Chicago Electric 90541 User manual

CORDLESS SHEAR
18 VOLT
Model 90541
OPERATING INSTRUCTIONS
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our Web site at: http://www.harborfreight.com
Copyright 2003 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, please call 1-800-444-3353.
®

PRODUCT SPECIFICATIONS
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures, parts list and as-
sembly diagram. Keep your invoice with this manual. Write the invoice number
on the inside of the front cover. Keep this manual and invoice in a safe and dry
place for future reference.
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 injury.
SAVE THESE INSTRUCTIONS
WORK AREA
1. Keep your work area clean and well lit. Cluttered benches and dark areas
invite accidents.
2. 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.
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(Rechargeable)

3. Keep bystanders, children, and visitors away while operating a power tool.
Distractions can cause you to lose control. Protect others in the work area from
debris such as chips and sparks. Provide barriers or shields as needed.
ELECTRICAL SAFETY
4. Grounded tools must be plugged into an outlet properly installed and
grounded in accordance with all codes and ordinances. Never remove the
grounding prong or modify the plug in any way. Do not use any adapter
plugs. Check with a qualified electrician if you are in doubt as to whether
the outlet is properly grounded. If the tools should electrically malfunction or
break down, grounding provides a low resistance path to carry electricity away
from the user.
5. Double insulated tools are equipped with a polarized plug (one blade is
wider than the other). This plug will fit in a polarized outlet only one way. If
the plug does not fit fully in the outlet, reverse the plug. If it still does not
fit, contact a qualified electrician to install a polarized outlet. Do not
change the plug in any way. Double insulation eliminates the need for the
three wire grounded power cord and grounded power supply system.
6. Avoid body contact with grounded surfaces such as pipes, radiators,
ranges, and refrigerators. There is an increased risk of electric shock if your
body is grounded.
7. Do not expose power tools to rain or wet conditions. Water entering a power
tool will increase the risk of electric shock.
8. Do not abuse the Power Cord. Never use the Power Cord to carry the tools
or pull the Plug from an outlet. Keep the Power Cord away from heat, oil,
sharp edges, or moving parts. Replace damaged Power Cords immedi-
ately. Damaged Power Cords increase the risk of electric shock.
9. When operating a power tool outside, use an outdoor extension cord
marked “W-A” or “W”. These extension cords are rated for outdoor use, and
reduce the risk of electric shock.
PERSONAL SAFETY
10. Stay alert. Watch what you are doing, and use common sense when oper-
ating a power tool. Do not use a power tool while tired or under the influ-
ence of drugs, alcohol, or medication. A moment of inattention while operat-
ing power tools may result in serious personal injury.
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11. Dress properly. Do not wear loose clothing or jewelry. Contain long hair.
Keep your hair and clothing away from moving parts. Loose clothes, jewelry,
or long hair can be caught in moving parts. Wear heavy duty, leather, work
gloves when handling workpieces with sharp edges.
12. Avoid accidental starting. Be sure the Power Switch is off before plugging
in. Carrying power tools with your finger on the Power Switch, or plugging in
power tools with the Power Switch on, invites accidents.
13. Remove adjusting keys or wrenches before turning the power tool on. A
wrench or a key that is left attached to a rotating part of the power tool may result
in personal injury.
14. Do not overreach. Keep proper footing and balance at all times. Proper
footing and balance enables better control of the power tool in unexpected
situations.
15. Use safety equipment. Always wear eye protection. Dust mask, non-skid
safety shoes, hard hat, or hearing protection must be used for appropriate
conditions.
TOOL USE AND CARE
16. Use clamps (not included) or other practical ways to secure and support
the workpiece to a stable platform. Holding the work by hand or against your
body is unstable and may lead to loss of control.
17. Do not force the tool. Use the correct tool for your application. The correct
tool will do the job better and safer at the rate for which it is designed.
18. Do not use the power tool if the Power Switch does not turn it on or off.
Any tool that cannot be controlled with the Power Switch is dangerous and must
be replaced.
19. Disconnect the Power Cord Plug from the power source before making any
adjustments, changing accessories, or storing the tool. Such preventive
safety measures reduce the risk of starting the tool accidentally.
20. Store idle tools out of reach of children and other untrained persons. Tools
are dangerous in the hands of untrained users.
21. Maintain tools with care. Keep cutting tools sharp and clean. Properly
maintained tools with a sharp cutting edge are less likely to bind and are easier
to control. Do not use a damaged tool. Tag damaged tools “Do not use” until
repaired.
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22. Check for misalignment or binding of moving parts, breakage of parts, and
any other condition that may affect the tool’s operation. If damaged, have
the tool serviced before using. Many accidents are caused by poorly main-
tained tools.
23. Use only accessories that are recommended by the manufacturer for your
model. Accessories that may be suitable for one tool may become hazardous
when used on another tool.
SERVICE
24. Tool service must be performed only by qualified repair personnel. Service
or maintenance performed by unqualified personnel could result in a risk of injury.
25. When servicing a tool, use only identical replacement parts. Follow
instructions in the “Inspection, Maintenance, And Cleaning” section of this
manual. Use of unauthorized parts or failure to follow maintenance instructions
may create a risk of electric shock or injury.
SPECIFIC SAFETY RULES
1. Maintain a safe working environment. Keep the work area well lit. Make sure
there is adequate surrounding workspace. Always keep the work area free of
obstructions, grease, oil, trash, and other debris. Do not use the Cordless Shear
in areas near flammable chemicals, dusts, and vapors. Do not use this product
in a damp or wet location.
2. Maintain labels and nameplates on the Cordless Shear. These carry
important information. If unreadable or missing, contact Harbor Freight Tools for
a replacement.
3. When using the Cordless Shear, always maintain a firm grip on the tool
with both hands.
4. Hold the tool by its insulated gripping surfaces when performing an opera-
tion where the Cordless Shear may contact hidden wiring. Contact with a
“live” wire will make exposed metal parts of the Cordless Shear “live” and shock
the operator.
5. Do not use the Cordless Shear or Charger (part #38) if it has been dropped,
damaged, left outdoors, or immersed in liquid.
SKU 90541 PAGE 5
6. To avoid electrical shock, do not pull or carry the Charger (part #38) by its
Power Cord or pull the Power Cord around sharp corners or edges. Do not
unplug the Charger by pulling on the Power Cord. Keep the Power Cord away
from heated surfaces.

7. To avoid electrical shock, do not handle the Charger (part #38), its Power
Cord Plug, or the Cordless Shear with wet hands.
8. Keep the Handle of the Cordless Shear dry, clean, free from oil and
grease.
9. Avoid unintentional starting. Make sure you are prepared to begin work
before turning on the Cordless Shear.
10. Never leave the Charger (part #38) unattended when it is plugged into an
electrical outlet. Make sure to unplug it from its electrical outlet before leaving.
11. Always turn off the Cordless Shear and unplug the Charger (part #38) from
its electrical outlet before changing accessories or performing any inspec-
tion, maintenance, or cleaning procedures.
12. PROPER BATTERY PACK CARE: Battery Pack (part #36) leakage may occur
under extreme usage or temperature conditions. If Battery Pack fluid comes in
contact with skin, wash with soap and water and rinse with lemon juice and
vinegar. If the fluid comes into contact with the eyes, flush with water for several
minutes and contact a doctor immediately. Never burn the Battery Pack, as it can
explode in a fire. Do not charge the Cordless Shear with a leaking Battery Pack.
Contact local solid waste authorities for instructions on correct disposal or
recycling of the Battery Pack.
Note: Always switch to a fresh battery when tool performance begins to
diminish. Severe heat is most destructive to a battery; the more heat
generated, the faster the battery loses power. A battery that gets too hot can be
permanently damaged. Never over-discharge a battery by using the tool even
after tool performance is decreasing. Never attempt to discharge a tool’s battery
by continuing to pull the tool trigger. When tool performance begins to
diminish, stop the tool, re-charge the battery and use the fresh battery for
optimal performance.
13. Use eye and hearing protection. Always wear ANSI approved safety impact
eye goggles and hearing protectors when using this product.
14. Do not allow children to use or play with this product.
15. Keep hands and fingers away from the Blades (parts #4, #5, #6) at all times.
If both hands are holding the Cordless Shear by its Handle (parts #2, #34), they
cannot be cut by the Blades.
16. Feed the Cordless Shear gradually into the workpiece. Do not attempt to
force the Shear to remove material faster than it was designed to cut.
17. Secure the workpiece. Whenever possible, secure the workpiece with a vise or
clamps (not included).
SKU 90541 PAGE 6

21. Do not overreach. Keep proper footing and balance at all times. Do not reach
over or across a running Cordless Shear .
22. Industrial applications must follow OSHA requirements.
23. Maintain this product with care. Keep this product clean, dry, and its Blades
(parts #4, #5, #6) sharp for better and safer performance.
24. Maintenance: For your safety, service and maintenance should be performed
regularly by a qualified technician.
25. Check for damaged parts. Before using this product, carefully check that it will
operate properly and perform its intended function. Check for damaged parts
and any other conditions that may affect the operation of this product. Replace
or repair damaged or worn parts immediately.
26. Replacement parts and accessories: When servicing, use only identical re-
placement parts. Only use accessories intended for use with this product.
27. Use the right tool or attachment for the job. Do not attempt to force a small
tool or attachment to do the work of a larger industrial tool or attachment.
There are certain applications for which this product was designed. It will do the
job better and more safely at the rate for which it was intended. Do not modify
this product.
20. Dress properly. Do not wear loose clothing or jewelry as they can be caught in
moving parts. Wear restrictive hair covering to contain long hair.
18. Store idle equipment. When not in use, tools and equipment should be stored
in a dry location to inhibit rust. Always lock up tools and equipment, and keep out
of reach of children.
19. Do not use this product if under the influence of alcohol or drugs. Read
warning labels on prescriptions to determine if your judgement or reflexes are
impaired while taking drugs. If there is any doubt, do not attempt to use this
product.
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29. WARNING! People with pacemakers should consult their physician(s)
before using this product. Operation of electrical equipment in close proximity to
a heart pacemaker could cause interference or failure of the pacemaker.
28. WARNING! The warnings, precautions, and instructions discussed in this
manual cannot cover all possible conditions and situations that may occur. The
operator must understand that common sense and caution are factors which
cannot be built into this product, but must be supplied by the operator.
Some dust created by power sanding, sawing, grinding, drilling, and other
construction activities, contain chemicals known [to the State of California] to cause cancer, birth defects
or other reproductive harm. Some examples of these chemicals are: A) Lead from lead-based paints, B)
Crystalline silica from bricks and cement or other masonry products, C) 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 filter out microscopic
particles. (California Health & Safety Code 25249.5, et seq. )
WARNING!

GROUNDING
WARNING!
Improperly connecting the grounding wire can result in the risk of electric
shock. Check with a qualfified 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 fit the outlet, have a proper
outlet installed by a qualified electrician.
GROUNDED TOOLS: TOOLS WITH THREE PRONG PLUGS
1. Tools marked with “Grounding Required” have a three wire cord and three prong
grounding plug. The plug must be connected to a properly grounded outlet. If
the tool should electrically malfunction or break down, grounding provides a low
resistance path to carry electricity away from the user, reducing the risk of elec-
tric shock. (See Figure A.)
2. The grounding prong in the plug is connected through the green wire inside the
cord to the grounding system in the tool. The green wire in the cord must be the
only wire connected to the tool’s grounding system and must never be attached
to an electrically “live” terminal. (See Figure A.)
3. Your tool must be plugged into an appropriate outlet, properly installed and
grounded in accordance with all codes and ordinances. The plug and outlet
should look like those in the following illustration. (See Figure A.)
FIGURE A
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FIGURE B
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DOUBLE INSULATED TOOLS: TOOLS WITH TWO PRONG PLUGS
4. Tools marked “Double Insulated” do not require grounding. They have a special
double insulation system which satisfies OSHA requirements and complies with
the applicable standards of Underwriters Laboratories, Inc., the Canadian
Standard Association, and the National Electrical Code. (See Figure B.)
5. Double insulated tools may be used in either of the 120 volt outlets shown in the
following illustration. (See Figure B.)
EXTENSION CORDS
1. Grounded tools require a three wire extension cord. Double Insulated tools
can use either a two or three wire extension cord.
2. As the distance from the supply outlet increases, you must use a heavier gauge
extension cord. Using extension cords with inadequately sized wire causes a
serious drop in voltage, resulting in loss of power and possible tool damage.
(See Figure C, next page.)
3. The smaller the gauge number of the wire, the greater the capacity of the cord.
For example, a 14 gauge cord can carry a higher current than a 16 gauge cord.
(See Figure C.)
4. When using more than one extension cord to make up the total length, make
sure each cord contains at least the minimum wire size required.
(See Figure C.)
5. If you are using one extension cord for more than one tool, add the nameplate
amperes and use the sum to determine the required minimum cord size.
(See Figure C.)

6. If you are using an extension cord outdoors, make sure it is marked with the
suffix “W-A” (“W” in Canada) to indicate it is acceptable for outdoor use.
7. Make sure your extension cord is properly wired and in good electrical condition.
Always replace a damaged extension cord or have it repaired by a qualified
electrician before using it.
8. Protect your extension cords from sharp objects, excessive heat, and damp or
wet areas.
SKU 90541 PAGE 10
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS*
(120 VOLT)
NAMEPLATE
AMPERES
(
At Full Load
)
EXTENSION CORD LENGTH
25
Feet 50 Feet 75 Feet 100 Feet 150 Feet
0 – 2.0 18 18 18 18 16
2.1 – 3.4 18 18 18 16 14
3.5 – 5.0 18 18 16 14 12
5.1 – 7.0 18 16 14 12 12
7.1 – 12.0 18 14 12 10 -
12.1 – 16.0 14 12 10 - -
16.1 – 20.0 12 10 - - -
* Based on limiting the line voltage drop
to five volts at 150% of the rated amperes.
FIGURE C
SYMBOLOGY
Double Insulated
Canadian Standards
Association
Underwriters
Laboratories, Inc.
Volts Alternating Current
Amperes
No Load Revolutions
per Minute (RPM)
noxxxx/min.
A
V ~

UNPACKING
When unpacking, check to make sure all the parts shown on the Parts List on page 14
are included. 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.
PRODUCT FEATURES
NOTE: For additional information regarding the parts listed in the following pages, refer
to the Assembly Diagram on page 15.
1. WARNING! Always make sure the Trigger Switch (part #35) of the
Cordless Shear is in its “OFF” position, the Battery Pack (part #36) is removed
from the Cordless Shear, and the Charger (part #38) is unplugged from its electri-
cal outlet prior to making any adjustments to the tool. (See Figure D.)
SKU 90541 PAGE 11
FIGURE D
CENTER BLADE (#4)
RIGHT BLADE (#5)
LEFT BLADE (#6)
TRIGGER SWITCH
(#35)
BATTERY PACK
(#36)
2. TheTrigger Switch is operated manually simply by squeezing theTrigger Switch to
turn on the Cordless Drill and releasing pressure on the Trigger Switch to turn off
the Cordless Shear. (See Figure D.)
3. To power the Cordless Shear, simply insert the Battery Pack (part #36) upward
into the Handle (parts #2, #34) of the tool. (See Figure D.)
4. The Cordless Shear features a Center Blade (part #4), a Right Blade (part #5),
and a Left Blade (part #6). (See Figure D.)
HANDLE
(#2, #34)

SKU 90541 PAGE 12
TO CHARGE THE CORDLESS SHEAR
1. NOTE: The Battery Pack (part #36) requires charging. The first charge requires
5 hours charge time prior to using the Cordless Shear
(See Figure E.)
2. The Battery Pack (part #36) should only be re-charged when the Cordless Shear
begins to run slowly. (See Figure E.)
3. When the Battery Pack (part #36) requires re-charging, a 3 to 5 hour charge
allows the tool to operate at full power. Do not re-charge the Battery Pack longer
than 5hours, as damage to the Battery Pack and/or Cordless Shear will occur.
(See Figure E.)
4. Make sure the Trigger Switch (part #35) on the Cordless Shear is in its “OFF”
position. Slide the Battery Pack (part #36) into the Handle of the Cordless Shear.
Next, plug the Charger Plug into the Charging Socket of the Battery Pack. Then,
plug the Charger (part #38) into the nearest 120 volt, grounded, electrical outlet.
(See Figure E.)
5. A Charging Indicator Light on the Battery Pack (part #36) will illuminate to show
that charging is taking place. NOTE: The Charger (part #38) will not automati-
cally turn off when the Battery Pack is fully charged, and the Charging Indicator
Light will remain on until the Charger is disconnected from the electrical outlet.
Re-charging the Battery Pack more than 5 hours can cause damage to the
battery cells. (See Figure E.)
6. While charging, the Battery Pack (part #36) and Charger (part #38) may
become warm to the touch. This is normal, and does not indicate a problem.
(See Figure E.)
7. Once the Battery Pack (part #36) is fully charged, disconnect the Charger
(part #38) from the electrical outlet. Then, disconnect the Charger Plug from the
Battery Pack. (See Figure E.)
120 VOLT
GROUNDED
ELECTRICAL
OUTLET
CHARGER
(#38)
CHARGER
CORD
CHARGER
PLUG
BATTERY
PACK
(#36)
FIGURE E

OPERATING INSTRUCTIONS
1. WARNING! Always keep fingers and hands away from the Blades
(parts #4, #5, #6). Keep spectators away from the work area while using
this tool.
2. Make sure the workpiece is supported at all times. Whenever possible, secure
the workpiece in a vise or with clamps (not included). If necessary, use a roller
stand (not included) with larger workpieces.
3. Insert the fully charged Battery Pack (part #36) into the Handle of the Cordless
Shear.
4. Make sure to hold the Cordless Shear firmly with both hands, as torque from the
Motor will cause the tool to twist.
SKU 90541 PAGE 13
5. Make sure the workpiece is free from screws, rivets, and any other foreign ob-
jects which could damage the Blades (parts #4, #5, #6).
6. Before trying new or complicated cutting techniques, study the procedure and
practice with scrap metal.
7. Firmly grip the Handle (parts #2, #34) of the Cordless Shear with both hands.
Squeeze the Trigger Switch (part #35) to turn on the Cordless Shear.
8. Allow the Blades (parts #4, #5, #6) to move at full speed before feeding the
Cordless Shear into the workpiece.
9. Make straight cuts and wide angle cuts only. Do not attempt to twist the Cordless
Shear to the right or left while cutting. If this occurs, the Blades (parts #4, #5, #6)
will “bind” in the workpiece causing potential personal injury, and/or damage to
the workpiece and Cordless Shear.
10. Do not force the Cordless Shear to remove material faster than it was designed
to cut. Make sure to feed the Blades (parts #4, #5, #6)
gradually into the
workpiece.
11. Turn off the Cordless Shear if its Blades (parts #4, #5, #6) are to be backed out
of an uncompleted cut. When turning off the Cordless Shear, allow the Blades to
fully stop on their own before removing the Cordless Shear. Do not press against
the Blades to stop the tool.
12. Once the cutting job is completed, turn off the Cordless Shear and wait until the
Blades (parts #4, #5, #6) have stopped moving. Then, remove the Battery Pack
(part #36) from the Cordless Shear.

INSPECTION, MAINTENANCE, AND CLEANING
1. WARNING! Always turn the Trigger Switch (part #35) to its “OFF” posi-
tion, and unplug the Charger (part #38) from its electrical outlet before
performing any inspection, maintenance, or cleaning.
2. BEFORE EACH USE, inspect the general condition of the Cordless Shear.
Check for misalignment or binding of moving parts, cracked or broken parts,
leaking Battery Pack, damaged Charger wiring, chipped or broken Blades, and
any other condition that may affect its safe operation. If abnormal noise or vibra-
tion occurs, have the problem corrected before further use.
Do not use damaged equipment.
3. DAILY: With a soft brush or cloth, remove all dirt and debris from the Cordless
Shear. Do not immerse the Cordless Shear in any liquids.
SKU 90541 PAGE 14
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PARTS LIST

SKU 90541 PAGE 15
NOTE: Some parts are listed and shown for illustration purposes only, and are not
available individually as replacement parts.
ASSEMBLY DIAGRAM
PLEASE READ THE FOLLOWING CAREFULLY
THEMANUFACTURERAND/ORDISTRIBUTORHAS PROVIDEDTHEPARTS LISTAND
ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER
THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION ORWAR-
RANTY OF ANY KINDTOTHE BUYERTHAT HE OR SHE IS QUALIFIEDTO MAKE ANY
REPAIRS TOTHE PRODUCT, ORTHAT HE OR SHE IS QUALIFIEDTO REPLACE ANY
PARTS OF THE PRODUCT. IN FACT, THE MANUFACTUER 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 REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO,
OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS
THERETO.
1
2
3
456
789
10
11
12
13
14
15
16
17
18
19
20
21 22
23 24
25
26 27 28
29
30 31 32
33
34
35
36
37
38: CHARGER NOT SHOWN.