Drill Master 40056 User manual

14.4 VOL14.4 VOL
14.4 VOL14.4 VOL
14.4 VOLT CORDLESST CORDLESS
T CORDLESST CORDLESS
T CORDLESS
COMBO PACKCOMBO PACK
COMBO PACKCOMBO PACK
COMBO PACK
ASSEMBLY AND OPERATING INSTRUCTIONS
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our Web site at http://www.harborfreight.com
Copyright © 2002 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 and replacement parts, please call 1-800-444-3353
40056
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Specifications
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 tools, basic safety precautions should always be followed to
reduce the risk of personal injury and damage to equipment.
Read all instructions before using any of these tools!
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 lighted. Do not use electrically
powered tools in the presence of flammable 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. Do not force tool. It will do the job better and more safely at the rate for which it was
intended. Do not use inappropriate attachments in an attempt to exceed the tool
capacity. Caution: Always keep guards in place.
Circular Saw
Reciprocating Saw
Flashlight
Batteries
Accessories
0 550 RPM
3/8 inch keyless chuck
Variable speed Switch
Forward / Reverse Switch
6 torque settings
2400 RPM
Saw Blade Size 5-3/8”
1-1/2 inch cut depth at 90 degrees
1-1/4 inch cut depth at 45 degrees
Bevel: 50 degree
200 output watts
0-2800 SPM
Stroke: 7/8 inch
90 degree swivel head
Two 14.4 VDC batteries provided
120 VAC (input) 3 to 5 hour charging time,
1.3 amp/hour UL approved
Molded case for all items
Two reciprocating saw blades
Drill
Charger
≅≅
≅≅
≅
REV 11/02
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6. 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. Do not modify this tool and do not use this tool for a purpose for which it
was not intended.
7. 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.
8. Use eye and ear protection. Always wear ANSI approved impact safety goggles.
Wear a full face shield if you are producing metal filings or wood chips. Wear an ANSI
approved dust mask or respirator when working around metal, wood, and chemical
dusts and mists.
9. Do not overreach. Keep proper footing and balance at all times. Do not reach over or
across running machines.
10. 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.
11. Disconnect power. Unplug charger when not in use.
12. Remove adjusting keys and wrenches. Check that keys and adjusting wrenches
are removed from the tool or work surface before turning on.
13. Avoid unintentional starting. Be sure the switch is in the Off position when not in
use. Do not carry any tool with your finger on the trigger.
14. Stay alert. Watch what you are doing, use common sense. Do not operate any tool
when you are tired.
15. 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.
16. 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 fixtures; and any other condition that may affect proper operation. Any
part that is damaged should be properly repaired or replaced by a qualified
technician. Do not use the tool if any switch does not turn On and Off properly.
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.
18. Do not operate tool if under the influence of alcohol or drugs. Read warning
labels on prescriptions to determine if your judgment or reflexes are impaired while
taking drugs. If there is any doubt, do not operate the tool.
19. Maintenance. For your safety, service and maintenance should be performed
regularly by a qualified technician.
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Note: Performance of these tools (if powered by line voltage) 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 under-
stood by the operator that common sense and caution are factors which cannot be
built into this product, but must be supplied by the operator.
Unpacking
When unpacking, check to make sure that all the parts are included. Refer to the Specifications on
page 2. If any parts are missing or broken, please call Harbor Freight Tools at the number on the
cover of this manual as soon as possible.
Battery Precautions
1. Read all instructions and warnings on the battery before charging the battery.
2. To avoid accidents, charge the supplied battery only. Do not use a different charger
with this battery.
3. Do not expose the battery to rain or wet conditions.
4. To avoid damage of cable and plug, never pull the cable to
disconnect the charger.
5. Do not use the charger if the cable or plug are damaged.
6. Repairs should be carried out by a qualified technician only.
7. Do not touch the battery poles with any conductive source.
8. Do not store the battery in a box with other metal objects.
9. Do not throw the battery in a fire. Ni-Cd Battery must be
recycled or disposed of properly, in accord with all laws.
Charging Battery
The batteries do not come charged from the factory. Charge before using. Charging room tempera-
ture: 500 F - 1040F.
1. Insert the battery into the Charger (#21). The battery can only insert one way.
2. Plug the line cord into an electrical outlet.
3. Verify that the red charging indicator light comes on. If it does not come on, check the
power connection or try a different wall outlet.
4. Charge the battery initially for no more than 5 hours continuously. Chargers should not
be left plugged in or charging for more than 5 hours. Subsequent charges should only
take 3 hours. Allow charger to cool down before charging another battery.
5. After charging, unplug the Charger from the electrical outlet.
6. Insert the battery into the tool by pressing on the two side tabs while inserting.
Note: the operation time of a new battery will ramp up as it is properly used and recharged.
REV 05/02 REV 11/02 REV 10/03
.
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.
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Drill Operation
1. Insert a drill or screw bit into the Chuck (8). Securely tighten.
Turn the chuck counterclockwise to open, and clockwise to close while holding on to
the chuck sleeve. Use 3/8 inch bits or smaller to avoid damage to gears and motor.
2. Set the desired drill torque by turning the Torque Selector to setting 1 to 6.
The higher the number, the more the torque. Use # 6 for drilling, and the others for
driving. Do this when the drill if off.
3. Set the desired drill rotation by pressing the Rotation Switch (7) for drilling or driving;
Press Reverse for removing screws. Press Forward for drilling. Do this when the drill is
off.
4. Press the Trigger Switch (5) in to turn the drill on.
The harder you press, the faster the rotation.
Circular Saw Operation
Install saw blade. Prepare and secure the material to be cut before turning on saw. Battery
should have a full charge before using saw. Refer to illustrations that follow. Remove
battery before making any adjustments.
Warning: Do not hold tool by the handle while making adjustments as your fingers may
touch the Switch and Safe buttons and start the saw.
Installing Cutting Blade
1. Remove battery.
Disregard these steps if the saw blade is already installed.
2. Press on the stop button (17A) located on top of the saw to keep the saw blade from
moving while turning the nut bolt.
3. Using the hex key (48A), loosen and remove nut bolt (1A) and washer (2A).
4. Rotate movable guard (8A) clockwise to allow entry of blade.
Chuck (8)
Torque Selector
Rotation Switch (7)
Trigger Switch (5) The item numbers (in brackets)
can be found on the Drill
Assembly and Drill Parts List.
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5. Insert saw blade through the base with teeth facing forward (and up) until the center
holes of the saw blade and motor adapter (5A) align. (Notice the arrow on the movable
guard and the arrow on the saw blade, they should be pointing in the same direction.)
6. Replace washer (2A) and nut bolt (1). Tighten with hex key (48A) while pressing on the
stop button (1A7). Verify stop button is in the up (unlocked) position.
7. Replace key to its storage hole in the housing of the saw.
Adjusting The Saw Prior to Cutting
1. To adjust the angle of blade up to 50°, loosen knob (57A) and move base plate (50A)
down, observing the degrees indicated on the angle plate (53A). Tighten knob (57A).
2. To adjust the depth of the cut, loosen knob (43A, not visible) located behind motor
housing, and move base plate (50A) down while observing the amount of saw blade
exposed under base plate. Tight knob (43A).
Prepare Material Before Cutting
Refer to the illustrations on the next page.
1. Support large panels to be cut to minimize risk of blade pinching and saw kickback.
2. Use a rip fence or secured straight edge guide when ripping material.
3. Securely clamp material to be cut to work bench.
4. Make sure saw does not cut into supports or workbench.
5. Use the appropriate type of blade for the material you are cutting.
Knob (57A)
Angle Plate (53A)
Knob (#43A, not visible)
Battery (14A)
Base (50A)
Nut Bolt (1A)
Washer (2A)
Guard (9A)
Exhaust Hole
Movable Guard
(8A)
Hex Key (48A)
Safe Button (45A)
Switch Button (47A)
Stop Button (17A, not visible)
The item numbers (in brackets)
can be found on the Circular Saw
Assembly drawing and Parts List.
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Cutting
Warning: this tool can cause serious injury if not used properly. Read this entire manual
before using. Note: The moveable Guard (#8A) must be in place at all times.
Note: verify that saw blade is securely tightened and both angle and height adjusting knobs
are tight.
1. Secure rip fence or straight edge to the material to guide the saw on a straight path.
2. Place the saw base (50A) on material to be cut. Align the front notch (right edge
aligns with saw blade) on the cut line.
3. Pull the rear lock switch (safe button 45A) back with the middle finger and squeeze
the switch button (47A) with the index finger. Do this before the saw blade touches
the material.
4. With the saw at full speed, move the saw slowly forward to complete the cut.
5. When the cut is complete, release the power switch button (47A). Do not set the saw
down until the blade stops turning.
Reciprocating Saw Operation
For this procedure, it may be helpful to look at the Reciprocating Saw assembly diagram
at the end of this manual.
1. Remove the Battery from the housing.
2. Install the Saw Blade by passing it through the Adjustable Pad (7B) and into the
Carrier (32B), between the Washer (2B) and the Carrier (32B), with teeth facing
downward. Tighten the hex bolt with the hex wrench to lock the blade in place.
The item numbers (in brackets) can be
found on the Reciprocating Saw
Assembly drawing and Parts List.
Adjustable Pad (7B)
Switch Button Lock (14B)
Battery (20B)
Blade
Trigger Switch (15B)
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Caution: Avoid possible injuries while carrying the reciprocating saw. Lock the Trigger
Switch in the off position by pressing in on the Trigger Switch Lock (14B).
3. With the blade installed, press the Switch Lock to lock the Trigger Switch.
Squeeze the Trigger Switch. It should not move.
4. After the Battery is charged, insert into the housing.
5. To turn the saw on, press the Switch Lock in the opposite direction, then squeeze the
Trigger Switch.
6. Prepare and secure the material to be cut.
Use the correct blade for the material being cut. Fine tooth blades are generally used
for cutting metal. Blades with larger teeth are generally used for cutting wood.
Properly support long items being cut so as to not pinch the blade, preventing
kickback and pending the blade.
7. To begin cutting, firmly hold the saw handle with one hand, and the housing with the
other hand. Squeeze the Trigger Switch to start the cutting blade and rest the
Adjustable Pad on the material to be cut. Slowly lower the moving blade onto the
material.
8. When the cut is complete, press in on the Switch Lock.
Caution: Avoid possible injuries, always remove the battery before making any adjust-
ments or changing blades.
Flashlight Operation
1. Insert the charged Battery (27C) into the Flashlight housing.
2. Press the On/Off Switch (23C) to turn on.
3. Push the Flashlight head to the desired angle.
4. To replace the light bulb, unscrew the Lamp Cover Ring (3C) and
twist out the (18 V) Bulb (5C).
Maintenance
1. Use only sharp bits and blades with these tools.
2. Regularly inspect all mounting screws and knobs for tightness.
3. Keep safety guards in good working order.
4. Keep motor air vents clean of dust and debris. Vacuum periodically.
5. Clean tools with a damp cloth and light detergent. Do not use solvents.
6. Regularly charge batteries, whether used or not.
The item numbers (in brackets) can
be found on the Flashlight Assembly
drawing and Parts List.
(3C)
(27C)
(23C)
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7. Store these tools in a clean and dry area. Avoid storing in high temperature areas.
WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other
construction activites, 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 cilica 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. )
Drill Parts List
ITEM DESCRIPTION
1 Screw driver B itClam p
2 S crew driver B it,double-head
3 L e ft C a s e
4 B a tte ry C lam p
5TriggerS w itc h
6GearBox
7 R otation S w itc h
8 C huck
9 S crew ,M 5x25
11 RightCase
12 Screw,ST 2.9x15
13 Screw,ST 2.9x18
15 C onnector
16 Vm os Bulb
17 Screw,M 3x8
18 R adiator
19 W ire
2 0 B a tte ry
21 Battery C harger
NOTE: Some parts are listed and shown for illustration purposes only and are not
available individually as replacement parts.
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Drill Assembly Drawing
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 DISTRIBU-
TOR 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 THAT 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.
Battery Charger (#21)
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Circular Saw Parts List
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A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
NOTE: Part numbers for Circular Saw parts have an “A” suffix.
Please include this suffix when ordering replacement parts.
40056 combo pack.p65 10/10/03, 10:11 AM11

Page 12SKU 40056
Circular Saw Assembly Drawing
NOTE: Part numbers for Circular Saw
parts have an “A” suffix.
Please include this suffix when order-
ing replacement parts.
66
40056 combo pack.p65 10/10/03, 10:11 AM12

Page 13SKU 40056
Reciprocating Saw Parts List
NOTE: Part numbers for Reciprocating Saw parts have an “B” suffix.
Please include this suffix when ordering replacement parts.
1B Saw 1
2B Washer 1
3B Snap Washer, 5 1
4B Stud Screw, M5x12 1
5B Screw, M4x14 3
6B Snap Washer, 4 3
7B Adjustable Pad 1
8B Pin, A5x14 2
9B Flange 2
11B Snap Washer, 4 13
12B Screw, ST 4.2x22-C-H 13
13B Right Case 1
14B Switch Button Lock 1
15B Trigger Switch 1
16B Wire 1
17B Wire 1
18B Battery Clip 1
19B Battery 1
20B Screw, M3x10 2
21B Washer 1
22B Sealing Washer 1
23B Washer 1
24B Ball Bearing Case 1
25B Ball, 3 8
26B Washer 1
27B Slide Case 1
28B Snap Washer, 4 2
29B Nut, M4 2
30B Bearing 1
31B Pin, A3x9 1
32B Carrier 1
33B Carrier Pin 1
34B Axle Sleeve 1
35B Connecting Bar 1
36B Snap Washer, 6 1
37B Washer 1
38B Axle Sleeve 1
39B Small Axle 1
40B Big Gear 1
41B Main Shaft 1
42B Bearing, 80019 1
43B Axle Sleeve 1
44B Bearing, 1000097 1
45B Snap Washer, 6 1
46B Screw, M4x9 2
47B Transmission 1
Supporting Pack
48B Gear Box 1
49B Motor 1
50B Shrink Tube 2
51B Left Case 1
52B Hex Key, 1.9 inch 1
ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY
40056 combo pack.p65 10/10/03, 10:11 AM13

Page 14SKU 40056
Reciprocating Saw Assembly Drawing
NOTE: Part numbers for Reciprocating
Saw parts have an “B” suffix.
Please include this suffix when ordering
replacement parts.
20
40056 combo pack.p65 10/10/03, 10:11 AM14

Page 15SKU 40056
Flashlight Parts List
 
 ?$=
 `_=
 `=&?$
 `
'
! `?_
% '}
 =$\
+ =
< 
 
 `}=
 
 =
 @=
! =
% Z
 >
+ >
< ?
 ?
 ?
 `&
 &=
 
! 
% @\]
NOTE: Part numbers for Flashlight parts have an “C” suffix.
Please include this suffix when ordering replacement parts.
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
40056 combo pack.p65 10/10/03, 10:11 AM15

Page 16SKU 40056
Flashlight Assembly Drawing
NOTE: Part numbers for Flashlight parts have an “C” suffix.
Please include this suffix when ordering replacement parts.
40056 combo pack.p65 10/10/03, 10:11 AM16