Harbor Freight Tools 90120 User Manual

CORDLESS DRILL

®

VARIABLE SPEED - 18 VOLT

Model 90120

OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Web site at: http://www.harborfreight.com

Copyright
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.

©

2003 by Harbor Freight Tools®. All rights reserved. No portion of

Manual revised 01/05

PRODUCT SPECIFICATIONS

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SAVE THIS MANUAL

You will need this manual for the safety warnings and precautions, assembly, oper­ating, inspection, maintenance and cleaning procedures, parts list and assembly
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 pres-
ence of flammable liquids, gases, or dust. Power tools create sparks which may
ignite the dust or fumes.

SKU 90120 For technical questions, please call 1-800-444-3353. PAGE 2

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, ground-

ing 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

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.

eliminates the need for the three wire 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 Adapter’s power cord. Never use the Power Cord to carry

the Charger or pull the Plug from an outlet. Keep the Power Cord away from
heat, oil, sharp edges, or moving parts. Replace damaged Power Cords im­mediately. Damaged Power Cords increase the risk of electric shock.

PERSONAL SAFETY

9. Stay alert. Watch what you are doing, 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 power

tools may result in serious personal injury.

10. 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.

11. Avoid accidental starting. Be sure the Rotation Button (33) is in the locked
position before inserting the Battery. Carrying power tools with your finger on
the trigger, or inserting the Battery with the trigger depressed, invites accidents.

12. 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.

SKU 90120 For technical questions, please call 1-800-444-3353. PAGE 3

13. Use safety equipment. Always wear eye protection. Dust mask, nonskid safety
shoes, hard hat, or hearing protection must be used for appropriate conditions.
Always wear ANSI approved safety goggles when working with this tool.

TOOL USE AND CARE

14. 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.

15. 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.

16. Do not use the power tool if the trigger does not operate it. Any tool that cannot
be controlled with the trigger is dangerous and must be replaced.

17. Remove the battery from the tool and set the Rotation Button (33) to its cen-

ter, locked position before making any adjustments, changing accessories,
or storing the tool. Such preventive safety measures reduce the risk of starting

the tool accidentally.

18. Store idle tools out of reach of children and other untrained persons. Tools
are dangerous in the hands of untrained users.

19. Maintain tools with care. Keep drill bits sharp and clean. Properly maintained
accessories with a sharp cutting edge are less likely to bind and are easier to con­trol. Do not use a damaged tool or accessory. Tag damaged tools “Do not use” until
repaired.

20. 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 maintained

tools.

21. 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

22. Tool service must be performed only by qualified repair personnel. Service or
maintenance performed by unqualified personnel could result in a risk of injury.

23. When servicing a tool, use only identical replacement parts. Follow instruc-

tions in the

Use of unauthorized parts or failure to follow maintenance instructions may create
a risk of electric shock or injury.

“Inspection, Maintenance, and Cleaning”

section of this manual.

SKU 90120 For technical questions, please call 1-800-444-3353. PAGE 4

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 Drill 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 Drill. These carry important
information. If unreadable or missing, contact Harbor Freight Tools for a replace­ment.

3. When using the Cordless Drill, always maintain a firm grip on the tool with

both hands.

4. Hold the tool by its insulated gripping surfaces when performing an opera­tion where the Cordless Drill may contact hidden wiring. Contact with a “live”

wire will make exposed metal parts of the Cordless Drill “live” and shock the opera­tor.

5. Do not use the Cordless Drill or Charger (34) if it has been dropped, damaged,

left outdoors, or immersed in liquid.

6. To avoid electrical shock, do not pull or carry the Charger (34) 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 (34), its Adapter (35), or

the Cordless Drill with wet hands.

8. Keep the Handle of the Cordless Drill dry, clean, free from oil and grease.

9. Avoid unintentional starting. Make sure you are prepared to begin work before
turning on the Cordless Drill.

10. Never leave the Charger (34) unattended when it is plugged into an electrical
outlet. Make sure to unplug it from its electrical outlet before leaving.

11. PROPER BATTERY PACK CARE: Battery Pack (4) leakage may occur under ex-
treme 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 Drill with a leaking Battery Pack. Contact local solid waste
authorities for instructions on correct disposal or recycling of the Battery Pack.

12.

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

SKU 90120 For technical questions, please call 1-800-444-3353. PAGE 5

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,

13. 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.

et seq.)

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 electric 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 Figure A.

SKU 90120 For technical questions, please call 1-800-444-3353. PAGE 6

FIGURE A

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.)

FIGURE B

SKU 90120 For technical questions, please call 1-800-444-3353. PAGE 7

EXTENSION CORDS

E

(

)

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.)

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)

NAMEPLAT

AMPERES

At Full Load

25

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

FIGURE C

to five volts at 150% of the rated amperes.

EXTENSION CORD LENGTH

50

Feet

75

Feet

100

Feet

150

Feet

SKU 90120 For technical questions, please call 1-800-444-3353. PAGE 8

SYMBOLOGY

Double Insulated

Canadian Standards
Association

Underwriters
Laboratories, Inc.

V ~

n

o

xxxx/min.

A

Volts Alternating Current

Amperes

No Load Revolutions
per Minute (RPM)

UNPACKING

When unpacking, check to make sure that the product is complete and undamaged (see
Parts List on page 14 for reference). 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.

CHARGING

1. NOTE: The Battery Pack (4) requires charging. The first charge requires 5 hours
charge time prior to using the Cordless Drill.

2. 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,

recharge the battery and use the fresh battery for optimal performance.

SKU 90120 For technical questions, please call 1-800-444-3353. PAGE 9

3. When the Battery Pack (4) requires recharging, a 3 to 5 hour charge allows the tool
to operate at full power.

Do not recharge the Battery Pack longer than 5 hours, as

damage to the Battery Pack and/or Cordless Drill will occur.

°

4. Charging room temperature: 50

F – 104° F. Insert the Battery Pack (4) into the
Charger (34). Next, plug the Charger Adapter (35) into the socket on the side of the
Charger (34). Then, plug the Charger Adapter (35) into the nearest 120 volt,
grounded, electrical outlet. (See Figure D, below.)

BATTERY

PACK (4)

120 VOLT

ELECTRICAL

OUTLET

CHARGER

(34)

CHARGER

ADAPTER

(35)

FIGURE D

5. A Charging Indicator Light on the Charger (34) will illuminate to show that charging
is taking place.

NOTE: The Charger (34) will not automatically 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. Recharging the Battery Pack
more than 5 hours can cause damage to the battery cells.

6. While charging, the Battery Pack (4), Charger (34), and Charger Adapter (35) may
become warm to the touch. This is normal, and does not indicate a problem.

7. Once the Battery Pack (4) is fully charged, disconnect the Charger Adapter (35)
from the electrical outlet. Then, disconnect the Charger Adapter (35) and Battery
Pack (4) from the Charger.

SKU 90120 For technical questions, please call 1-800-444-3353. PAGE 10

OPERATING INSTRUCTIONS

NOTE: For additional information regarding the parts listed in the following pages, refer to

the

Assembly Diagram on page 14.

1.

WARNING! Remove the Battery (4) from the tool and set the Rotation
Button (33) to its center, locked position before making any adjustments,
changing accessories, or storing the tool.

CHUCK SLEEVE

CHUCK

(12)

ROTATION

BUTTON (33)

TORQUE
SETTING

RING (8)

BATTERY PACK (4)

TORQUE

INDICATOR

ARROW

TRIGGER
(3)

FIGURE E

2. To install a drill/screwdriver bit, hold the Chuck Sleeve firmly in place and turn the
Chuck (12)
(12). While holding the Chuck Sleeve in place, turn the Chuck
bit in place. The Chuck (12) accepts up to

counterclockwise

. Insert the shank of the bit all the way into the Chuck

clockwise

3

/8” diameter bits. Insert the appropriate

to lock the

bit for your application and tighten the Chuck (12) firmly. (See Figure E, above.)

3. Secure the workpiece in place, using a vise or clamps (not included).

4. The Torque Setting Ring (8) allows you to select 16 different driving torque settings,
depending on the job required.

Torque Settings (1-8):

The different numbers on the Ring are an indication of how much torque the
screwdriver will apply to the bit before the clutch slips, allowing the bit to stop
and helping to prevent damage to the screw, bit, or workpiece. The higher the
number, the more torque is applied before the clutch slips. Unless you are
drilling, always start with a lower number to help prevent damage. This drill also
has torque settings between the numbers to allow a greater range of control.

SKU 90120 For technical questions, please call 1-800-444-3353. PAGE 11

Drill Setting ( ):

This setting essentially prevents the clutch from slipping entirely. It is designed
for drilling, but is not advised for using the screwdriver because it offers no
protection against stripping the head or splitting the wood.

Set the driving torque by turning the Torque Setting Ring (8) to align the torque
indicator arrow with the desired setting. (See Figure E, previous page.)

5. When drilling in light gauge metal or wood, use a wooden block to back up the
material to prevent damage to the workpiece.

6. Mark the center of the hole to be drilled with a center punch to give a Drill Bit a start
and to prevent it from “walking”.

7. Lubricate the Drill Bit with cutting oil when drilling iron or steel. Use a coolant when
drilling nonferrous metals such as copper, brass, or aluminum.

8. Insert the fully charged Battery Pack (4) into the Handle of the Cordless Drill.

9. The Rotation Button (33) allows you to change the rotational direction of the Cord­less Drill. For a
counterclockwise rotation, move the Rotation Button to the
locks the Trigger (3), helping to prevent the Drill from operating. (See Figure E.)

clockwise rotation, move the Rotation Button to the

left

. The center position

right

. For a

10. Make sure to hold the Cordless Drill firmly with both hands, as torque from the
Motor will cause the tool to twist.

11. Operate the Drill, by squeezing the Trigger (3). The speed of the Drill can be con­trolled by varying the pressure on the Trigger (3).

12. If Drilling:

• Use the Drill torque setting, as described above.

• Drill only as deep as necessary. Do not drill deeper than necessary into walls or

other areas where you cannot identify any possible hazards behind the drilling
surface.

• To reduce jamming as the Bit breaks through the workpiece, decrease the drill-

ing pressure when the point of the Bit breaks through the workpiece.

• When you have drilled the hole, remove the Bit from the hole while the Cordless

Drill is still running. This prevents the Bit from getting caught in the hole and
causing damage.

If Driving Screws:

• Start with a low torque setting.

• If the clutch starts slipping before the screw is in all the way, stop the drill, put

the Reverse Button (33) in the center position, remove the Battery (4), and change
the torque setting. Reinstall the Battery (4), and set the direction before continu­ing.

13. Release the Trigger (3) to stop the Drill. Then, remove the Battery Pack (4), put the
Reverse Button (33) in the center position, and remove the bit from the Drill.

SKU 90120 For technical questions, please call 1-800-444-3353. PAGE 12

INSPECTION, MAINTENANCE, AND CLEANING

1. WARNING! Remove the Battery (4) from the tool and set the Rotation
Button (33) to its center, locked position before performing any inspection,
maintenance, or cleaning.

2. BEFORE EACH USE, inspect the general condition of the Cordless Drill. Check for
misalignment or binding of moving parts, cracked or broken parts, leaking Battery
Pack, damaged Charger wiring, chipped or broken Drill Bits, and any other condi­tion that may affect its safe operation. If abnormal noise or vibration 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 Drill.
Do not immerse the Cordless Drill in any liquids.

4. If the battery needs replacement keep in mind that the Nickel-Cadmium (Ni-

Cd) battery in this tool must be recycled or disposed of properly.

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM

THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBU-

IN

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.

SKU 90120 For technical questions, please call 1-800-444-3353. PAGE 13

PARTS LIST

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2erusolcnEthgiR41sgniraeBllaB62wercSgnippaTfleS

3ylbmessAhctiwSreggirT51gniRgn

4kcaPyrettaB61gniRllamS82wercSgnippaTfleS

5gniR71sgniraeBllaBllamS92rotoM

6gnirpS81xoBronrevoG03erusolc

7gniRdedaerhTrennI91taoCtfahS13tiBrevirdwercS

8gniRgnitteSeuqroT02eldnipS23pilCtiB

9gnirpSgninoitisoPeuqroT12g

01redloHgnirpS22raeGyratenalP43regrahC

11wercSgnippaTfleS32tekcarByratenalP53retpadAregrahC

21kcuhC42raeGyratenalP

ixiF72egnalFrotoM

nEtfeL

niRraeG33nottuBnoitatoR

ASSEMBLY DIAGRAM

32

31

33

2

1

3

4

34

35

30

29

28

27

26

25

24

23

15

13

22

14

21

20

19

18

17

16

5

6

7

8

9

10

11

12

NOTE: Some parts are listed and shown for illustration

purposes only, and are not available individually
as replacement parts.

SKU 90120 For technical questions, please call 1-800-444-3353. PAGE 14