its specified stock.
2. Using the supplied Hex Key Wrench, loosen, but do not remove Screw (4).
3. Slide the blade (teeth down) into the blade holder as far as possible.
4. Tighten Screw (4).
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Screw (4)
Blade
Adjusting Shoe
Use the Adjustable Bottom Plate (1) to determine the depth of your cut. Position the Shoe
close to the Rubber Sleeve (3) for a deeper cut, further out for a shallower cut.
Rubber Sleeve (3)
Adjustable Bottom Plate (1)
Saw Blade
Hex Screws (2)
1. Loosen Hex Screws (2) with supplied Hex Key Wrench.
2. Position the Adjustable Bottom Plate (1) to the desired position.
3. Tighten Hex Screws (2).
Operation
Operational Precautions
1. Check the Saw Blade to make sure it does not have any missing teeth or cracks. Do
not use a damaged Saw Blade.
2. Check that there is enough space under and behind the workpiece for the
reciprocation blade. Be sure that you will not be cutting through any electrical wires or
your workbench.
3. Do not put side-to-side pressure on the blade as it may break.
4. Never attempt to remove material stuck in the moving parts of the saw while the saw in
running and plugged in.
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5. Always unplug the Line Cord (54) before making adjustments or repairs.
6. Never cut stock that is thicker than 1-1/2 inches.
7. Do not attempt to cut curves with the saw as it may break the blade.
Warning: Always use clamps or other safe, practical ways to hold and support the
workpiece. Holding the work by hand or against your body is unstable and may
lead to loss of control.
Caution: Some woods contain preservatives such as copper chromium arsenate
(CCA) which can be toxic. When cutting these materials extra care should be
taken to avoid inhalation and minimize skin contact.
General Operation
1. Before plugging the Line Cord (54) into an outlet, make sure the Safety Button is not
being pushed in and fingers are off the Trigger Switch (57).
2. Plug the Line Cord (54) into the outlet.
3. Grip the Saw with both hands, one on the back handle and one on the Rubber Sleeve
(3).
Note: The Saw is equipped with a Safety Button which must be depressed before squeezing
the Trigger Switch (54).
4. To start the Saw, push in the Safety Button with your thumb and squeeze the Trigger
Switch (57) with your index finger.
Speed Adjust (58)
Trigger Switch (57)
Safety Button
Caution:When cutting metal, use cutting oil to cool the blade or damage may result to
the blade.
5. With the blade in motion, place it against the stock to be cut.
Press down on the Saw to help it cut. Do not use too much force, only enough to keep
the Saw cutting.
Caution: When cutting into walls, floor or any object where live electrical wires may be
present, DO NOT TOUCH ANY METAL PARTS OFTHE TOOL! Hold the tool only
by insulated grasping surfaces to prevent electric shock if you cut into a live
wire.
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REV 09/01 REV 04/03
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6. Adjust the reciprocating speed of the Saw by moving the Speed Adjust (58) with your
thumb (forward or backward) while the Saw is turned ON.
7. To stop the Saw, release the Trigger Switch (57).
8. Rotate the Variable Switch to return the reciprocating speed to its slowest position.
Warning: If the saw jams, immediately shut off the saw and then remove the saw from
the cutting area. If finished with the cut, shut off the saw and be careful not to
come into contact with the blade.
Maintenance
1. Periodically clean or blow out the motor ventilation slots.
This will prevent the motor from overheating.
2. Replace the saw blade when it becomes worn, bent, or damaged in any other way.
3. Wipe the tool with a clean cloth after every use.
4. Over time, the Carbon Brush (46) in the motor will wear and may need replacement.
When the Carbon Brush is completely worn out, the Saw will not operate. The Carbon
Brush should be replaced by a qualified technician. The Carbon Brush can be
accessed for evaluation or replacement by a qualified technician, by removing the
Brush Holder (44) atop the Left and Right Body (49 and 50).
SKU 42597
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REV 09/01 REV 04/03
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Parts List
Item #
Description
Qty
Item #
Description
Long Shaft
Qty
1
Adjustable Bottom Plate
1
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
1
2
Hex Screw
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Gear
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
Rubber Sleeve
Screw
Screw
4
Connecting Frame
Ball Bearing
Screw
5
Screw
6
Retaining Washer
Washer
7
Rotor
8
Blade Holder Plate
Felt Retainer
Shock Absorber
Screw
Ball Bearing
Guide Wing Ring
Screw
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Pin
Cap
Line
Machine Head
Screw
Stator
Brush Holder
Copper Bushing
Carbon Brush
Frame
Retainer Washer
Washer
Plain Bearing Bushing
Reciprocating Bar
Ball Bearing
Rating Plate
Left Body
Right Body
Screw
Jacket
Guide Jacket
Counter Balance
Long Oscillating Bar
Crankshaft
Screw
Screw
Line Cord
Cable Support
Cable Sleeve
Trigger Switch
Speed Adjust
Line
Circlips for Holds
Angular Contact Bearing
Short Oscillating Bar
Circlips for Shaft
Hexagon Nut with Flangs
Spring
Line
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Parts Diagram
and
oses
able
individually as replacement parts
PLEASE READTHE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDEDTHE PARTS DIAGRAM INTHIS MANUAL
AS A REFERENCETOOL ONLY. NEITHERTHE MANUFACTURER NOR DISTRIBUTOR MAKES ANY
REPRESENTATION OR WARRANTY OF ANY KINDTO THE BUYER THAT HE OR SHE IS QUALIFIEDTO
MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS
OFTHE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATESTHAT
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 REPAIRSTOTHE ORIGINAL PRODUCT OR REPLACEMENT PARTSTHERETO, OR
ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTSTHERETO.
SKU 42597
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