Chicago Electric 91618 User manual

®
ASSEMBLY AND OPERATING INSTRUCTIONS
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our Web site at: http://www.harborfreight.com
Copyright 2004 by Harbor FreightTools®. 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.
3 IN 1 MINI POWER TOOL SET
Model 91618

SKU 91618 For technical questions, please call 1-800-444-3353. Page 2
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.
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.
Voltage (all tools) 110 VAC / 15 VDC
Power (each tool) 30-45 Watts
Drill Speed 12,000 RPM
Collet Sizes 1/32”, 3/32”, 1/8”
Drill Dimensions 5” L x 1-1/4” Dia.
Sander Pad Dimensions 2-3/4” L x 2” W
Sander Speed 4,500 RPM
Sander Dimensions 5-1/2” L x 2” Dia.
Jig Saw Speed 4,500 SPM
Jig Saw Plate Dimensions 2-3/4” L x 3-1/4”W
Jig Saw Dimensions 5” L x 1-3/4” W
PRODUCT SPECIFICATIONS
Accessories: 3 Collets (1/32”, 3/32”, 1/8”), Jigsaw Clamp, AC/DC Transformer, 2 Sheets Hook & Loop
Sandpaper, 2 Jigsaw Blades, 1 Hex Wrench, 2 Drill Bits, 2 Diamond Bits, 2 Grinding Stones

SKU 91618 For technical questions, please call 1-800-444-3353. Page 3
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.
11. Dress properly. Do not wear loose clothing or jewelry. Contain long hair.
Keep your hair, clothing, and gloves away from moving parts. Loose
clothes, jewelry, or long hair can be caught in moving parts.

SKU 91618 For technical questions, please call 1-800-444-3353. Page 4
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 ANSI approved eye protection. Dust
mask, non-skid safety shoes, work gloves, 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.
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.

SKU 91618 For technical questions, please call 1-800-444-3353. Page 5
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.
GROUNDING
WARNING!
Improperly connecting the grounding wire can result in the risk of electric
shock. Check with a qualified 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, next page.)
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, next page.)

SKU 91618 For technical questions, please call 1-800-444-3353. Page 6
FIGURE A
FIGURE B
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

SKU 91618 For technical questions, please call 1-800-444-3353. Page 7
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.
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 16 16 16
2.1 - 3.4 18 18 16 14 14
3.5 - 5.0 18 18 16 14 12
5.1 - 7.0 18 16 14 12 12
7.1 - 12.0 16 14 12 10 -
12.1 - 16.0 14 12 10 - -
16.1 - 20.0 12 10 - - -
FIGURE C *Based on limiting the line voltage drop
to five volts at 150% of the rated amperes.

SKU 91618 For technical questions, please call 1-800-444-3353. Page 8
SYMBOLOGY
SPECIFIC SAFETY RULES
1. Maintain labels and nameplates on the Tools. These carry important informa-
tion. If unreadable or missing, contact Harbor Freight Tools for a replacement.
2. Maintain a safe working environment. Make sure there is adequate surrounding
workspace. Always keep the work area free of obstructions, grease, oil, trash, and
other debris.
3. Never leave theTools unattended when plugged into an electrical outlet. Turn
off the tools, and unplug them from the electrical outlet before leaving. Make sure
you are prepared to begin work before turning on a PowerTool.
4. Always unplug the Tools from the electrical outlet before performing any in-
spection, maintenance, or cleaning procedures.
5. WARNING! The brass components of this product contain lead, a chemical
known to the State of California to cause birth defects (or other reproductive harm).
(California Health & Safety code 25249.5, et seq.)
6. WARNING! Some dust created by power sanding, sawing, grinding, drilling,
and other construction activities, contain chemicals known (to the State of Califor-
nia) 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 cement 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 filter out microscopic particles.
(California Health & Safety Code 25249.5, et seq.)
7. WARNING! People with pacemakers should consult their physician(s) before
using this product. Electromagnetic fields in close proximity to a heart pace-
maker could cause interference to or failure of the pacemaker.
Double Insulated
Canadian Standards
Association
Underwriters
Laboratories, Inc.
Volts Alternating Current
Amperes
No Load Revolutions
per Minute (RPM)
noxxxx/min.
A
V ~

SKU 91618 For technical questions, please call 1-800-444-3353. Page 9
UNPACKING
When unpacking, check to make sure all the parts shown on the Parts Lists on pages 14,
16, and 18 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.
DRILL ASSEMBLY INSTRUCTIONS
NOTE: For additional information regarding the parts listed in the following pages, refer
to the Assembly Diagram on page 15.
CAUTION: Always make sure the Power Cord of the Drill is unplugged from its
electrical outlet
prior to making any adjustments to the tool.
Changing a Drill Collet
Press the Lock Button (14) and fully unscrew the Collet Nut (1d). Remove the
current Collet (2d) and replace with another Collet (2d). Depress the Lock Button
(14) again, replace the Collet Nut (1d), and tighten slightly. See FIGURE 1.
FIGURE 1
Lock
Button (14)
Collet (2d)
Collet Nut (1d)
Collet Nut (1d)
Collet Nut (1d)
FIGURE 2 FIGURE 3
Switch(11d)
Attaching a Drill Bit
Press the Lock Button (14) and loosen the Collet Nut (1d). Insert the bit (not
included) all the way into the Collet. Depress the Lock Button (14) again and
tighten the Collet Nut (1d). See FIGURE 2.
Warning!! Never use cracked, bent, or chipped bits.They may break, causing the
operator injury.

SKU 91618 For technical questions, please call 1-800-444-3353. Page 10
Note: TheTransformer is not shown on any of the parts lists or assembly draw-
ings.
DRILL OPERATING INSTRUCTIONS
Operating the Drill
Note: First, determine which application you will be using the Drill for, and then attach
the appropriate accessory by following the instructions on page 9.
Warning! Always make sure the Switch (11d) is OFF before plugging in the unit.
1. Plug the Drill into the Transformer and the Transformer into a power outlet as
shown in FIGURES 4 and 5, below.
2. Make sure your workpiece is secured in a vise or clamp.
3. Turn on the Switch (11d). See FIGURE 3 on page 9.
4. After completing your task, turn off the Drill and unplug the unit from the Trans-
former. Unplug the Transformer from the wall outlet.
FIGURE 4
FIGURE 5
Transformer
From Tool
To Transformer
To Power Outlet
Connect Tool Here
Power Connection For All Three Tools
Close-up of Connection
Transformer