MasterCraft 54-8235-6 User manual

18 V CORDLESS RECIPROCATING SAW
(Battery & Charger Not Included)
54-8235-6
Owner’s Manual
PRODUCT SPECIFICATIONS
Batteries:
18 V
Ni-Cd (54-3102-2; sold separately)
Li-ion (54-3100-6; sold separately)
Variable speed:
0–2400 SPM (no load)
Blade stroke:
1" (2.5 cm)
Blade type:
Universal shank
Blade change system:
Tool free
Blade:
4" (10.2 cm)
Rotating blade head:
Locks at 0°, 90°, 180° and 270°
Front shoe:
Extendable and pivoting
Chargers:
1-hour, diagnostic (54-3103-0 or
54-3101-4; both sold separately)
Weight:
6 lb 11 oz (3.04 kg) without battery
NEED ASSISTANCE?
Call us on our toll-free Customer Support Line:
1-800-689-9928
Imported by Mastercraft Canada Toronto, Canada M4S 2B8
Battery not
included

2
Product specifications ………….…………………………………………………….
1
Table of contents ……………………………………………………………………...
2
General safety warnings ……………………………………………………………..
3–4
Eye, ear & lung protection ……………………………………………………………
3–4
Electrical safety ……………………………………………………………………….
4
Power tool safety ……………………………………………………………………...
5–7
General safety rules …………………………………………………………………..
5
Work area ………………………………………………………………….…………..
5
Electrical safety ……………………………………………………………………….
5
Personal safety ………………………………………………………………………..
5–6
Use and care of power tools .………………………………………………………..
6
Service …………………………………………………………………………………
6–7
Specific safety rules …………………………………………………………………..
7–8
Battery and charger safety …………………………………………………………..
8
Symbols ………………………………………………………………………………..
9
Know your cordless reciprocating saw ……………………………………………..
10
Accessories and contents ……………………………………………………………
11–12
Available accessories ………………………………………………………………...
11
Contents ……………………………………………………………………………….
11–12
Assembly and operation ……………………………………………………………..
13–21
Installing a battery in the reciprocating saw ………………………………………..
13
Installing a blade ………………………………………………………………………
13–14
Removing a blade …………………………………………………………………….
14
Adjusting the pivoting shoe …………………………………………………………..
14–15
Variable speed control ……………………………………………………………….
15
Lock-off button ………………………………………………………………………...
15
Trigger switch ………………………………………………………………………….
15–16
Adjusting the rotating cutting head ………………………………………………….
16
Materials you can cut …………………………………………………………………
17
General cutting ………………………………………………………………………..
18–19
Plunge cutting …………………………………………………………………………
19–20
Metal cutting …………………………………………………………………………...
20–21
Maintenance …………………………………………………………………………..
22
Exploded view …………………………………………………………………………
23
Parts list ………………………………………………………………………………..
24–25
Warranty ……………………………………………………………………….………
26–27
TABLE OF CONTENTS

3
EYE, EAR & LUNG PROTECTION
This instruction manual includes the following:
General Safety Rules
Specific Safety Rules and Symbols
Functional Description
Assembly
Operation
Maintenance
Accessories
!
ALWAYS WEAR EYE PROTECTION THAT CONFORMS WITH CSA
REQUIREMENTS or ANSI SAFETY STANDARD Z87.1
FLYING DEBRIS can cause permanent eye damage. Prescription
eyeglasses ARE NOT a replacement for proper eye protection.
WARNING: Non-compliant eyewear can cause serious injury if
broken during the operation of a power tool.
SAVE THESE INSTRUCTIONS FOR REFERENCE
WARNING: Use hearing protection, particularly during extended
periods of operation of the tool, or if the operation is noisy.
!
GENERAL SAFETY WARNINGS
CAUTION: Before using this tool or any of its accessories, read this
manual and follow all Safety Rules and Operating Instructions.
!

4
ELECTRICAL SAFETY
WARNING: To avoid electrical hazards, fire hazards or damage to the
tool, use proper circuit protection.
This tool is wired at the factory for 110–120 V operation. It must be
connected to a 110–120 V, 15 A circuit that is protected by a time-delayed
fuse or circuit breaker. To avoid shock or fire, replace power cord
immediately if it is worn, cut or damaged in any way.
GENERAL SAFETY WARNINGS
WEAR A DUST MASK THAT IS DESIGNED TO BE USED WHEN
OPERATING A POWER TOOL IN A DUSTY ENVIRONMENT.
WARNING: Dust that is created by power sanding, sawing, grinding,
drilling, and other construction activities may contain chemicals that are
known to cause cancer, birth defects, or other genetic abnormalities. These
chemicals include:
Lead from lead-based paints
Crystalline silica from bricks, cement, and other masonry products
Arsenic and chromium from chemically treated lumber
The level of risk from exposure to these chemicals varies, according to how
often this type of work is performed. In order to reduce exposure to these
chemicals, work in a well-ventilated area, and use approved safety
equipment, such as a dust mask that is specifically designed to filter out
microscopic particles.
!

5
GENERAL SAFETY RULES
WARNING: Read and understand
all instructions. Failure to follow all
instructions listed below may result in
electric shock, fire and/or serious personal
injury.
WORK AREA
Keep your work area clean and well lit.
Cluttered benches and dark areas invite
accidents.
Do not operate power tools in potentially
explosive environments, such as in the
presence of flammable liquids, gas or dust.
Power tools create sparks that may ignite
dust or fumes.
Keep bystanders, children and visitors
away while operating the tool. Distractions
can cause the operator to lose control.
ELECTRICAL SAFETY
Double insulated tools are equipped with a
polarized plug (one blade is wider than the
other). This plug will only fit into a
polarized plug one way.
If the plug does not fit into the outlet
properly, reverse the plug. If it still does not
fit, contact a qualified electrician to install a
polarized outlet. Do not alter the plug in
any way. Double insulation eliminates the
need for the three-pronged grounded
power cord and grounded power supply
system.
Avoid contact between the operator's body
and grounded surfaces such as pipes,
radiators, ranges, and refrigerators. There
is an increased risk of electric shock if the
operator's body is grounded.
Do not expose power tools to rain or wet
conditions. Water entering the power tool
will increase the risk of electric shock.
Do not abuse the cord. Do not use the
power cord to carry the tool or to pull the
plug out of the outlet. Keep the power cord
away from heat, oil, sharp edges, and
moving parts. Replace a damaged power
cord immediately. A damaged power cord
increases the risk of electric shock.
When operating a power tool outdoors,
use an outdoor-rated extension cord type
“W-A” or “W”. These cords are rated for
outdoor use and they reduce the risk of
electric shock.
PERSONAL SAFETY
Stay alert, be aware of the surroundings,
and use common sense when operating a
power tool. Do not use a power tool while
tired or under the influence of drugs,
alcohol, or medication. A moment of
inattention while operating a power tool
may result in serious personal injury.
Dress properly. Do not wear loose clothing
or jewellery.
Contain long hair. Keep hair, clothing, and
gloves away from moving parts. Loose
clothing, jewellery, or long hair can get
caught in moving parts.
!
POWER TOOL SAFETY

6
PERSONAL SAFETY –cont’d
Avoid accidental start-ups. Verify that the
switch is in the OFF position before
plugging in the tool. Carrying a power tool
with a finger on the switch or plugging in a
tool that has the switch in the ON position
invites accidents.
Remove adjusting keys and wrenches
before turning the tool ON. A wrench or
key that is left attached to a rotating part of
the tool may result in personal injury.
Do not overreach. Keep proper footing and
balance at all times. Proper footing and
balance allows the operator to maintain
better control of the tool in unexpected
situations.
Use safety equipment. Always wear eye
protection.
Use a dust mask, non-skid safety shoes, a
hardhat, or hearing protection when
appropriate.
USE AND CARE OF POWER TOOLS
Use clamps or another practical means to
secure and support the workpiece to a
stable platform. Holding the work in a hand
or against the body is not stable, and may
lead to loss of control.
Do not force the tool. Use the correct tool
for the application. The correct tool will do
the job better and safer when used at the
rate that it was designed to work at.
Do not use a power tool if it cannot be
turned ON or OFF using the power switch.
A tool that cannot be controlled using the
switch is dangerous, and must be repaired.
Disconnect the plug from the outlet before
making any adjustments, changing
accessories, or storing the tool. Such
preventive safety measures reduce the risk
of accidental start-ups.
When power tools are not in use, store
them out of the reach of children or
untrained persons. Tools are dangerous in
the hands of untrained users.
Maintain tools with care. Keep cutting tools
sharp and clean. Properly maintained
cutting tools with sharp cutting edges are
less likely to bind, and are easier to
control.
Inspect the tool for misalignment or binding
of moving parts, broken parts, and any
other condition that may affect the
operation of the tool. If it is damaged, have
the tool serviced before using it. Many
accidents are caused by poorly maintained
tools.
Use only accessories that are
recommended by the manufacturer for this
model. Accessories that are suitable for
one tool may become hazardous when
used with another tool.
SERVICE
Tool servicing must be performed by
qualified personnel. Service or
maintenance performed by non-qualified
personnel could result in a risk of injury.
POWER TOOL SAFETY

7
SERVICE –cont’d
When servicing a tool, use only identical
replacement parts. Follow the instructions
in the Maintenance section of this Manual.
The use of unauthorized parts or failure to
follow the instructions in the Maintenance
section of this Manual may create a risk of
electric shock or injury.
WARNING: Know your cordless
reciprocating saw. Do not plug in the
charger or install the battery in the tool
until you have read and understand this
Instruction Manual. Learn the tool’s
applications and limitations, as well as
the specific potential hazards related to
this tool. Following this rule will reduce the
risk of electric shock, fire, or serious injury.
Always wear eye protection. Any power
tool can throw foreign objects
into your eyes and cause
permanent eye damage.
ALWAYS wear safety goggles
(not glasses) that comply with ANSI safety
standard Z87.1. Everyday glasses have
only impact resistant lenses. They ARE
NOT safety glasses.
WARNING: Glasses or goggles
not in compliance with ANSI Z87.1
could cause serious injury when they
break.
Hold the tool by insulated gripping
surfaces when performing an operation
where the saw blade 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.
Always hold the tool with two hands.
Attempting to control the tool with only one
hand is dangerous. It could result in loss of
control and serious injury.
Always make sure the work surface is free
of nails and other foreign objects. Cutting
into a nail can cause the blade and the tool
to jump and damage the blade.
Never hold the workpiece in one hand and
the tool in the other hand when sawing.
Never place your hands near or below the
cutting surface. Clamping the material and
guiding the tool with both hands is much
safer.
Never lay the workpiece on hard surfaces
like concrete, stone, etc. The protruding
blade may cause the tool to jump.
Always wear safety goggles, hearing
protection and a dust mask. Use only in
well-ventilated areas. Using personal
safety devices and working in a safe
environment reduces the risk of injury.
DANGER: Always remove the
battery when changing the blade.
SPECIFIC SAFETY
RULES
!
!
!
!
POWER TOOL SAFETY

8
Use only 4" (10.2 cm) universal
reciprocating saw blades. Never use a
broken blade, as it will not be securely held
in the tool.
After changing a blade, make sure the
blade is securely held in the blade holder.
Loose blades will be violently thrown.
After adjusting the pivoting shoe, make
sure the adjusting screw is fully tightened.
An improperly tightened pivoting shoe may
work loose and cause the blade to break.
Never touch the blade during or
immediately after use. After use, the blade
is too hot to be touched by bare hands.
Never use dull or damaged blades. Sharp
blades must be handled with care.
Damaged blades can snap during use.
Dull blades require more force to cut the
workpiece, possibly causing the blade to
break.
Battery packs and chargers must be
purchased separately.
This reciprocating saw has been designed
to be powered by one of the following
battery packs:
●18 V Nickel-Cadmium #54-3102-2
●18 V Lithium-ion #54-3100-6
WARNING: Only use the battery
packs listed above to power this tool.
Using any other battery pack could
cause serious injury or damage the
tool.
Both battery packs can be charged using
one of the following chargers:
●14.4 V / 18 V LED Diagnostic Battery
Charger #54-3103-0
●14.4 V / 18 V LCD Diagnostic Battery
Charger with LCD Status Display
#54-3101-4
WARNING: Only use the battery
chargers listed above to charge the
battery packs listed above. Charging
any other batteries may damage the
charger and possibly cause serious
injury.
WARNING: Follow all safety rules
and warnings included with the battery
pack and charger purchased for use
with this tool. Failure to follow those
safety rules and warnings may result in
serious injury or damage to the charger
and battery pack.
Never dispose of defective batteries with
your household waste. Always recycle
defective batteries in accordance with your
local municipal policies.
BATTERY AND
CHARGER SAFETY
!
!
!
SPECIFIC SAFETY RULES

9
V
Volts
A
Amperes
Hz
Hertz
W
Watts
kW
Kilowatts
Microfarads
L
Litres
kg
Kilograms
H
Hours
N/cm2
Newtons per square
centimetre
Pa
Pascals
Min
Minutes
S
Seconds
Alternating current
Three-phase alternating
current
Three-phase alternating
current with neutral
Direct current
No load speed
Alternating or direct
current
Class II construction
Splash-proof
construction
Watertight construction
Protective grounding at
grounding terminal,
Class I tools
Revolutions or
reciprocations per
minute
Diameter
Off position
Arrow
Warning symbol
SYMBOLS
WARNING: Some of the following symbols may appear on the cordless
reciprocating saw. Study these symbols and learn their meaning. Proper
interpretation of these symbols will allow for more efficient and safer
operation of this tool.
!
This symbol designates that this tool is
listed with Canadian requirements by ETL
Testing Laboratories, Inc.
Conforms to UL STD. 73
Certified to CAN/CSA STD. C22.2 No. 12
3042597
HOMOLOGUÉ

10
KNOW YOUR CORDLESS RECIPROCATING SAW
NOTE: Battery & Charger are NOT included and must
be purchased separately. Reciprocating saw is
compatible with all 18 V PowerXchange batteries.
Battery
pack
Battery release
button
Trigger
switch
Lock-off
button
Pivoting shoe
Hex key
(inside battery
cavity)
Pivoting shoe
adjusting screws
Tool free
blade holder
Rotating blade
head
Rotating blade
head locking
button
Speed control
wheel

11
AVAILABLE ACCESSORIES
WARNING: Use only saw blades
that are recommended for this cordless
reciprocating saw. Follow the
instructions that accompany the saw
blades. The use of improper saw blades
may result in injury to the operator or
damage to the reciprocating saw.
Before using any accessory, carefully read
the instructions or the owner’s manual for
the accessory.
Reciprocating saw blades
WARNING: If any part is missing or
damaged, do not install a battery in the
tool until the missing or damaged part is
replaced.
CONTENTS
Carefully unpack the cordless
reciprocating saw. Compare the contents
against the “RECIPROCATING SAW
COMPONENTS” chart below.
NOTE: See illustration of the cordless
reciprocating saw and components on
Page 12.
Battery packs and chargers must be
purchased separately.
●This reciprocating saw has been
designed to be powered by one of the
following battery packs:
●18 V Nickel-Cadmium #54-3102-2
●18 V Lithium-ion #54-3100-6
WARNING: Only use the battery
packs listed above to power this tool.
Using any other battery pack could
cause serious injury or damage the
tool.
Both battery packs can be charged using
one of the following chargers:
●14.4 V / 18 V LED Diagnostic Battery
Charger #54-3103-0
●14.4 V / 18 V LCD Diagnostic Battery
Charger with LCD Status Display
#54-3101-4
WARNING: Only use the battery
chargers listed above to charge the
battery packs listed above. Charging
any other batteries may damage the
charger and possibly cause serious
injury.
WARNING: Follow all safety rules
and warnings included with the battery
pack and charger purchased for use
with this tool. Failure to follow those
safety rules and warnings may result in
serious injury or damage to the charger
and battery pack.
ACCESSORIES AND CONTENTS
!
!
RECIPROCATING SAW
COMPONENTS
KEY
DESCRIPTION
QTY
A
Saw assembly
1
B
5/32" (4 mm)
hex key
1
C
Saw blade for
wood
1
Owner’s Manual
1
!
!
!

12
CONTENTS

13
INSTALLING A BATTERY IN THE
RECIPROCATING SAW
1. Remove the discharged battery (1)
from the tool by pressing on one the
battery release buttons (2) on the
sides of the tool handle (Fig. 1).
NOTE: There is one battery release button
on each side of the handle. It is only
necessary to press one of the buttons to
release the battery.
2. Pull the battery out of the tool handle
(3).
3. Slide the fully charged battery into the
matching cavity in the tool handle
where the discharged battery has
been removed.
NOTE: Make sure the battery is fully
engaged with the mounting slots in the tool
handle. The battery release buttons will
“click” into place when the battery is fully
installed.
WARNING: Do not immerse the
battery pack in water. Sudden cooling
could cause the hot battery to explode or
leak.
INSTALLING A BLADE
WARNING: Always remove the
battery before installing or removing a
blade or adjusting the saw in any way.
1. To install a blade in the saw, slide the
blade-locking sleeve inward (1)
(Fig. 2).
ASSEMBLY AND OPERATING
Fig. 1
!
!
Fig. 2

14
INSTALLING A BLADE –cont’d
2. Insert the appropriate blade (2) into
the blade slot (3) as far as it will go.
3. Release the blade-locking sleeve.
NOTE: The blade will automatically be
locked into the blade holder. Pull outward
on the blade to ensure it is properly locked
into the blade holder.
REMOVING A BLADE
To remove a blade, simply push inward on
the blade-locking sleeve and remove the
blade from the blade holder.
ADJUSTING THE PIVOTING SHOE
The pivoting shoe will pivot to follow the
angle of the blade to the workpiece. This
action ensures the flat surface of the shoe
is against the workpiece for better cutting
action and easier control of the saw.
The shoe can be adjusted in or out,
allowing the use of the blade teeth at
different points on the blade. This will
provide longer blade life as one section of
the blade becomes dull.
1. Remove 5/32" (4 mm) hex key (1)
from the battery cavity in the tool
handle (2) (Fig 3).
2. To adjust the pivoting shoe (3), loosen
the two pivoting shoe hex screws (4)
on the lower side of the saw using the
5/32" (4 mm) hex key (1) (Fig. 4).
3. Slide the pivoting shoe in or out until it
is in the appropriate position.
ASSEMBLY AND OPERATING
Fig. 2
Fig. 4
Fig. 3

15
4.
ADJUSTING THE PIVOTING SHOE - cont’d
5. Lock the pivoting shoe in place by
tightening the pivoting shoe hex
screws.
6. Pull outward on pivoting shoe to
ensure it is firmly locked in place.
VARIABLE SPEED CONTROL
Set the reciprocating saw speed by
rotating the variable speed control dial (1)
to the appropriate speed (Fig. 5). Position
the speed control dial at “1” for the slowest
speed, “3” for medium speed and at “6” for
the highest speed.
LOCK-OFF BUTTON
The lock-off button (1) is a safety device
designed to reduce the possibility of a user
accidentally starting the saw (Fig. 6). This
button must be pressed before the trigger
switch (2) can be squeezed.
NOTE: The lock-off button can be pressed
from either the left or right side of the
handle.
TRIGGER SWITCH
The trigger switch turns the reciprocating
saw ON and Off.
1. To turn the saw ON, press the lock-off
button with your thumb.
2. While holding the lock-off button in the
pressed position, squeeze the trigger
switch to start the saw.
ASSEMBLY AND OPERATING
Fig. 5
Fig. 6

16
TRIGGER SWITCH –cont’d
3. Once the saw starts, release the lock-
off button. The saw will remain
running until the trigger switch is
released.
4. To turn the saw OFF, release the
trigger switch.
NOTE: To re-start the saw, the lock-off
button must be pressed again before the
trigger switch is squeezed.
ADJUSTING THE ROTATING CUTTING
HEAD
The rotating cutting head can be set at 0°,
90°, 180° and 270° for easy cutting in any
direction. The 0° setting is the most
commonly used setting for vertical cutting.
To rotate the cutting head:
1. Pull back on the cutting head locking
button (1) (Fig. 7).
2. While holding the cutting head locking
button back, rotate the cutting head
(2) counter clockwise to the desired
position, then release the cutting head
locking button.
3. Slightly rotate the cutting head in both
directions until the cutting head locks
into position.
NOTE: Make sure the cutting head is firmly
locked into position before making any
cuts.
ASSEMBLY AND OPERATING
Fig. 7

17
MATERIALS YOU CAN CUT
This reciprocating saw is a versatile tool
that allows you to cut many different types
of materials. Some of these materials
include:
●Wood products such as lumber,
hardwood, plywood, composite board,
and panelling
●Drywall
●Fibre board and plastic
●Metals, such as pipe, steel rods, sheet
steel, aluminium, brass, and copper.
NOTE: There are many different types of
blades available. Generally, there are
metal cutting blades (fine teeth) and wood
cutting blades (coarse teeth). Use the
correct blade for your application. The
packaging on the blade will indicate the
type of materials each blade is designed to
cut.
ASSEMBLY AND OPERATING

18
GENERAL CUTTING
1. Clearly mark the workpiece to locate
the position of the cut.
2. Hold smaller workpieces with a vice.
Clamp larger workpieces to a
workbench or table.
DANGER: Any workpiece that is
not adequately clamped in place may
come loose and cause serious injury.
Never hold the workpiece with your
hand.
ASSEMBLY AND OPERATING
!
For safety reasons, the operator
must read the sections of this
Owner’s Manual entitled “GENERAL
SAFETY WARNINGS”, “POWER
TOOL SAFETY”, “SPECIFIC SAFETY
RULES”, “BATTERY AND CHARGER
SAFETY” and “SYMBOLS” before
using this cordless reciprocating
saw.
Verify the following every time the
cordless reciprocating saw is used:
1. The blade is sharp and in good
condition.
2. The blade is firmly clamped in
the blade holder.
3. The workpiece is properly
secured.
4. Safety glasses and hearing
protection are being worn.
Failure to observe these safety rules
will significantly increase the risk of
injury.
WARNING
!

19
GENERAL CUTTING –cont’d
3. Make sure there are no nails, screws,
clamps or foreign materials in the path
of the saw blade.
4. Hold the saw away from your body
and in front of you (Fig. 8).
5. With both hands firmly gripping the
saw, and with the blade NOT in
contact with the surface to be cut,
start the saw by pressing the lock-off
button and squeezing the trigger
switch.
6. Once the saw has reached the
desired speed, place the adjustable
pivoting shoe against the workpiece
and gradually bring the moving blade
into contact with the workpiece at the
appropriate location.
CAUTION: Do not force the saw.
Use only enough force to keep the
blade cutting. Excessive pressure on
the blade will cause it to bend and twist,
which may result in breaking the blade.
PLUNGE CUTTING
1. Clearly mark the workpiece to locate
the position of the cut.
2. Clamp the workpiece to a workbench
or table (Fig. 9).
NOTE: Make sure the area to be cut is
clear under the workpiece so that the
blade will not come into contact with
anything other than the workpiece.
3. Select a convenient starting point in
the area to be cut out. Place the tip of
the blade over that point.
!
ASSEMBLY AND OPERATING
Fig. 8
Fig. 9

20
PLUNGE CUTTING –cont’d
4. Rest the lower edge of the adjustable
pivoting shoe on the workpiece and
hold it firmly in that position,
maintaining a shallow cutting angle.
5. Press the lock-off button and squeeze
the trigger switch to start the saw.
WARNING: Make sure the blade
does not touch the workpiece until the
saw reaches full speed. Loss of control
and possible injury could result.
6. With the saw running at full speed,
slowly tilt the saw until the tip of the
blade contacts the workpiece and
begins to cut. After the blade cuts
through the workpiece, tilt the saw
upward until the blade is
perpendicular to the workpiece.
METAL CUTTING
Metals such as pipe, steel rods, sheet
steel, aluminium, brass and copper can be
cut with your reciprocating saw (Fig. 10).
●To cut thin sheet material, “sandwich”
the material between hardboard or
plywood and clamp the layers to limit
vibration and material tearing.
●Always use a fine toothed metal
cutting blade and run the saw at
medium speeds when cutting metal.
●Use cutting oil to keep the blade cool,
increase cutting action, and prolong
the life of the blade.
●Do not twist or bend the saw blade.
!
ASSEMBLY AND OPERATING
Fig. 10
Fig. 9