Mastercraft 20V Max Variable Speed Cordless Reciprocating Saw Owner Manual

RECIPROCATING SAW

054-8255-8

IMPORTANT:

Read and understand this instruction manual thoroughly before using the product.

INSTRUCTION

MANUAL

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TABLE OF CONTENTS

Technical Specifications

Safety Guidelines

Key Parts Diagram

Operating Instructions

Maintenance

Troubleshooting

Parts List

Warranty

NOTE:

If any parts are missing or damaged, or if you have any questions, please call our toll-free helpline at 1-800-689-9928.

SAVE THESE INSTRUCTIONS

• This manual contains important safety and operating instructions. Read all instructions and follow them with use of this product.

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TECHNICAL SPECIFICATIONS

Rated Voltage

No-load Speed

Blade Stroke

Base Shoe Adjustment Length

Sawing Capacity In Wood

Sawing Capacity In Aluminum

Sawing Capacity In Metal

20 V d.c.

0-3000 SPM

1” (25 mm)

45/64” (18 mm)

15/16” (24 mm)

25/32” (20 mm)

*Maximum battery voltage without workload; with workload nominal voltage is 18V.

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NOTICE:

Recommend using tool with Mastercraft ® 20V max* Lithium-Ion 4.0 Ah battery (054-7557-6; sold separately) for optimal performance.

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SAFETY GUIDELINES:

WARNING!

Safety symbols in this Instruction Manual are used to flag possible dangers. The safety symbols and their explanations require your full understanding. The safety warnings do not, by themselves, eliminate any danger, nor are they substitutes for proper accident prevention measures.

WARNING!

This Safety Alert Symbol indicates caution, warning, or danger. Failure to obey a safety warning can result in serious injury to yourself or others. To reduce the risk of injury, fire, or electric shock, always follow the safety precautions.

KNOW YOUR TOOL

To operate this tool, carefully read this Instruction Manual and all labels affixed to the cordless reciprocating saw before using. Keep this instruction manual available for future reference.

IMPORTANT

This tool should only be serviced by a qualified service technician. For more information, call the toll free helpline at 1-800-689-9928.

READ ALL INSTRUCTIONS THOROUGHLY.

SAVE THESE INSTRUCTIONS.

GENERAL POWER TOOL SAFETY WARNINGS

WARNING!

Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire 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 batteryoperated (cordless) power tool.

WORK AREA SAFETY

• Keep work area clean and well lit . Cluttered or dark areas invite accidents.

• Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.

• Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

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ELECTRICAL SAFETY

• Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.

• Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.

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Water entering a power tool will increase the risk of electric shock.

• Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock.

• When operating a power tool outdoors, use an extension cord suitable for outdoor use.

• If operating a power tool in a damp location is unavoidable, use a ground fault circuit interrupter (GFCI) protected supply. Use of a GFCI reduces the risk of electric shock.

PERSONAL SAFETY

• Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.

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Protective equipment such as a dust mask, non-skid safety shoes, hard hat or hearing protection used for appropriate conditions will reduce personal injuries.

• Prevent unintentional starting. Ensure 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 finger on the switch or energising power tools that have the switch on invites accidents.

• Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.

• Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.

• Dress properly. Do not wear loose clothing or jewellery. Keep your hair and clothing away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts.

• If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dustrelated hazards.

• Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.

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POWER TOOL USE AND CARE

• 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.

• 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.

• Disconnect the plug from the power source and/or remove the battery pack, if detachable, 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.

• 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.

• Maintain power tools and accessories. 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.

• Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.

• 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.

• Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

BATTERY TOOL USE AND CARE

• 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.

• Use power tools only with specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire.

• 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.

• 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.

• Do not use a battery pack or tool that is damaged or modified. Damaged or modified batteries may exhibit unpredictable behaviour resulting in fire, explosion or risk of injury.

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• Do not expose a battery pack or tool to fire or excessive temperature. Exposure to fire or temperature above 130°C (265°F) may cause explosion.

• Follow all charging instructions and do not charge the battery pack or tool outside the temperature range specified in the instructions. Charging improperly or at temperatures outside the specified range may damage the battery and increase the risk of fire.

SERVICE

• 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.

• Never service damaged battery packs. Service of battery packs should only be performed by the manufacturer or authorized service providers.

SAFETY INSTRUCTIONS FOR RECIPROCATING SAWS

• the cutting accessory may contact hidden wiring. Cutting accessory contacting a “live” wire may make exposed metal parts of the power tool “live” and could give the operator an electric shock.

• Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the workpiece by hand or against your body leaves it unstable and may lead to loss of control.

ADDITIONAL SAFETY GUIDELINES FOR CORDLESS RECIPROCATING SAW

• The label on your tool may include the following symbols. The symbols and their definitions are as follows: warnings

V ..................... Volts

A ..................... Amperes

Hz ................... Hertz

W .................... Watts min ................. Minutes

................. Alternating current

or d.c ..... Direct current

n

0

................... No-load speed

............... Class II Construction

SPM ........... Strokes per minute

............... Grounding terminal

.............. WARNING – To reduce the risk of injury, user must read instruction manual .

.............. WARNING – To reduce the risk of injury always wear eye protection.

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.............. WARNING – To reduce the risk of injury always wear ear protection.

• Always remove the battery pack before changing the saw blade and/or adjusting the saw base.

• The saw blade must be securely locked in its holder. Check that it has been securely seated before use.

• Make certain that all adjusting levers and the blade holder are tight before making a cut. Loose adjusting levers and holders can cause the tool or blade to slip; loss of control may result.

• Check that the switch is “off” before attaching a battery pack. Accidental starting could cause injury.

• Secure material before cutting. Never hold the workpiece in your hand or across your legs. Small or thin material may flex or vibrate with the blade, causing loss of control.

• Never touch the saw blade immediately after use. It may be hot after prolonged use.

• Always wear safety goggles or eye protection when using this tool. Use a dust mask or respirator or connect the tool to an external dust vacuum if cutting generates a great amount of dust.

• Keep hands away from cutting area. Do not reach under the material being cut. The proximity of the blade to your hand is hidden from your sight.

• Do not use dull or damaged saw blades and accessories.

WARNING!

To reduce the risk of electric shock or damage to the charger and battery, use only the

Mastercraft ® batteries and chargers listed.

BATTERY PACK

054-3124-0, 054-7553-4, 054-7557-6, 054-2434-8

CHARGER

054-3126-6, 054-7559-2

• For best results, your battery tool should be stored and used in a location where the temperature is more than 5°C (41°F) but less than 40°C (104°F). Do not store outside or in vehicles.

• Protect your hearing. Wear appropriate personal hearing protection during use. Under some conditions and duration of use, noise from this product may contribute to hearing loss.

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PACKAGE CONTENTS:

Cordless reciprocating saw, hex wrench (inserted onto the saw), saw blade, and instruction manual

KEY PARTS DIAGRAM

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4

No.

Description

1 Base shoe

LED worklight

Tool-less blade-clamp lever

Variable-speed trigger switch warnings

No.

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6

7

Description

Lock-off button

Tool-less blade clamp

Hex wrench

Before attempting to use this tool, become familiar with all of its operating features and safety requirements. For optimum performance and safety, read the following operating instructions carefully before using.

WARNING!

• Remove the cordless reciprocating saw from the package and examine it carefully. Do not discard the carton or any packaging material until all parts have been examined.

• If any part of the reciprocating saw is missing or damaged, do not attach the battery pack to the tool or use the tool until the part has been repaired or replaced. Failure to heed this warning could result in serious injury.

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OPERATING INSTRUCTIONS

TO ATTACH THE BATTERY PACK (fig 1)

1. Ensure that the trigger switch is in the “OFF” position and the lock-off button is pressed to the right side of the tool.

2. Align the raised rib on the battery pack with the grooves on the bottom of the saw, and then attach the battery pack to the saw.

3. Make sure that the latch on the battery pack snaps into place and that the battery pack is attached securely to the tool before beginning operation.

fig 1

Battery-release button

TO DETACH THE BATTERY PACK (fig 1)

1. Ensure that the trigger switch is in the “OFF” position and the lock-off button is pressed to the right side of the tool.

2. Depress the battery-release button, located on the front of the battery pack, to release the battery pack.

3. Pull the battery forward to remove it from the tool.

BLADE SELECTION

To obtain the best performance from the saw, it is important to select the correct blade for the particular application and type of material to be cut.

Blades with fewer teeth, e.g., 7 teeth per inch (TPI), are typically used for cutting wood; blades with more teeth per inch are better for cutting metal or plastic. We recommend 14 TPI blades for plastics and soft metals and 18 TPI blades for hard metals.

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NOTICE:

When attaching a battery pack to the tool, be sure that the raised rib on the battery pack aligns with the groove on the cordless reciprocating saw and the latches snap into place properly. Improper assembly of the battery pack can cause damage to internal components.

WARNING!

• Do not allow familiarity with the cordless reciprocating saw to cause a lack of alertness. A fraction of a second of carelessness is enough to cause severe injury.

• To avoid the possibility of accidental starting, always take care to engage the lock-off button and not to activate the variable-speed trigger switch when you are attaching the battery pack or performing other adjustments to the tool.

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INSTALL A SAW BLADE (fig 2)

fig 2

1. Remove the battery pack from the saw.

2. Pivot the blade-clamp lever to open the blade clamp.

3. Insert the saw blade into the blade clamp as far as possible, then release the blade-clamp lever to lock the blade in position.

Open

Blade-clamp lever

REMOVE A SAW BLADE ( fig 2)

1. Remove the battery pack from the saw.

2. Pivot the blade-clamp lever to open the blade clamp.

BASE SHOE ADJUSTMENT (fig 3)

For maximum control and longer blade life, the base shoe assembly slides in and out to adjust the effective cutting length.

1.

Remove the battery pack from the saw.

2.

Use the hex wrench (included) to loosen the two screws on the bottom of saw housing.

3.

retighten both screws.

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PIVOTING THE SHOE (fig 4)

The base shoe pivots to provide maximum contact with the surface being cut.

1.

Remove the battery pack from the saw.

2.

Hold the saw securely, and then pivot the base shoe to the desired angle.

fig 3

Base shoe

fig 4

Hex wrench

Shoe

WARNING!

• Never touch the saw blade immediately after use. It may be hot after prolonged use.

• After adjusting the base shoe, two locking screws should be fully retightened, otherwise the base shoe will become loose during the operation.

• To avoid injury and damage, do not operate the saw without the base shoe in place. The spindle may strike against the workpiece and damage the reciprocating mechanism.

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STORE/REMOVE THE HEX WRENCH

(fig 5)

To store the hex wrench, just insert it into the receptacle on the saw. To remove the hex wrench, simply pull it out from the hole on the saw.

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Hex wrench

VARIABLE-SPEED TRIGGER SWITCH

(fig 6)

fig 6

Your reciprocating saw is equipped with a variablespeed trigger switch to turn the saw on and off and to control the speed.

1.

To start the saw, press the lock-off button to the direction of “ ” (left side of the tool) and then squeeze the trigger switch.

2.

To stop the saw, release the trigger switch and press the lock-off button to the direction of

“ ” (right side of the tool) to lock the trigger switch in the “OFF” position.

Lock-off button

Variable-speed trigger switch

VARIABLE-SPEED (fig 6)

The variable-speed trigger switch delivers higher speed with increased trigger pressure and lower speed with decreased trigger pressure.

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WARNING!

• To avoid the possibility of accidental starting, always press the lock-off button to the right side of the tool to lock the trigger switch in the “OFF” position after each use.

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LED WORKLIGHT (fig 7)

fig 7

The LED worklight, located on the front of the saw, provides additional light on the work surface for operation in lower-light areas. The LED worklight will turn on when the trigger switch is depressed. The

LED worklight will turn off when the trigger switch is released.

LED worklight

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GENERAL CUTTING (fig 8)

1. Remove the battery pack from the saw.

fig 8

2. Make sure that the workpiece is firmly clamped in place.

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3. Install the appropriate type and size of blade for the workpiece material and size.

4. Adjust the base shoe as necessary to make sure that the blade will extend beyond the shoe and the workpiece at all times.

5. Adjust the base shoe as necessary to expose unworn blade teeth for longer blade life.

6. Check for clearance behind the workpiece so that the blade will not impact another surface.

8. Attach the battery pack to the saw.

9. Hold the saw firmly with both hands. Make sure to keep your hands on the insulated gripping areas only.

10. Press the lock-off button to the left side of the tool and then squeeze the trigger switch to start the saw; allow it to reach the maximum desired cutting speed before applying the blade to the workpiece.

NOTICE:

Cutting speeds should vary with the workpiece. Hard materials, such as metals, require lower speeds; use higher speeds for softer materials.

WARNING!

• Before attaching the battery pack to the tool, always check to determine that the switch performs properly and returns to the

“OFF” position when released.

• Hold the tool only by the plastic handle and the insulated grip area to help prevent electric shock. You may encounter electrical wiring when sawing into walls or floors. Sawing into a “live” wire will cause electric shock.

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11. Place the flat surface of the shoe firmly on the workpiece while cutting. Use only enough steady pressure on the blade to keep the saw cutting; do not force the tool.

12. Reduce pressure as the blade comes to the end of the cut.

13. Allow the saw to come to a complete stop before removing the blade from the workpiece.

14. If sawing fibreglass, plaster, wallboard, or spackling compound, clean the motor vents frequently with a vacuum or compressed air. These materials are highly abrasive and may accelerate the wear on motor bearings and brushes.

METAL CUTTING

The saw can be used to cut metals, such as sheet steel, pipe, steel rods, aluminum, brass, and copper.

Be careful not to twist or bend the saw blade. Do not force the tool.

The use of cutting oil is recommended when cutting soft metals and steel. Cutting oil will keep the blade cool, increase cutting action, and prolong blade life.

1. Securely clamp the workpiece in position and make the cut close to the clamping point to minimize vibration.

2. When cutting conduit pipe or angle iron, clamp the work in a vise, if possible, and cut close to the vise.

3. To cut thin sheet material, “sandwich” the material between pieces of hardboard or plywood and clamp the layers together to reduce vibration and tearing of the material.

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WARNING!

• Always wear safety goggles when cleaning tools with compressed air.

• Do not allow familiarity with the saw to make you careless. One careless fraction of a second is enough to inflict serious injury.

• To reduce the risk of explosion, electric shock and property damage, always check the work area for hidden gas pipes, electrical wires or water pipes when making blind cut.

• To avoid loss of control and serious injury, make sure that the blade reaches maximum speed before touching it to the workpiece.

• Never use gasoline, because normal sparking could ignite the fumes.

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MAINTENANCE

The tool may be cleaned most effectively with compressed dry air. Always wear safety goggles when cleaning tools with compressed air. Before each use:

• Inspect the cordless tool and the trigger switch for damage.

• Check for damaged, missing, or worn parts.

• Check for loose screws, misalignment or binding of moving parts, or any other condition that may affect the operation.

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WARNING!

• Do not allow brake fluids, gasoline, petroleum-based products, penetrating oil, etc., to come into contact with plastic parts.

These substances contain chemicals that can damage, weaken, or destroy plastic.

• When servicing, use only identical replacement parts. The use of any other parts may create a hazard or cause damage to the product.

• Use only accessories that are recommended for this cordless reciprocating saw by the manufacturer. Accessories that may be suitable for one tool may become hazardous when used with another tool.

• To ensure safety and reliability, all repairs should be performed by a qualified service technician.

• Turn the variable-speed trigger switch to the “OFF” (centre) position and remove the battery from the power tool before performing troubleshooting procedures.

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TROUBLESHOOTING

Problem

The motor does not start.

Possible Causes

The battery is depleted.

The battery is overloaded.

The battery is overheated.

Solution

Charge the battery pack.

Decrease the load on the tool and restart the tool.

Cool the battery and restart the tool.

Replace the blade.

Replace the blade.

The blade binds, jams, or burns the wood.

The blade is dull.

An improper blade is being used.

The blade is warped.

The blade is damaged.

Replace the blade.

Replace the blade.

The saw vibrates or shakes.

The base shoe is loose during the operation.

The blade is loose.

Two locking screws of the base shoe are not fully tightened.

Remove the blade and reinstall it.

Fully tighten two locking screws. Refer to the “BASE

SHOE ADJUSTMENT” part for detailed operation.

If the problem remains unsolved after performing the checks described above, call the toll-free helpline at 1-800-689-9928.

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EXPLODED VIEW

No. Part No.

Description

1 3130331000 Switch Button

2 5610225000 Hexagon Lobuar Screw

3 3900180000 L R Housing Set

4 3123928000 Rubber Pole

5 5680031000 Hexagon Wrench

6 3810008000 Jigsaw Blade

7 4870706000 Switch Assembly

8 2790455000 Motor And Gear ASSY

9 5620011000 Hexagon Socket Screw

10 5650007000 Spring Washer

11 3422234000 Gear Case

12 5700032000 Needle Bearing

13 5620506000 Flange Screw

14 2825802000 Gear Set

No. Part No.

Description

15 3520415000 Crank Roller

16 5700283000 Aligning Bearing

17 2826691000 Quick Clamp Assembly

18 3650158000 Clamp Wire

19 3705764000 Bearing Clamp

20 5610057000 Thread Forming Screw

21 3129618000 Gear Case Cover

22 5610094000 Thread Forming Screw

23 3706670000 Felt Block

24 3130173000 Rotate Bush

25 3660760000 Tension Spring

26 2825804000 Pivot Shoe

27 3704168000 Clamp

28 5620019000 Hexagon Socket Screw

If any parts are missing or damaged, or if you have any questions, please call the toll-free helpline at

1-800-689-9928.

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This Mastercraft product is guaranteed for a period of 3 years from the date of original retail purchase against defects in workmanship and materials, except for the following components: a) Component A: Batteries, chargers and carrying case, which are guaranteed for a period of 2 years from the date of original retail purchase against defects in workmanship and materials; b) Component B: Accessories, which are guaranteed for a period of 1 year from the date of original retail purchase against defects in workmanship and materials.

Subject to the conditions and limitations described below, this product, if returned to us with proof of purchase within the stated warranty period and if covered under this warranty, will be repaired or replaced (with the same model, or one of equal value or specification), at our option. We will bear the cost of any repair or replacement and any costs of labour relating thereto.

These warranties are subject to the following conditions and limitations:

a) a bill of sale verifying the purchase and purchase date must be provided; b) this warranty will not apply to any product or part thereof which is worn or broken or which has become inoperative due to abuse, misuse, accidental damage, neglect or lack of proper installation, operation or maintenance (as outlined in the applicable owner’s manual or operating instructions) or which is being used for industrial, professional, commercial or rental purposes; c) this warranty will not apply to normal wear and tear or to expendable parts or accessories that may be supplied with the product that are expected to become inoperative or unusable after a reasonable period of use; d) this warranty will not apply to routine maintenance and consumable items such as, but not limited to, fuel, lubricants, vacuum bags, blades, belts, sandpaper, bits, fluids, tune-ups or adjustments; e) this warranty will not apply where damage is caused by repairs made or attempted by others (i.e., persons not authorized by the manufacturer); f) this warranty will not apply to any product that was sold to the original purchaser as a reconditioned or refurbished product (unless otherwise specified in writing); g) this warranty will not apply to any product or part thereof if any part from another manufacturer is installed therein or any repairs or alterations have been made or attempted by unauthorized persons;

h) this warranty will not apply to normal deterioration of the exterior finish, such as, but not limited to, scratches, dents, paint chips, or to any corrosion or discolouring by heat, abrasive and chemical cleaners; and i) this warranty will not apply to component parts sold by and identified as the product of another company, which shall be covered under the product manufacturer’s warranty, if any.

Additional Limitations

This warranty applies only to the original purchaser and may not be transferred. Neither the retailer nor the manufacturer shall be liable for any other expense, loss or damage, including, without limitation, any indirect, incidental, consequential or exemplary damages arising in connection with the sale, use or inability to use this product.

Notice to Consumer

This warranty gives you specific legal rights, and you may have other rights, which may vary from province to province. The provisions contained in this warranty are not intended to limit, modify, take away from, disclaim or exclude any statutory warranties set forth in any applicable provincial or federal legislation.

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Made in China

Imported by

Mastercraft Canada Toronto, Canada M4S 2B8