Chicago Electric 92880 Installation manual

9.6V CORDLESS
ROTARY TOOL KIT
Model 92880
SET UP AND OPERATING INSTRUCTIONS
Diagrams within this manual may not be drawn proportionally.
Due to continuing improvements, actual product may differ slightly from the product described herein.
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Copyright©2005 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 or replacement parts, please call 1-800-444-3353.
Cover revised 07j

SKU 92880 For technical questions please call 1-800-444-3353 Page 2
Specications
Construction
High-Impact Plastic Housing
Brass Spindle & Collets
Stainless Chuck Body
Power Required 9.6 VDC / NiCd Battery Pack
Battery Recharge 120 VAC to 12 VDC transformer
Tool Speed Variable:
3,600 - 25,000 RPM
LED Source (2) CR-927 3 VDC batteries
Features Variable Speed,
LED Light Attachment
Save This Manual
You will need the manual for the safety warnings and precautions, assembly
instructions, operating and maintenance procedures, parts list and diagram. Keep
your invoice with this manual. Write the invoice number on the inside of the front
cover. Keep the manual and invoice in a safe and dry place for future reference.
Safety Warnings and Precautions
WARNING: When using tool, basic safety precautions should always be
followed to reduce the risk of personal injury and damage to equipment.
Read all instructions before using this tool!
1. Keep work area clean. Cluttered areas invite injuries.
2. Observe work area conditions. Do not use machines or power tools in
damp or wet locations. Don’t expose to rain. Keep work area well lit. Do
not use electrically powered tools in the presence of ammable gases or
liquids.
3. Keep children away. Children must never be allowed in the work area. Do
not let them handle machines, tools, or extension cords.
4. Store idle equipment. When not in use, tools must be stored in a dry
location to inhibit rust. Always lock up tools and keep out of reach of
children.
5. Use the right tool for the job. Do not attempt to force a small tool or
attachment to do the work of a larger industrial tool. There are certain
applications for which this tool was designed. It will do the job better
and more safely at the rate for which it was intended. Do not modify this
tool and do not use this tool for a purpose for which it was not intended.
6. Dress properly. Do not wear loose clothing or jewelry as they can be
caught in moving parts. Protective, electrically non-conductive clothes and
non-skid footwear are recommended when working. Wear restrictive hair
covering to contain long hair.
7. Use eye and ear protection. Always wear ANSI approved impact safety
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SKU 92880 For technical questions please call 1-800-444-3353 Page 3
goggles. Wear a full face shield if you are producing metal lings or wood
chips. Wear an ANSI approved dust mask or respirator when working around
metal, wood, and chemical dusts and mists.
8. Do not overreach. Keep proper footing and balance at all times. Do not
reach over or across running machines.
9. Maintain tools with care. Keep tools sharp and clean for better and safer
performance. Follow instructions for lubricating and changing accessories.
Inspect tool cords periodically and, if damaged, have them repaired by an
authorized technician. The handles must be kept clean, dry, and free from oil
and grease at all times.
10. Disconnect power. Unplug battery from tool and charger/transformer from
power outlet when not in use.
11. Remove adjusting keys and wrenches. Check that keys and adjusting
wrenches are removed from the tool or machine work surface before plugging it
in.
12. Avoid unintentional starting. Be sure the switch is in the Off position when
not in use and before plugging in. Do not carry any tool with your hand on
the power switch, whether it is energized or not.
13. Stay alert. Watch what you are doing, use common sense. Do not operate
any tool when you are tired.
14. Take caution as some woods contain preservatives such as copper
chromium arsenate (CCA) which can be toxic. When cutting these
materials extra care should be taken to avoid inhalation and minimize skin
contact.
15. Check for damaged parts. Before using any tool, any part that appears
damaged should be carefully checked to determine that it will operate
properly and perform its intended function. Check for alignment and binding
of moving parts; any broken parts or mounting xtures; and any other
condition that may affect proper operation. Any part that is damaged should
be properly repaired or replaced by a qualied technician. Do not use the
tool if any switch does not turn On and Off properly.
16. Guard against electric shock. Prevent body contact with grounded
surfaces such as pipes, radiators, ranges, and refrigerator enclosures.
17. Replacement parts and accessories. When servicing, use only identical
replacement parts. Use of any other parts will void the warranty. Only use
accessories intended for use with this tool. Approved accessories are
available from Harbor Freight Tools.

SKU 92880 For technical questions please call 1-800-444-3353 Page 4
18. Do not operate tool if under the inuence of alcohol or drugs. Read
warning labels on prescriptions to determine if your judgment or reexes are
impaired while taking drugs. If there is any doubt, do not operate the tool.
19. Use proper size and type extension cord. If an extension cord is required,
it must be of the proper size and type to supply the correct current to the
charger without heating up. Otherwise, the extension cord could melt and
catch re, or cause electrical damage to the transformer or battery charger.
This item requires use of an extension cord of 0 to 10 amps capability (up
to 50 feet), with wire size rated at 18 AWG. Longer extension cords require
larger size wire. If you are using the products outdoors, use an extension
cord rated for outdoor use (signied by “WA” on the jacket).
20. Maintenance. For your safety, service and maintenance should be
performed regularly by a qualied technician.
21. Pacemaker safety warning. People with pacemakers should consult with
their physician(s) before using this product; operation of equipment in close
proximity to a heart pacemaker could cause interference or failure of the
pacemaker.
22. 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.)
23. WARNING: 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:
Lead from lead-based paints
Crystalline silica from bricks and cement or other masonry products
Arsenic and chromium from chemically treated lumber
(California Health & Safety Code 25249.5, et seq. )
WARNING: Keep this tool and its attachments out of reach of children.
Small parts can easily be swallowed by children.
Note: Performance of the transformer and battery charger may vary depending
on variations in local line voltage. Extension cord usage may also affect tool
performance.
Warning: The warnings, cautions, and instructions discussed in this instruction
manual cannot cover all possible conditions and situations that may occur.
It must be understood by the operator that common sense and caution are
factors which cannot be built into this product, but must be supplied by the
operator.

SKU 92880 For technical questions please call 1-800-444-3353 Page 5
Unpacking
When unpacking, check to make sure the following parts are included.
9.6V Rotary Tool with Battery
LED Light Attachment
AC/DC Transformer
9.6V Battery Charger Base
3- piece Cutoff Wheel Set
4-piece Sanding Drum Set
36-piece Sanding Disc Set
 2-pieceBufngWheelSet
2-piece Brass Collet Set
2-piece Drill Bit Set
10-piece Mounted Stone Set
2-piece Diamond Burr Set
Flat Wrench
Square Stone Dresser
Plastic Carrying Case
If any parts are missing or broken,
please call Harbor Freight Tools at the
number on the cover of this manual.
Charging the Battery
Charging the Battery Pack:
1. Battery packs are normally shipped with low or no charge to prevent
potential problems during shipment. Before use, you must charge your new
battery pack. Note: Time to charge battery is approximately 3 to 3-1/2
hours.
NOTE: Batteries will not reach
full charge the rst time they are
charged. Allow several cycles
(operation followed by recharging)
before the battery will become
fully charged.
PHOTO: Rechargeable Battery
in Battery Charger Base which is
plugged into the Transformer.
Battery
Charger Base
Transformer
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SKU 92880 For technical questions please call 1-800-444-3353 Page 6
Battery Temperature Warning:
WARNING: Battery explosion may cause serious
personal or property injury including death. Charge the
battery only within a 50° to 100° temperature range.
Lower temperatures may inhibit charging. Higher
temperatures increase chance of battery failure,
including explosion.
2. Charge the battery pack only with the included
Charger Base (25). Use of other chargers may
cause battery failure including explosion.
3. Ensure that the Charger Base (25) is connected to
a circuit breaker protected 120 VAC, 60 Hz power
supply only.
4. Connect the Charger Base to the Transformer (24),
by plugging it in as shown in the photo. Plug the
Transformer (24) into a 120 VAC wall outlet.
5. Insert the battery pack into the Charger Base (25) by aligning the ribs on the
battery pack with the grooves in the battery pack. Press the battery pack into
place.
NOTE: The Battery has Release Tabs (19) on both sides. Press these in to
release the battery from the Rotary Tool or from the Battery Charger Base
(25).
6. Press down on the battery pack to make sure that the contacts on the
battery pack are fully engaged with the contacts in the charger unit.
7. While being charged, the green LED will be lit, indicating that the charger is
in operation. During recharging, the battery pack will become slightly warm
to the touch. This is normal and not a cause for concern.
8. Do not place the battery and charger in an environment of extreme heat or
cold. They will work best at room temperature.
9. Note: The Charger Base (25) will not shut off automatically. When the
battery is fully charged (after 3 to 3-1/2 hours), unplug the battery charger
and remove the battery pack. Do not leave the battery in the Charger Base
(25) indenitely.
REV 07h
Transformer (24)

SKU 92880 For technical questions please call 1-800-444-3353 Page 7
Installing the Battery Pack
1. Place the battery pack in the tool,
aligning the arrows on the battery
pack with the arrows on the tool.
2. Press the battery pack into the
tool. Make sure that the battery
pack snaps into place, and that the
battery pack is secure in the tool
before beginning use.
Removing the Battery Pack
1. Press the Release Tabs (19) on both sides of the battery pack to release the
battery from the tool.
2. Remove the battery pack from the tool by pulling straight out.
Inserting or removing a bit from the tool.
Note: Only use accessories that are rated at or above the RPM rating of the
Cordless Rotary Tool.
WARNING: Always allow the motor to come
to a complete stop before engaging the
spindle lock.
WARNING: Always remove the battery pack
before making any adjustments or changing
bits, to prevent accidental starting of the tool.
Accidental starting of the tool may result in
serious personal or property injury.
1. Depress the Spindle Lock (10). Rotate
collet until shaft is engaged by the lock.
2. Loosen the Collet Nut (1) by turning it
counterclockwise, using the Wrench
provided.
WARNING: If you are changing a bit immediately after use, be careful not to
touch the bit. It may be very hot from use, possibly causing injury. Allow the bit
time to cool before handling it.
3. To remove a bit: Pull the bit straight out of the Collet once the Collet Nut is
loose. To insert a bit: Insert the shank end if the bit into the Collet once the
Collet Nut is loose.
Spindle Lock (10)
Collet Nut (1)
Wrench

SKU 92880 For technical questions please call 1-800-444-3353 Page 8
NOTE: Your tool is provided with two collets, 1/8” and 1/4” diameter. These are
precision manufactured to t comparably sized bits. Do not force a bit into
the wrong sized collet, nor do not modify a mismatched collet or bit.
Severe personal or
property damage may
result from using
mismatched collets or
bits.
4. Tighten Collet Nut securely
using the provided wrench.
Ensure that the spindle lock
is released before turning on the tool.
WARNING: Be sure the Collet Nut is tight before turning on the tool. Bits may be
ejected from a tool if the Collet Nut is loose, potentially causing severe personal
or property damage.
Installing or Removing the LED Collar
1. The Front Collar (3) is interchangeable
with the LED Lighted Attachment (23).
To install the LED Lighted Attachment,
remove the standard collar by turning
counterclockwise, and install the LED
Lighted Attachment by turning clockwise.
2. When installing or removing, use only
hand pressure and tighten rmly by
hand. Do not overtighten, as this may
damage the part.
3. To change the batteries in the LED Lighted Attachment, rst remove it from
the Rotary Tool.
4. Using a phillips
screw driver, open the
battery compartment.
5. Replace the
batteries with the
same type as
originally installed
(Two CR-927 3 VDC
batteries). Be sure
to match the polarity
marking in the battery
compartment.
Collet size must match tool shaft diameter.
Collet Nut Collets
Battery

SKU 92880 For technical questions please call 1-800-444-3353 Page 9
Operation
1. Charge the Battery Pack (18) and insert it in the tool, as described in the
previous section.
2. Select an appropriate bit or attachment
for the job. Insert the bit or attachment as
described in the previous section.
3. The LED Lighted Collar may be turned on by
moving the switch on the collar.
4. Rotate the Switch (8) to the ON position.
NOTE: This is a variable speed switch. The
tool bit speed is dependent on the position
of the Switch. Use a speed appropriate to
the bit and the material being worked on.
In general harder materials require faster
speeds and softer materials require slower speeds. Relative speeds are
indicated by the numbers on the Switch.
5. Apply the tool bit to the work material as needed.
6. When the task has been completed, stop the tool by rotating the Switch (8) to the OFF
(“O”) position. If the LED Collar light is ON, switch it OFF. Unplug the rechargeable
battery. Remove the bit or attachment as discussed in the previous section.
7. Store the tool, its battery, and its bits and attachments in their case in a safe location.
8. Dispose of used batteries properly. Consult your local hazardous waste
authority for disposal guidelines.
Maintenance
1. A plastic storage case has been provided for safe storage of your Rotary
Tool and its bits, parts and accessories. Always store your tool and its
accessories in the case provided.
2. Protect the tool and its parts and accessories from moisture and damp or
corrosive atmospheres.
3. Keep this tool out of reach of children and other unauthorized persons.
4. Protect this tool from damage. Do not leave it in a place where it can be
banged around, such as a truck bed or vehicle trunk.
5. Some of the bits provided are “grinding bits” using stone abrasives. During
use, these may clog up with removed material or lose their shape. To clean
and reshape these bits, run them against the provided Dressing Stone. The
Dressing Stone will abrade away the clogging materials and will reshape the
Grinding Bits as appropriate.
Switch

SKU 92880 For technical questions please call 1-800-444-3353 Page 10
Parts List
Part Description Qty.
1 Collet Nut 1
2 Collet 1
3 Front Collar 1
4 Driver Shaft 1
5 Bearing 1
6 Sleeve 1
7 Motor 1
8 Switch 1
9 Shaft Lock Spring 1
10 Shaft Lock Button 1
11 Left Cover 1
12 Left Cover Label 1
13 Rubber Buffer 1
14 Right Cover 1
15 Screw 4
16 Right Cover Label 1
17 Battery Cover 1
18 Battery 1
19 Release Tab 2
20 Back - Moving Spring 2
21 End Cover 1
22 Hanger 1
23 LED Light Attachment 1
24 Transformer 1
25 Charger Base 1
Note: Some parts are listed and shown for illustration purposes only and are not available
individually as replacement parts.
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS
MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR
MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE
IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO
REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR
EXPRESSLY STATES THATALL 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.
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SKU 92880 For technical questions please call 1-800-444-3353 Page 11
Assembly Drawing
#23 LED Light Attachment (not shown)
#24 Transformer (not shown)
#25 Charger Base (not shown)