Kawasaki 840138-1HR User Manual

COMPONENT

#840138-1HR

19.2V 2-SPEED BATTERY-OPERATED DRILL

INSTRUCTION MANUAL

FOR CUSTOMER SERVICE

POUR LE SERVICE APRÉS VENTE

OU DU CONSOMMATEUR

PARA EL SERVICIO

PARA EL CONSUMIDOR

1-800-590-3723

Printed in China

KAWASAKI™IS A TRADEMARK LICENSED BY KAWASAKI™
MOTORS CORP., U.S.A., WHICH DOES NOT MANUFACTURE OR
DISTRIBUTE THIS PRODUCT. CONSUMER INQUIRES SHOULD BE
DIRECTED TO:

©COPYRIGHT 2006 ALLTRADE TOOLS, LLC.
1431 VIA PLATA
LONG BEACH, CA 90810-1462 USA

840138 – 19.2V Green Cordless Drill_Rev 8/26/06

THIS MANUAL CONTAINS IMPORTANT INFORMATION REGARDING SAFETY, OPERATION,
MAINTENANCE AND STORAGE OF THIS PRODUCT. BEFORE USE, READ CAREFULLY AND
UNDERSTAND ALL CAUTIONS, WARNINGS, INSTRUCTIONS AND PRODUCT LABELS.FAILURE TO DO
SO COULD RESULT IN SERIOUS PERSONAL INJURY AND/OR PROPERTY DAMAGE.

IF YOU SHOULD HAVE ANY QUESTIONS OR EXPERIENCE A PROBLEM WITH YOUR ALLTRADE
PRODUCT, DO NOT RETURN THIS PRODUCT TO THE STORE. PLEASE CALL OUR CUSTOMER SERVICE
DEPARTMENT AT 1-800-590-3723. BEFORE YOU CALL, HAVE THE FOLLOWING INFORMATION
AVAILABLE: MODEL No., DATE PURCHASED AND STORE LOCATION. AN ALLTRADE
REPRESENTATIVE CAN RESOLVE YOUR PROBLEM OVER THE PHONE. IF YOU WOULD LIKE TO MAKE
A SUGGESTION OR COMMENT, GIVE US A CALL OR EMAIL US AT: [e-mail].
YOUR FEEDBACK IS VITAL TO US.

87-1904-60957

SECTION FOUR

MAINTENANCE AND CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

PROTECTING THE ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

OTHER CONSUMER DO-IT-YOURSELF (DIY) TOOLS . . . . . . . . . . . . . . 18

SECTION FIVE

3 YEAR LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-22

CONGRATULATIONS!

Thanks for choosing this product. At Alltrade, our aim is to provide you with quality
products at an affordable price, and we want you to be totally satisfied with your
product and our Customer Service. If any help and advice is needed, please
contact us at 1-800-590-3723. Properly cared for, this tool will give you many
years of satisfaction.

INTENDED USE

This tool is intended for consumer use only. Your charger and/or adapter has been
designed for charging batteries of the type approved and supplied with this tool.

GENERAL SAFETY RULES – FOR ALL BATTERY OPERATED TOOLS

READ AND UNDERSTAND ALL INSTRUCTIONS.Failure to

follow all instructions listed below may result in electric shock, fire and/or
serious personal injury.

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS

The safety instructions provided in this manual are not intended to cover all possible
conditions and practices that may occur when operating, maintaining and cleaning
power tools.

Always use common sense and pay particular attention to all the DANGER,
WARNING, CAUTION and NOTE statements of this manual.

This is the safety alert symbol. It is used to alert
you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid
possible injury or death.

TABLE OF CONTENTS

CONGRATULATIONS! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION ONE

GENERAL SAFETY RULES – FOR ALL BATTERY OPERATED TOOLS . . 2

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS . . . . . . . . 2-3

IMPORTANT SAFEGUARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

WORK AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ELECTRICAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

TOOL USE AND CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION TWO

SPECIFIC SAFETY RULES AND/OR SYMBOLS . . . . . . . . . . . . . . . . . . . 6

SAFETY RULES FOR CORDLESS DRILL/DRIVERS . . . . . . . . . . . . . 6-7

SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION THREE

FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

REMOVING/ATTACHING BATTERY PACK . . . . . . . . . . . . . . . . . . . . 10

CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

CHARGING BATTERY PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12

INSTALLING DRILL BIT INTO KEYLESS CHUCK . . . . . . . . . . . . . . 12

OPERATING THE CORDLESS DRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15

VARIABLE SPEED TRIGGER SWITCH . . . . . . . . . . . . . . . . . . . . . . . 13

FORWARD/REVERSE AND TRIGGER LOCK LEVER . . . . . . . . . . . . 13

TORQUE SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14

HIGH/LOW SPEED (GEAR) SHIFTING . . . . . . . . . . . . . . . . . . . . . . 14

SCREWDRIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

DRILLING METAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

DRILLING MASONRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

DRILLING WOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

HINTS FOR OPTIMUM USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16

21

DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.

WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.

CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.

CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which,
if not avoided, may result in property damage.

NOTE provides additional information that is useful
for proper use and maintenance of this tool. If a
NOTE is indicated make sure it is fully understood.

IMPORTANT SAFEGUARDS

People with electronic devices, such as 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.

WARNING: Some dust created by power sanding, sawing, grinding, drilling and

other construction activities contains 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 and other masonry products,
and 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 dust masks that are
specially designed to filter out microscopic particles.

WARNING: Handling the power cord on corded products may expose you to
lead, a chemical known to the State of California to cause cancer and birth
defects or other reproductive harm.

Wash hands after handling.

SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.

WORK AREA

Keep your work area clean and well lit. Cluttered work benches and dark work

areas may cause accidents or injury.

Do not operate power tools in explosive areas, such as in the presence of
flammable liquids, gases or dust. Power tools create sparks which may ignite

the dust or fumes.

Keep bystanders, children and visitors away while operating a power tool.

Distractions can cause you to lose control.

ELECTRICAL SAFETY

Do not abuse the cord. Never use the cord to carry the tool. Keep the cord
away from heat, oil, sharp edges, or moving parts. Replace damaged cords
immediately. Damaged cords may create a fire.

A battery operated tool with integral batteries or a separate battery pack
must be recharged only with the specified charger for the battery. A charger

that may be suitable for one type of battery may create a risk of fire when used with
another battery.

Use battery operated tool only with specifically designated battery pack. Use of
any other batteries may create risk of fire.

PERSONAL SAFETY

Stay alert, watch what you are doing, and use common sense when operat­ing a power tool. Do not use 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.

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.

Avoid accidental starting. Be sure switch is in the locked or “OFF” position
before inserting battery pack. Carrying power tools with your finger on the switch
or inserting battery pack into a tool with the power switch “ON” invites accidents.

4

SERVICE

Tool service must be performed only by qualified repair personnel. Service or

maintenance by unqualified personnel may result in a risk of injury.

When servicing a tool, use only identical replacement parts. Follow instructions
in the Maintenance section of this manual. Use of unauthorized parts or failure to

follow Maintenance Instructions may create a risk of shock or injury.

SPECIFIC SAFETY RULES AND/OR SYMBOLS

Hold tool by insulated gripping surfaces when perform-

ing an operation where the cutting tool may contact hidden wiring. Contact

with a “live” wire will also make exposed metal parts of the tool “live” and shock
the operator.

SAFETY RULES FOR CORDLESS DRILL / DRIVERS

Always wear safety goggles or eye protection when using this tool. Use a

dust mask or respirator for applications which generate dust.

Do not grasp the tool or place your hands too close to the spinning chuck or
drill bit. Your hand may be lacerated or may cause injury.

Secure the material being worked on. Never hold it in your hand or across
your legs. Unstable support can cause loss of control and injury.

Position yourself to avoid being caught between the tool or side handle and
walls or posts. Should the socket or bit become bound in the work, the

reaction torque of the tool could crush your hand or leg.

Check to see that keys and adjusting wrenches are removed from the
Cordless Drill before switching the tool “ON”. Keys or wrenches can fly away

at high velocity striking you or a bystander.

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

Keep the handle of the Cordless Drill dry, clean, and free from oil and grease.
Do not run the Cordless Drill while carrying it at your side. A spinning

socket or bit could become entangled with clothing and injury may result.

Disconnect the plug or remove the battery pack from tool and place the switch
in the locked or “OFF” position before making any assembly adjustments,
changing accessories, performing any inspection, maintenance or cleaning
procedures. Such preventive safety measures reduce the risk of starting the

tool accidentally.

Remove adjusting keys or wrenches before turning the tool “ON”. A wrench or a
key that is left attached to a rotating part of the tool may result in personal injury.

Do not overreach. Keep proper footing and balance at all times. Proper foot­ing and balance enable better control of the tool in unexpected situations.

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

Use clamps 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.
Do not force 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.
Do not use the tool if the power switch does not turn it “ON” or “OFF”. A tool that

cannot be controlled with the switch is dangerous and must be repaired.

Disconnect battery pack from tool or place the switch in the locked or “OFF” posi­tion before making any adjustments, changing accessories, or storing the tool.

Such preventative safety measures reduce the risk of starting the tool accidentally.
Store idle tools out of reach of children and other untrained persons. Tools

are dangerous in the hands of untrained users.

When battery pack is not in use, keep it away from other metal objects like:
paper clips, coins, keys, nails, screws, or other small metal objects that can
make a connection from one terminal to another. Shorting the battery termi-

nals together may cause sparks, burns or a fire.
Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained

tools with sharp cutting edge are less likely to bind and are easier to control.

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.

Use only accessories that are recommended by the manufacturer for your
model. Accessories that may be suitable for one tool may create a risk of injury

when used on another tool.

5 6

FUNCTIONAL DESCRIPTION

CONTROLS AND COMPONENTS:

1. Battery Pack

2. Release Buttons on Each Side

3. Charger

4. Indicator Lights

5. 12.7mm (1/2") Keyless Chuck

6. 22 Adjustable Torque Settings
Control Ring

7. Forward/Reversing and
Trigger Lock Lever

COMPONENT MODEL NUMBER

BATTERY PACK 690549
CHARGER 690543

12.7mm (1/2") KEYLESS CHUCK 690552

8

Do not use the Cordless Drill if it has been damaged, left outdoors in the
rain, snow, wet or damp environments, or immersed in liquid.

Maintain labels and nameplates on the Cordless Drill. These carry important

information. If unreadable or missing, contact Alltrade for a replacement.

SYMBOLS

IMPORTANT: Some of the following symbols may be used on your tool. Please

study them and learn their meaning. Proper interpretation of these symbols will
allow you to operate the tool better and safer.

SYMBOL NAME EXPLANATION

V Volts Voltage (Potential)
A Amperes Current

Hz Hertz Frequency (Cycles per Second)

W Watt Power

Kg Kilograms Weight

Alternating Current Type of Current
Direct Current Type of Current
Alternating or Direct Current Type of Current
Earthing Terminal Grounding Terminal
Class II Construction Denotes Double Insulation

min Minutes Time

s Seconds Time

 Diameter Size of Drill Bits,

Grinding Wheels, etc.

No load speed No-load Rotational Speed

.../min Revolutions per Minute Revolutions, Sur face Speed,

Strokes, etc. per Minute

1,2,3, … Ring Selector Settings Speed, Torque or Position Settings

8. High/Low Speed Switch

9. Variable Speed Controlled
Trigger Switch

10. Accessory/Bit Holder

11. Comfort Rubber Grip

ACCESSORIES:

12. Double Ended Screwdriver Bits (2)

11

12

10

5

6

8

9

7

2

1

3

4

7

BATTERY

Before using battery pack, please read carefully all instruc­tions and cautionary markings on battery pack, battery
charger and product using battery.

Do not incinerate the battery pack even if it is severely dam­aged or is completely worn out. The battery pack can explode.

Do not carry battery packs in aprons, pockets, or tool

boxes, product kit boxes, drawers, etc. with loose metal objects. Battery

pack terminals could be short circuited causing damage to the battery pack,
severe burns or fire.

The battery pack is Nickel-Cadmium (Ni-Cad) and is considered to be a toxic
material by the Environmental Protection Agency. Before disposing of dam-

aged or worn out Ni-Cad battery packs, check with your State Environmental
Protection Agency to find out about special restrictions on the disposal of these
battery packs, take them to your local recycling center for proper disposal, or
call 1-800-822-8837.

The battery is not fully charged. Before first use, the battery pack requires
3-5 hours charge time to be fully charged. Subsequent recharging needs 1 hour
for the battery to be fully charged.

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 have a shortened life.

Never over-discharge a battery by using the tool even after tool performance
has decreased. Do not attempt to discharge a tool’s battery by continuing to

pull on the tool trigger . When tool performance begins to diminish, stop the tool
and recharge the battery for optimal performance.

Charge battery pack at ambient temperatures between 50° F – 104° F.
Store tool and battery pack in locations where temperatures will not exceed

120°F. This is important to prevent serious damage to the batter y cells.
The battery pack should always be recharged when the Cordless Drill begins to

run slowly.
When battery pack is not in use, keep it away from other metal objects such as

paper clips, coins, keys, nails, screws or other small metal objects that can
make a connection from one terminal to another. Shorting the battery terminals

together may cause sparks, burns, or fire.

REMOVING/ATTACHING BATTERY PACK

REMOVE BATTERY PACK:

1. Press both release buttons on either
side of the Cordless Drill to release
the battery pack.

2. Pull battery pack free of Cordless Drill.

ATTACH BATTERY PACK:

1. Align the raised portion of the battery
pack with the groove in the battery
compartment of the Cordless Drill.

2. Press the battery pack
into place. Make sure the
latches are securely fastened.
Do not use the Cordless
Drill if the battery pack is
not seated properly.

CHARGER

Before using battery charger, please read carefully all
instructions and cautionary markings on battery charger, battery pack and
product using battery.

Use only the charger which accompanied your product or direct replacement as
listed in this manual. Do not substitute any other charger. Use only Alltrade

approved chargers with your product.

Do not disassemble charger.
Do not use charger if it has been damaged, left outdoors in the rain, snow, wet

or damp environments, or immersed in liquid.
The battery pack and charger heat during charging. Place the charger on a flat,

non-flammable surface away from flammable materials with at least four inches of
clearance to allow proper air circulation around the charger and battery pack.

When the battery pack requires recharging, a 1 hour charge allows the tool to
operate at full power. A charging indicator light on the charger will illuminate to

show that charging is taking place.

10

RELEASE BUTTON

®

CHARGING BATTERY PACK

CHARGE BATTERY PACK:

1. Plug the charger into
the nearest 120 volt
electrical outlet.

2. Make sure the trigger
on the Cordless Drill
is in the “OFF”
position and remove
the battery pack from
the Cordless Drill.

3. Insert the battery pack
into the charger. Be sure
that the battery pack is
fully seated in the charger.
Do not force.

4. The red indicator light should come “ON” indicating that the battery pack is in
a “Fast Charge” mode. If the green indicator light comes “ON”, then the battery
is already fully charged.

5. After approximately one hour of charging, the red indicator light should go
“OFF” and the green light should come “ON” indicating that the batter y is fully
charged and the charger is now in a “Trickle Charge” mode.

6. The battery can be left in a “Trickle Charge” mode until ready to use.

IMPORTANT INFORMATION FOR RECHARGING HOT BATTERIES

When using your Cordless Drill continuously, the batteries in your battery pack
will become hot. You should let a hot battery pack cool down for approximately
30 minutes before attempting to recharge. When the battery pack becomes
discharged and is hot, the red light on the charger will flash. When the battery
pack cools down, the red light will glow continuously to indicate fast charging
mode, 1-hour charge time.

This will occur when continuous use of your Cordless

Drill causes the battery pack to become hot. It does not occur under normal

circumstances.

ASSEMBLY

Be aware that this tool is always in an operating condition

because it does not have to be plugged into an electrical outlet. Always turn
the switch “OFF” and remove the battery pack before changing bits.

INSTALLING DRILL BIT INTO KEYLESS CHUCK

Before inserting a drill bit or other accessory, make sure the for ward/reverse

and trigger lock lever is in the center “OFF” position to prevent accidental starts
that may result in injury.

Do not attempt to tighten drill bits (or any other accessory) by gripping the
front of the chuck and turning the tool on. This may cause personal injury

and/or damage to the chuck.

When removing the bit from the tool, avoid contact with skin and use proper
protective gloves when grasping the bit or accessory.Accessories may be hot

after prolonged use.

1. Hold the rear end of the chuck
in one hand and use the other
hand to rotate the front end in a
counterclockwise direction to
open the jaws of the chuck.

2. Insert the shank of the bit (or
other accessory) fully into the
keyless chuck, taking care to
keep the bit in the center of
the jaws of the chuck.

3. Turn the front end of the chuck clockwise to hold the bit in place.

4. Tighten securely by turning the front end of the chuck clockwise while holding
the rear end.

OPERATING THE DRILL

Never tape the trigger switch down to provide continu-

ous high speed. The tool may fail under such conditions causing fire or

personal injury.

WARNING

12

BATTERY PACK

LED

LIGHT

BATTERY

CHARGER

TIGHTEN

LOOSEN

HOLD

THE CONTROL RING ADJUSTS THE LEVEL OF TORQUE:

• For light duty work, use lower settings.

• For heavy duty work, use higher settings.

PROPER SETTING FOR DRIVING SCREWS:

1. Set the ring on the lowest
setting to begin.

2. Try tightening the first screw.
If the drill drives smoothly,
proceed with the next screw.

3. If the Drill’s clutch slips,
increase the torque setting
and try again until the Drill
drives the screw without incident.

HIGH/LOW SPEED (GEAR) SHIFTING

FOR LOW SPEED SETTING:

• Slide the switch on top of the

Drill to Position 1 for high
torque applications and driving
screws.

FOR HIGH SPEED SETTING:

• Slide the switch to Position 2

for light duty projects.

SCREWDRIVING

WHEN DRIVING FASTENERS:

• Always start slowly and gradually increase the speed of the Drill.

• Release the trigger when you feel the clutch slip.

• Always keep the driver bit straight to prevent damage to the screw.

• Hold the Drill with both hands to ensure control if the bit should stick or slip.

• To prevent wood from splitting, drill pilot holes into the wood before driving

in the screws.

14

VARIABLE SPEED TRIGGER SWITCH

THIS TOOL IS CONTROLLED
BY A TRIGGER SWITCH:

• The speed of the Cordless Drill depends
on the amount of pressure you put on the
trigger.

• The more pressure you apply, the faster
the Cordless Drill will go.

• Release the pressure and the Cordless Drill
will slow down.

FORWARD/REVERSE AND TRIGGER LOCK LEVER

Be sure the trigger is released when changing the position of the lever.
Always store the tool in the “LOCKED/OFF” position.

Always check the direction of the Cordless Drill's rotation before use.

TO SELECT THE DIRECTIONS
OF ROTATION:

• To select for ward Cordless Drill
rotation, press the trigger lock
from left to right flat against the Cordless
Drill body.

• To select reverse, press the trigger lock
lever in the opposite direction.

• The center position locks the tool.

TORQUE SETTINGS

To prevent damaging the tool or driving screw too deep

into work piece, release the trigger when you feel the clutch slip.

13

TRIGGER

LOCK

TRIGGER

SWITCH

HIGH SPEEDLOW SPEED

CONTROL RING