MasterCraft 54-2903-2 Owner's Manual

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Page 1

18 V Ni-Cd HAMMER DRILL

54-2903-2

Owner’s Manual

PRODUCT SPECIFICATIONS

Battery:

Two 18 V, 1.9Ah Nickel-cadmium

Maximum torque:

400 in-lb

Variable speed ranges:

0–400 & 0–2,000 RPM (no load)

Hammer speeds:

0–36,000 BPM

Torque clutch positions:

25 + drill + hammer modes

Keyless chuck:

1/2" (13 mm) single sleeve Jacobs®

Maximum drilling depth:

1/2" (13 mm) in steel 2 9/16" (6.5 cm) in wood

Charger:

1 hour diagnostic, Class 2

Charger input:

120 V AC, 60 Hz

Charger output:

14.4 to 18 V DC, 2.8 A (maximum)

Replacement chargers:

54-3103-0 (LED), 54-3101-4 (LCD)

Replacement battery:

54-3102-2 (Ni-Cd)

Replacement battery:

54-3100-6 (Lithium-ion)

Weight:

4 lb 6 oz (2.0 kg) without battery

NEED ASSISTANCE?

Call us on our toll-free Customer Support Line:

1-800-689-9928

Imported by Mastercraft Canada Toronto, Canada M4S 2B8

Patent Pending

Page 2

Product specifications ………….…………………………………………………….

Table of contents ……………………………………………………………………...

General safety warnings ……………………………………………………………..

3–4

Eye, ear & lung protection ……………………………………………………………

3–4

Electrical safety ……………………………………………………………………….

Power tool safety ……………………………………………………………………...

5–6

General safety rules …………………………………………………………………..

Work area ………………………………………………………………….…………..

Electrical safety ……………………………………………………………………….

Personal safety ………………………………………………………………………..

5–6

Use and care of power tools .………………………………………………………..

Service …………………………………………………………………………………

Specific safety rules …………………………………………………………………..

Battery & charger safety ………………………………………………………….….

8–9

Battery pack recycling ………………………………………………………………..

Symbols ………………………………………………………………………………..

Know your hammer drill ………………………………………………………………

Available accessories ………………………………………………………………...

Contents ……………………………………………………………………………….

12–13

Assembly and operating ……………………………………………………………..

14–31

Positioning the charger ……………………………………………………………….

Storing the charger ……………………………………………………………………

Charging the battery pack ……………………………………………………………

15–16

Installing a battery in the hammer drill ……………………………………………..

Adjusting the torque ………..…………………………………………………………

Installing the auxiliary side handle …………………………………………………..

Bit storage in auxiliary handle ……………………………………………………….

Installing the depth stop rod …………………………………………………………

Two-speed gear box switch ………………………………………………………….

20–21

Forward/reverse switch ………………………………………………………………

Spirit level ……………………………………………………………………………..

21–22

Variable-speed trigger switch ………………………………………………………..

Dual LED worklights ………………………………………………………………….

LCD display ……………………………………………………………………………

Installing bits …………………………………………………………………………..

24–25

Removing bits …………………………………………………………………………

Drilling ………………………………………………………………………………….

26–28

Drilling in concrete ……………………………………………………………………

Driving screws …………………………………………………………………………

28–29

Removing the chuck ………………………………………………………………….

29–30

Retightening a loose chuck ………………………………………………………….

30–31

Maintenance …………………………………………………………………………..

32–33

Exploded view …………………………………………………………………………

Parts list ………………………………………………………………………………..

Warranty ……………………………………………………………………….………

36–37

TABLE OF CONTENTS

Page 3

EYE, EAR & LUNG PROTECTION

This instruction manual includes the following:

 General Safety Rules  Specific Safety Rules and Symbols  Functional Description  Assembly  Operation  Maintenance  Accessories

ALWAYS WEAR EYE PROTECTION THAT CONFORMS WITH CSA REQUIREMENTS or ANSI SAFETY STANDARD Z87.1

FLYING DEBRIS can cause permanent eye damage. Prescription eyeglasses ARE NOT a replacement for proper eye protection.

WARNING: Non-compliant eyewear can cause serious injury if

broken during the operation of a power tool.

SAVE THESE INSTRUCTIONS FOR REFERENCE

WARNING: Use hearing protection, particularly during extended periods of operation of the tool, or if the operation is noisy.

GENERAL SAFETY WARNINGS

CAUTION: Before using this tool or any of its accessories, read this

manual and follow all Safety Rules and Operating Instructions.

Page 4

ELECTRICAL SAFETY

WARNING: To avoid electrical hazards, fire hazards or damage to the

tool, use proper circuit protection.

This tool is wired at the factory for 110–120 V operation. It must be connected to a 110–120 V 15 A circuit that is protected by a time-delayed fuse or circuit breaker. To avoid shock or fire, replace power cord immediately if it is worn, cut or damaged in any way.

GENERAL SAFETY WARNINGS

WEAR A DUST MASK THAT IS DESIGNED TO BE USED WHEN OPERATING A POWER TOOL IN A DUSTY ENVIRONMENT.

WARNING: Dust that is created by power sanding, sawing, grinding,

drilling, and other construction activities may contain chemicals that are known to cause cancer, birth defects, or other genetic abnormalities. These chemicals include:

Lead from lead-based paints Crystalline silica from bricks, cement, and other masonry products Arsenic and chromium from chemically treated lumber

The level of risk from exposure to these chemicals varies, according to how often this type of work is performed. In order to reduce exposure to these chemicals, work in a well-ventilated area, and use approved safety equipment, such as a dust mask that is specifically designed to filter out microscopic particles.

Page 5

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 personal injury.

WORK AREA

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

Do not operate power tools in potentially explosive environments, such as in the presence of flammable liquids, gas or dust. Power tools create sparks that may ignite dust or fumes.

Keep bystanders, children and visitors away while operating the tool. Distractions can cause the operator to lose control.

ELECTRICAL SAFETY

Double insulated tools are equipped with a polarized plug (one blade is wider than the other). This plug will only fit into a polarized plug one way.

If the plug does not fit into the outlet properly, reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized outlet. Do not alter the plug in any way. Double insulation eliminates the need for the three-pronged grounded power cord and grounded power supply system.

Avoid contact between the operator's body and grounded surfaces such as pipes, radiators, ranges, and refrigerators. There is an increased risk of electric shock if the operator's body is grounded.

Do not expose power tools to rain or wet conditions. Water entering the power tool will increase the risk of electric shock.

Do not abuse the cord. Do not use the power cord to carry the tool or to pull the plug out of the outlet. Keep the power cord away from heat, oil, sharp edges, and moving parts. Replace a damaged power cord immediately. A damaged power cord increases the risk of electric shock.

When operating a power tool outdoors, use an outdoor-rated extension cord type “W-A” or “W”. These cords are rated for outdoor use and they reduce the risk of electric shock.

PERSONAL SAFETY

Stay alert, be aware of the surroundings, 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 a power tool may result in serious personal injury.

Dress properly. Do not wear loose clothing or jewellery.

Contain long hair. Keep hair, clothing, and gloves away from moving parts. Loose clothing, jewellery, or long hair can get caught in moving parts.

POWER TOOL SAFETY

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PERSONAL SAFETY – cont’d

Avoid accidental start-ups. Verify that the switch is in the OFF position before plugging in the tool. Carrying a power tool with a finger on the switch or plugging in a tool that has the switch in the ON position invites accidents.

Remove adjusting keys and wrenches before turning the tool ON. A wrench or 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 allows the operator to maintain better control of the tool in unexpected situations.

Use safety equipment. Always wear eye protection.

Use a dust mask, non-skid safety shoes, a hardhat, or hearing protection when appropriate.

USE AND CARE OF POWER TOOLS Use clamps or another practical means to

secure and support the workpiece to a stable platform. Holding the work in a hand or against the body is not stable, and may lead to loss of control.

Do not force the tool. Use the correct tool for the application. The correct tool will do the job better and safer when used at the rate that it was designed to work at.

Do not use a power tool if it cannot be turned ON or OFF using the power switch. A tool that cannot be controlled using the switch is dangerous, and must be repaired.

Disconnect the plug from the outlet before making any adjustments, changing accessories, or storing the tool. Such preventive safety measures reduce the risk of accidental start-ups.

When power tools are not in use, store them out of the reach of children or untrained persons. Tools are dangerous in the hands of untrained users.

Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind, and are easier to control.

Inspect the tool for misalignment or binding of moving parts, broken parts, and any other condition that may affect the operation of the tool. If it is damaged, have the tool serviced before using it. Many accidents are caused by poorly maintained tools.

Use only accessories that are recommended by the manufacturer for this model. Accessories that are suitable for one tool may become hazardous when used with another tool.

SERVICE Tools servicing must be performed by

qualified personnel. Service or maintenance performed by non-qualified personnel could result in a risk of injury.

When servicing a tool, use only identical replacement parts. Follow the instructions in the Maintenance section of this Manual. The use of unauthorized parts or failure to follow the instructions in the Maintenance section of this Manual may create a risk of electric shock or injury.

POWER TOOL SAFETY

Page 7

WARNING: Know your hammer drill. Do not plug in the charger or install the battery in the tool until you have read and understand this

Instruction Manual. Learn the tool’s

applications and limitations, as well as the specific potential hazards related to this tool. Following this rule will reduce the

risk of electric shock, fire, or serious injury.

Always wear eye protection. Any power tool can throw

foreign objects into your eyes and cause permanent eye damage. ALWAYS wear safety goggles (not glasses) that comply with ANSI safety standard Z87.1. Everyday glasses have only impact resistant lenses. They ARE NOT safety glasses.

WARNING: Glasses or goggles not in compliance with ANSI Z87.1 could cause serious injury when they break.

WARNING: Always use a safety

shield, hearing protection and dust mask when operating the drill in

“hammer” mode. Use only hammer drill bits and accessories

that are designed for use with a hammer drill when using this hammer drill in the hammer mode. Standard drill bits are NOT designed for use in a hammer drill and MUST NOT be used with a hammer drill. They may shatter and possibly cause serious injury.

Do not drill material too small to be securely held.

Always keep hands out of the path of the drill bit. Avoid awkward hand positions where a sudden slip could cause your hand to move into the path of the drill bit.

Secure workpiece. Use clamps or a vice to hold the workpiece. It is safer than using your hand and it frees both hands to operate the tool.

Make sure there are no nails or foreign objects in the part of the workpiece to be drilled.

To avoid injury from accidental starting, always remove the battery from the tool before installing or removing a drill bit.

Do not install or use any drill bit that

exceeds 7” (17.5 cm) in length or extends more than 6” (15 cm) beyond the chuck

jaws. They can bend or break suddenly. Before starting the operation, jog the drill

switch to make sure the drill bit does not wobble or vibrate.

Do not use fly cutters or multiple-part hole cutters, because they can come apart or become unbalanced during use.

Make sure the spindle has come to a complete stop before touching the chuck or attempting to change the drill bit.

Always make sure the chuck is tight and the drill bit firmly tightened in the chuck before starting drill.

SPECIFIC SAFETY RULES

SAVE THESE INSTRUCTIONS FOR REFERENCE

Page 8

WARNING: Only use the PowerXchange diagnostic charger to charge the following Mastercraft batteries:

● 18 V Ni-Cd #54-3102-2

● 18 V Lithium-ion #54-3100-6

Charging any other batteries may damage the charger, and possibly cause serious injury. Check your PowerXchange diagnostic charger manual for other batteries that may be charged in the PowerXchange battery family.

Do not store or carry battery in a manner in which metal objects could contact the exposed metal end. Do not place battery in aprons, pockets, drawers, etc. with loose nails, screws, keys etc. The battery could short circuit causing a fire, personal injury or damage to the battery.

Never attempt to open the battery for any reason. If the housing of the battery breaks or cracks, immediately discontinue use and do not recharge.

Do not charge the battery if it is wet or shows any evidence of corrosion.

A small leakage from the battery may occur under extreme usage, charging or temperature conditions. This does not indicate a failure. However, if the outer seal is broken and this leakage gets on your skin, follow these steps:

1. Wash immediately with soap and

water.

2. Neutralize with a mild acid such as

lemon juice or vinegar.

3. If liquid gets into your eyes, flush

immediately with clean water for a minimum of 10 minutes and seek medical attention.

NOTE: The battery liquid is slightly acidic. Do not incinerate the battery. It can

explode in a fire. Do not use an extension cord. Plug the

charger cord directly into an electrical outlet.

Use the charger only in a standard 110–120 V, 60 Hz electrical outlet.

Do not use the charger in wet or damp conditions. It is intended for indoor use only. Do not use the charger near sinks or tubs. Do not immerse the charger in water.

Do not allow the cord to hang over the edge of a table or counter or touch hot surfaces. The charger should be placed away from sinks and hot surfaces.

Do not use charger to charge any batteries other than the hammer drill batteries specified for that charger. Other batteries may explode.

Do not operate charger if cord or plug is damaged. Replace damaged cord and plug immediately.

Do not operate charger if it has received a sharp blow, been dropped or otherwise damaged in any way. Have a qualified technician examine the charger and repair it if necessary. Do not disassemble the charger.

BATTERY & CHARGER SAFETY

Page 9

Do NOT charge Ni-Cd or Ni-MH batteries when the temperature of the work area or the battery is above 55° C (131° F). Do NOT charge Li-ion batteries when the work area or the battery temperature is at or below 0°C (32° F) or above 45° C (113° F).

Unplug the charger when not in use and before cleaning or maintenance.

BATTERY PACK RECYCLING To preserve our natural resources, please

recycle or dispose of batteries properly. The batteries accompanying this tool may

contain chemicals and metals that are harmful to the environment. Never dispose of re-chargeable batteries in your normal household garbage or in landfill sites as they will add to the pollution of the environment.

Please return all defective rechargeable battery packs to your local Canadian

Tire™ store for recycling. If you do not

have a Canadian Tire™ store in your area,

please call 1-800-822-8837 for the location of your nearest RBRC battery recycling location.

Consult your local waste authority for information regarding additional available recycling and disposal options.

BATTERY & CHARGER SAFETY

NOTE: See Pages 32 & 33 for

detailed information concerning preparation for recycling battery packs and exercising the Ni-Cd battery pack for peak performance.

Page 10

Volts

Amperes

Hertz

Watts

Kilowatts

Microfarads

Litres

Kilograms

Hours

N/cm2

Newtons per square centimetre

Pascals

Min

Minutes

Seconds

Alternating current

Three-phase alternating current

Three-phase alternating current with neutral

Direct current

No load speed

Alternating or direct current

Class II construction

Splash-proof construction

Watertight construction

Protective grounding at grounding terminal, Class I tools

Revolutions or reciprocations per minute

Diameter

Off position

Arrow

Warning symbol

SYMBOLS

WARNING: Some of the following symbols may appear on the tool.

Study these symbols and learn their meaning. Proper interpretation of these symbols will allow for more efficient and safer operation of this tool.

3042597

HOMOLOGUÉ

This symbol designates that this tool is listed with Canadian requirements by ETL Testing Laboratories, Inc. Conforms to UL Std. 60745-1, 60745-1-1, 60745-2-2. Certified to CAN/CSA Std. C22.2 No. 60745-1, 60745-2-1, 60745-2-2.

Page 11

AVAILABLE ACCESSORIES

WARNING: Use only accessories

that are recommended for this hammer drill. Follow the instructions that accompany the accessories. The use of improper accessories may result in injury to the operator or damage to the hammer drill.

Before using any accessory, carefully read

the instructions or the owner’s manual for

the accessory.

 Drill bits  Hammer drill bits  Screwdriver bits  Nut drivers

WARNING: If any part is missing or damaged, do not plug charger into the power source or install the battery in the tool until the missing or damaged part is replaced.

KNOW YOUR HAMMER DRILL

ACCESSORIES

LED lights

Depth

stop rod

Chuck

Variable speed

trigger switch

Forward/reverse

button

LCD

display

Gear box

switch

Battery release

button

Torque

clutch

LED Light

switch

LCD

Display switch

Spirit

level

Air vents

Auxiliary handle

with bit storage

Battery

Page 12

CONTENTS Carefully unpack the hammer drill.

Compare the contents against the “HAMMER DRILL COMPONENTS” chart at right. NOTE: See illustration of hammer drill on Page 13.

WARNING: To avoid fire or toxic reaction, never use gasoline, naphtha, acetone, lacquer thinner or similar highly volatile solvents to clean the tool.

CONTENTS

HAMMER DRILL COMPONENTS

KEY

DESCRIPTION

QTY

Hammer drill

Depth stop rod

Depth stop rod mounting clamp

1-hour LED diagnostic charger

Blow-moulded case

18 V Ni-Cd battery

Screwdriver bits

● #1/#2

● #2 & 15/64"

(6 mm)

1 1

Auxiliary handle

Owner’s manual

Page 13

CONTENTS

Page 14

POSITIONING THE CHARGER Position the charger (1) in a dry location

within 5’ (1.5 m) of a 110–120 V 60 Hz electrical outlet. The charger can either be placed with its rubber feet on a table or workbench, or hung on a wall.

1. To hang the charger on a wall, place 2

nails or screws (1) in the wall where you want the charger to hang (Fig. 1).

NOTE: The nail or screw heads must be 1/4" (6.4 mm) in diameter, and the head must be left 3/8" (8.3 mm) out from the wall, placed 3" (7.62 cm) apart.

2. Place the large mounting access hole

(2) over the nail or screw head and slide the charger downward until it hangs on the nail or screw.

STORING THE CHARGER

To store the charger, simply wrap the cord around the charger (1) and insert the cord into the cord clip (2) (Fig. 2).

ASSEMBLY AND OPERATING

Fig. 1

Fig. 2

Page 15

CHARGING THE BATTERY PACK WARNING: Only use the

PowerXchange diagnostic charger to charge the following Mastercraft batteries:

● 18 V Ni-Cd #54-3102-2

● 18 V Lithium-ion #54-3100-6

Charging any other batteries may damage the charger, and possibly cause serious injury.

1. To charge the battery, place the

charger (1) in a dry location near a 110–120 V, 60 Hz electrical outlet (Fig. 3).

2. Place the battery stem (2) into the

matching cavity (3) in the top of the charger.

NOTE: Make sure the battery is pressed fully onto the charger as far as it will go.

3. Plug the battery charger into the 110–

120 V, 60 Hz wall receptacle.

NOTE: Do NOT charge Ni-Cd or Ni-MH batteries when the temperature of the work area or the battery is above 55° C (131° F). Do NOT charge Li-ion batteries when the work area or the battery temperature is at or below 0° C (32° F) or above 45° C (113° F).

When the battery charger is plugged into a

“live” receptacle, the battery charger will

begin charging the battery. The red LED (4) and the green LED (5) on the top of the charger will indicate the charging status (Fig. 4).

ASSEMBLY AND OPERATING

Fig. 4

Fig. 3

Page 16

CHARGING THE BATTERY PACK – cont’d

CHARGER LED FUNCTIONS (Fig. 4a)

Power ON

The green LED will stay ON when the

charger is plugged into a ”live” power

source.

Battery partially charged

The red LED will flash during charging.

Battery fully charged

When a Ni-Cd or Ni-MH battery is approximately 98% charged, the red LED will turn OFF and the green LED will blink for about 1 hour then stay continuously ON, indicating the battery is fully charged. The blinking green LED indicates the charger is in trickle charge mode while completing the charging cycle. When a Li-ion battery is nearly fully charged, the red LED will turn OFF and the green LED will blink for a few minutes while completing the charge.

NOTE: You may use the battery as soon as the green LED begins to flash, as the battery will be at least 98% charged.

Defective battery

The red LED will stay ON when a defective battery is detected and it should be replaced.

Too hot or too cold

Both the red LED and the green LED will stay ON when the work area or battery temperature is either too high or too low. Remove the battery from the charger and let it sit at room temperature 21° C (70° F) for about one hour, and resume charging.

ASSEMBLY AND OPERATING

Red light

Green

light Function

—

---

—

Power ON

Battery charging

Trickle charging

Defective battery

Too hot or too cold

Flashing

Fig. 4a

Page 17

INSTALLING A BATTERY IN THE HAMMER DRILL

1. Remove the discharged battery (1)

from the tool by pressing on one the battery release buttons (2) on the sides of the drill handle (Fig. 5).

NOTE: There is one battery release button on each side of the handle. It is only necessary to press one of the buttons to release the battery.

2. Pull the battery out of the tool handle

(3).

3. Slide the fully charged battery into the

matching cavity in the tool handle where the discharged battery has been removed.

NOTE: Make sure the battery is fully engaged with the mounting slots in the tool handle. The battery release buttons will “click” into place when the battery is fully installed.

WARNING: Do not immerse battery

pack in water. Sudden cooling could cause hot battery to explode or leak.

ASSEMBLY AND OPERATING

Fig. 5

Page 18

ADJUSTING THE TORQUE

Your drill is equipped with an adjustable torque clutch for driving different types of screws into different types of materials. It

also has settings for “drilling” and “hammer

drilling”. The proper setting depends upon

the type of material and size of screw being used and the function required.

Adjust the torque setting as follows:

1. Identify the torque settings located on

the torque adjustment ring (1) (Fig. 6).

2. Rotate adjustment ring to align the

correct torque setting number with the torque indicator arrow (2). See the chart on the following page for correct torque settings.

 1–5 For driving small screws  6–10 For driving medium sized screws

into soft materials

 11–15 For driving screws into soft &

medium-density materials

 16–20 For driving screws into

hardwood

 21–25 For driving large screws  For drilling. This position is

marked with a drill bit icon (3) on the torque adjustment ring (Fig. 7).

 Use the highest setting

indicated by a hammer icon (4) for hammer mode.

ASSEMBLY AND OPERATING ASSEMBLY AND OPERATING

Fig. 6

Fig. 7

Page 19

INSTALLING THE AUXILIARY SIDE HANDLE

Install the auxiliary handle (1) for twohanded operation of the drill (Fig. 8). This is particularly important for hammer drilling in concrete.

NOTE: The auxiliary handle can be installed on either the left or right side of the hammer drill.

1. Insert the threaded mounting screw

(2) through the depth stop rod clamp (3) and into the threaded hole in the drill housing (4).

NOTE: Make sure the key in the clamp is aligned with the matching slot in the drill housing.

2. Turn the auxiliary handle clockwise to

tighten it into the drill housing.

NOTE: Tighten the handle by hand only. Do NOT overtighten the handle or you will damage the handle or the housing.

BIT STORAGE IN AUXILIARY HANDLE

Screwdriver bits and drill bits can be stored in the auxiliary handle.

1. To store bits in the auxiliary handle

(1), remove the end cap (2) by turning it counter-clockwise (Fig. 9).

2. Insert the bits to be stored in the

handle.

3. Insert the end cap into the handle and

tighten it into place by turning it clockwise.

ASSEMBLY AND OPERATING

Fig. 8

Fig. 9

Page 20

INSTALLING THE DEPTH STOP ROD

The depth stop rod is used as a gauge to control the depth of the drilled hole. The depth stop rod can be used with the hammer drill in either the normal drilling mode or in the hammer drill mode.

1. Turn the auxiliary handle (1) counter

clockwise about three turns to open the depth stop rod mounting clamp (2) (Fig. 10).

2. Insert hexagonal end of depth rod (3)

into the matching hole (4) in the depth stop rod mounting clamp.

3. Position the depth stop rod so the tip

of the round end will contact the workpiece when the drill reaches the appropriate depth.

4. When the depth stop rod is properly

positioned, tighten the depth stop rod mounting clamp by turning the auxiliary handle clockwise. Tighten by hand only.

NOTE: Tighten the handle by hand only. Do NOT overtighten or you will damage the handle or housing.

TWO-SPEED GEAR BOX SWITCH Set the speed-control switch (1) to the

desired speed (Fig. 11). Slide the speedcontrol switch FORWARD for low-speed operation. Slide the speed-control switch BACK for high-speed operation.

ASSEMBLY AND OPERATING

Fig. 10

Fig. 11

Page 21

TWO SPEED GEAR BOX SWITCH – Cont’d

NOTES: a) Use low-speed setting for drilling large

holes and for driving screws.

b) Use high-speed setting for drilling

smaller holes.

c) Do NOT change the speed-control

switch position while drill is turned ON. Damage to the gears may result.

FORWARD/REVERSE SWITCH

The forward/reverse switch (1) is conveniently mounted above the trigger switch (2) (Fig. 12). To make the drill rotate clockwise for drilling or driving screws, push the forward/reverse switch to the left. To make the drill rotate counter-clockwise for removing screws, push the forward/reverse switch to the right. NOTES: a) The auxiliary handle has been removed for illustrative purposes. b) Never change the position of the forward/reverse switch while chuck is turning. c) The trigger switch will NOT function with the forward/reverse switch in the middle position.

SPIRIT LEVEL

The drill is equipped with a dual reading horizontal/vertical level to assist in keeping the drill “level” while drilling horizontal and vertical holes.

The horizontal level (1) is located in the top of the drill housing (Fig. 13). The vertical level (2) is located on the rear of the drill housing.

ASSEMBLY AND OPERATING

Fig. 12

Fig. 13

Page 22

SPIRIT LEVEL – cont’d

To maintain a horizontal drilling position, hold the drill so the horizontal level bubble (3) is centred in the level indicator circle (4) (Fig. 14). To maintain a vertical drilling position, hold the drill so the vertical level bubble (5) is centred in the level indicator circle (6) (Fig. 15).

VARIABLE-SPEED TRIGGER SWITCH

This drill is equipped with a variable-speed ON/OFF trigger switch.

1. To start drill, gently squeeze the

trigger switch (1) (Fig. 16).

NOTE: The drill will turn at its slowest speed when the trigger switch is depressed slightly. The drill will turn at its fastest speed when the trigger switch is fully depressed.

2. To stop the drill, release the trigger

switch.

NOTE: Drilling at a slow speed for an extended period of time may cause the drill motor or the battery pack to overheat. If either the drill or the battery get hot, stop drilling and allow them to cool for at least 15 minutes.

ASSEMBLY AND OPERATING

Fig. 14

Fig. 15

Fig. 16

Page 23

DUAL LED WORKLIGHTS

Dual LED worklights (1) are located behind the torque collar (2) (Fig. 17). The LED switch button (3) is located below the LCD panel on the top of the drill (Fig. 18).

1. To turn the LED lights ON, first press

the LCD display switch (5) once, then press the LED switch (3) once. The LED lights will turn OFF automatically when the tool is not operated for approximately 5 minutes.

2. To turn the LED lights OFF, press the

LED switch again.

LCD DISPLAY

This hammer drill is equipped with an LCD panel (4) in the top of the drill housing (Fig. 19).

1. To turn the display ON, press the

display button (5) once. To turn the display OFF, press the display button again.

2. The light icon (6) will become visible

when the LED worklights are turned ON.

3. The battery icon (7) indicates the

amount of charge remaining in the battery. Each charge bar displayed indicates approximately 10% charge remaining in the battery. A total of 10 charge bars indicates a fully charged battery.

ASSEMBLY AND OPERATING

Fig. 18

Fig. 19

Fig. 17

Page 24

INSTALLING DRILL BITS

WARNING: Never hold the chuck

body with one hand and use the drill power to rotate the drill body to loosen or tighten bits. Serious injury may result.

This hammer drill is equipped with a Jacobs® single-sleeve keyless Hammerlock® chuck.

This chuck is designed to provide easy one-handed tightening and loosening of the chuck jaws. It also provides a positive bit locking mechanism that prevents the bit from slipping during the high vibration hammer drilling action.

1. To open the keyless drill chuck, grasp

and hold the chuck body (1) and rotate it in a counter-clockwise direction until the chuck jaws (2) open wide enough to accept the bit (3) (Fig. 20).

NOTE: The drill spindle will automatically lock when the drill is stopped.

2. Insert the bit into the chuck the full

length of the jaws. Raise the front of your drill slightly to prevent the bit from falling out of the chuck jaws.

3. Tighten the chuck jaws onto the bit by

turning the chuck body in a clockwise direction.

NOTE: Make sure the bit is properly aligned in the jaws and NOT at an angle. An improperly aligned bit could be thrown from the chuck when the drill is started. Make sure the chuck jaws grasp the flat sides of a screwdriver bit.

ASSEMBLY AND OPERATING

Fig. 20

Page 25

INSTALLING DRILL BITS – cont’d

4. Finish tightening the chuck jaws.

Firmly grasp the chuck body with your hand and rotate it in a clockwise direction.

NOTES:

a) The automatic spindle lock will prevent the spindle from rotating while the chuck body is being tightened. b) As the chuck jaws begin to tighten on the bit, you will hear a clicking sound. Continue to rotate the chuck body until the clicking stops and you can no longer turn it any further BY HAND. c) Hand-tighten chuck body. Do NOT use pliers. You will damage the chuck.

WARNING: Do not insert drill bit into chuck and tighten as shown in Fig. 21. The drill bit MUST be properly

inserted with all three of the chuck jaws holding the bit centred in the chuck. Failure to properly insert drill bit could cause the drill bit to be thrown from the chuck, resulting in possible serious injury or damage to the chuck.

REMOVING BITS

1. To open the keyless drill chuck, grasp

and hold the chuck collar and rotate it in a counter-clockwise direction until the chuck jaws open and release the bit.

2. Remove the bit.

ASSEMBLY AND OPERATING

Fig. 21

Page 26

DRILLING

When drilling into smooth, hard surfaces such as metal, use a centre punch to mark the desired hole location. This will prevent the drill bit from slipping off centre as the hole is started.

ASSEMBLY AND OPERATING

For safety reasons, the operator must read the sections of this

Owner’s Manual entitled “GENERAL SAFETY WARNINGS”, “POWER TOOL SAFETY”, “SPECIFIC SAFETY RULES”, “BATTERY & CHARGER SAFETY” and “SYMBOLS” before

using this hammer drill. Verify the following every time the

hammer drill is used:

1. Safety glasses, safety goggles, or face shield is being worn.

2. Hearing protection and dust mask are being worn when

using the drill in “hammer”

mode.

3. The chuck has not worked loose on the spindle.

4. A hammer rated drill bit is being

used when drilling in “hammer”

mode.

5. The bit is in good condition, and is properly tightened into the chuck.

Failure to observe these safety rules will significantly increase the risk of injury.

WARNING

Page 27

DRILLING – cont’d

The workpiece to be drilled should be secured in a vice or with clamps to keep it from turning as the bit rotates (Fig. 22).

1. Check the drill bit to make sure it is firmly locked into the drill chuck, and verify that the forward/reverse switch is in the forward position.

2. Set torque clutch to the drilling position.

3. Hold the drill firmly with both hands whenever possible. Use one hand to grasp the handle and switch, and the other to grasp the body of the drill or the auxiliary handle if it is installed.

NOTE: Make sure the hand placed on the body of the drill does not cover the air vents. Covering these air vents will reduce motor cooling, and possibly lead to overheating the motor.

4. While holding the drill firmly, place the point of the drill bit at the point to be drilled. Squeeze the switch trigger to start the drill.

NOTES: a) Always use a higher drill speed when drilling small holes. Use a slower drill speed when drilling large holes. b) Use a masonry bit with the drill in hammer mode ONLY when drilling in concrete or masonry.

5. Move the drill bit into the workpiece applying only enough pressure to keep the bit cutting. Do not force the drill bit or apply sideways pressure to elongate the hole.

ASSEMBLY AND OPERATING

Fig. 22

Page 28

DRILLING – cont’d

WARNING: Be prepared for

binding and bit breakthrough. When these situations occur, the drill bit has a tendency to grab the workpiece. This action will kick the drill opposite to the direction of drill bit rotation, and could cause loss of control when breaking through material as you complete drilling the hole. If you are not prepared, this loss of control can result in serious injury.

When drilling metals, use a light oil on the drill bit to keep it from overheating. The oil will prolong the life of the drill bit and improve the cutting action. If the bit jams in the workpiece, or if the drill stalls, release the trigger switch immediately. Remove the bit from the workpiece and determine the reason for jamming.

DRILLING IN CONCRETE WARNING: Always use a face

shield and hearing protection when drilling in concrete.

Always use the hammer mode for faster drilling in concrete. Use slower speeds when using bits over 1/2” (13 mm) in diameter. Always use carbide tipped masonry bits.

DRIVING SCREWS

When driving screws, care must be taken to use the bit that correctly fits the screw being driven. Make sure you use the largest bit size that will properly fit into the head of the screw.

ASSEMBLY AND OPERATING

Page 29

DRIVING SCREWS – cont’d

1. Select the correct screwdriver bit for the screw being driven.

2. Fasten the screwdriver bit into the chuck, making sure the flat sides of the bit are gripped by the chuck jaws.

3. Set the torque clutch to the appropriate setting based on the chart on Page 18.

NOTE: If material is particularly soft or porous, set the torque clutch to a lower setting to avoid overdriving the screw. When driving small screws in soft wood (torque settings 1-5), be ready to release the trigger to prevent overdriving the screw.

4. If the screw is driven too far into the workpiece before the clutch releases, set the clutch to a lower setting, and do not pull the trigger switch fully back. If the screw is not driven far enough into the workpiece, set the clutch to a higher setting.

NOTE: Do not continue to drive the screw once the clutch has released. This causes unnecessary wear of the clutch.

REMOVING THE CHUCK

To remove the chuck:

1. Remove the battery pack from the drill.

2. Insert a 5/16” (8 mm) or larger hex key (1) into the chuck (2) and tighten the chuck jaws securely (Fig. 23). Make sure each of the chuck jaws (3) is seated on the flat surfaces of the hex key.

ASSEMBLY AND OPERATING

Fig. 23

Page 30

REMOVING THE CHUCK – cont’d

3. Tap the hex key sharply with a mallet (4) in a clockwise direction. This action will loosen the screw in the chuck for easy removal.

4. Open chuck jaws and remove the hex key.

5. Open the chuck jaws as far as possible.

6. Remove the chuck screw using a #2 screwdriver (Fig. 24).

NOTE: Turn the screw CLOCKWISE to remove it. This screw has a left-handed thread.

7. Insert the hex key into the chuck and tighten jaws of chuck securely (Fig. 25). Tap the hex key sharply with a mallet in a COUNTER-CLOCKWISE direction. This will loosen the chuck on the spindle. The chuck can now be unscrewed and removed from the spindle by hand.

RETIGHTENING A LOOSE CHUCK

After installing a chuck that has previously been removed, the chuck may become loose on the spindle and develop a wobble. Also, the chuck screw may become loose, causing the chuck jaws to bind and preventing them from closing. To tighten the chuck, follow these steps:

1. Insert the hex key into the chuck and tighten the chuck securely.

ASSEMBLY AND OPERATING

Fig. 24

Fig. 25

Page 31

RETIGHTENING A LOOSE CHUCK – cont’d

2. Tap the hex key sharply with a mallet in a CLOCKWISE direction (Fig. 26). This will tighten the chuck on the spindle.

3. Open the chuck jaws and remove the hex key.

4. Tighten the chuck screw using a #2 screwdriver.

NOTE: Turn screw COUNTERCLOCKWISE to tighten it. This screw has a left-handed thread.

ASSEMBLY AND OPERATING

Fig. 26

Page 32

GENERAL

WARNING: When servicing, use

only identical replacement parts. The use of any other part may create a hazard or cause product damage.

DO NOT use solvents when cleaning plastic parts. Plastics are susceptible to damage from various types of commercial solvents and may be damaged by their use. Use a clean cloth to remove dirt, dust, oil, grease etc.

WARNING: Do not allow brake

fluids, gasoline, petroleum-based products, penetrating oils, etc. to come into contact with plastic parts. They contain chemicals that can damage, weaken or destroy plastic.

DO NOT abuse power tools. Abusive practices can damage the tool and the workpiece.

WARNING: DO NOT attempt to

modify tools or create accessories. Any such alteration or modification is misuse and could result in a hazardous condition leading to possible serious injury. It will also void the warranty.

LUBRICATION

All of the bearings in this tool are lubricated with a sufficient amount of highgrade lubricant for the life of the unit under normal conditions. Therefore, no further lubrication is required.

BATTERY PACK REMOVAL AND PREPARATION FOR RECYCLING

To preserve our natural resources, please recycle or dispose of batteries properly.

The batteries accompanying this tool may contain chemicals and metals that are harmful to the environment. Never dispose of rechargeable batteries in your normal household garbage or in landfill sites, because they will add to the pollution of the environment.

Consult your local waste authority for information regarding available recycling and disposal options.

WARNING: Upon removal of the

battery pack, cover the terminals of the battery pack with electrical tape or heavy-duty adhesive tape. Never touch both terminals with metal objects or body parts, because a short circuit may result. Keep away from children. Do not attempt to destroy or disassemble battery pack or remove any of its components. Rechargeable batteries must be recycled or disposed of properly. Failure to comply with these warnings could result in fire and serious injury.

MAINTENANCE

! ! !

Page 33

NICKEL-CADMIUM BATTERY MAINTENANCE

Nickel-cadmium batteries are powerful, rugged and provide hundreds of charge/discharge cycles if properly maintained and periodically ‘exercised’. Exercising is required to recover most of the capacity lost during usage. This process reduces the size of the active cadmium hydroxide crystals on the anode, to expose the entire surface area and restore capacity.

How to care for your Nickel-cadmium battery

1. Never allow a battery to freeze.

2. Never charge a Ni-CD or Ni-MH battery that has been stored at temperatures above 55° C (131° F). Allow it to sit at room temperature for at least 30 minutes before charging.

3. Do not charge a battery if it feels warm to the touch.

4. Never charge a battery after a short use. Let it sit until it is needed again.

5. Never charge the battery until the tool in which it is being used cannot produce useful work.

HOW TO EXERCISE A NICKELCADMIUM BATTERY

NOTE: Ni-Cd and Ni-Mh batteries have a

self discharge rate of approximately 1% per day. The self discharge rate depends upon the temperature.

1. Every two months or after 30 charge/discharge cycles, whichever comes first, fully discharge your battery. To fully discharge the battery, place it in the tool that it came with and work with the tool until it nearly stops and no longer produces useful action.

2. If the tool came in a kit with a worklight, insert the battery into the light. Turn the switch ON and leave it ON until the filament is cherry red.

3. Let the battery rest for 30 minutes at room temperature 21° C (70° F) before charging.

4. Charge the fully discharged battery for approximately 1 hour at 21° C (70° F).

LITHIUM-ION BATTERY MAINTENANCE

Lithium-ion batteries share many characteristics with Nickel-Cadmium batteries.

The major characteristic that is NOT shared with Nickel-Cadmium batteries is that Lithium-ion batteries do not have a

“memory” and do not require to be

completely discharged periodically. It is recommended that you charge your Lithium-ion batteries after each use so they will be fully charged when needed.

NOTE: A fully charged battery will loose about 2% of its charge per month during storage.

MAINTENANCE

Page 34

EXPLODED VIEW

Page 35

WARNING: When servicing, use only Mastercraft

replacement parts. The use of

any other parts may create a safety hazard or cause damage to the hammer drill. Any attempt to repair or replace electrical parts on this hammer drill may create a safety

hazard unless repairs are performed by a qualified technician. For more information, call the Toll-free Helpline, at 1-800-689-9928.

Always order by PART NUMBER, not by key number.

Key #

Part #

Part Name

Quantity

6516602033

Chuck screw

2800130101

Chuck

3100150101

Gear box

6511000812

Screw M5x8

2500200101

Motor assembly

4400700101

Speed selector button

4403890101

LED holder

4403900101

Depth rod clamp

5401980101

Depth rod

5800380101

Auxiliary handle

4403910101

Auxiliary handle end cap

5200990101

Decorative enclosure - left

6411391214

Screw ST3.9x12

3500420101

LCD display

4300710101

Left enclosure

8600840101

Spirit level

4403930101

Spirit level cover

3400480101

PCB

4403940101

Forward/reverse button

2700050301

Switch assembly

3601820101

Forward/reverse button retainer

5201000101

Decorative enclosure – right

6411391414

Screw ST3.9x14

6411391413

Screw ST3.9x14

4300720101

Right enclosure

2000070101

Battery pack

PARTS LIST

Page 36

3-Year Limited Warranty

This Mastercraft product is guaranteed for a period of 3 years from the date of original retail purchase against defects in workmanship and materials, except for the following components:

a) Component A: Batteries, chargers and carrying cases, which are

guaranteed for a period of 2 years from the date of original retail purchase against defects in workmanship and materials;

b) Component B: Accessories which are guaranteed for a period of 1 year

from the date of original retail purchase against defects in workmanship and materials.

Subject to the conditions and limitations described below, this product, if returned to us with proof of purchase within the stated warranty period and is covered under this warranty, will be repaired or replaced (with the same model, or one of equal value or specification),at our option. We will bear the cost of any repair or replacement and any costs of labour relating thereto.

These warranties are subject to the following conditions and limitations:

a) A bill of sale verifying the purchase and the purchase date must be

provided;

b) This warranty will not apply to any product or part thereof that is worn,

broken or that has become inoperative due to abuse, misuse, accidental damage, neglect or lack of proper installation, operation or maintenance (as outlined in the applicable owner’s manual or operating instructions) or that is being used for industrial, professional, commercial or rental purposes;

c) This warranty will not apply to normal wear and tear or to expendable parts

or accessories that may be supplied with the product that are expected to become inoperative or usable after a reasonable period of use;

d) This warranty will not apply to routine maintenance and consumable items

such as, including but not limited to, fuel, lubricants, vacuum bags, blades, belts, sandpaper, bits, fluids, tune-ups or adjustments;

e) This warranty will not apply where damage is caused by repairs made or

attempted by others (i.e.: persons not authorized by the manufacturer);

f) This warranty will not apply to any product that was sold to the original

purchaser as a reconditioned or refurbished product (unless specified otherwise in writing);

Page 1 of 2

Page 37

Rev 1.1 15/01/2008

3-Year Limited Warranty – cont’d

These warranties are subject to the following conditions and limitations:

g) This warranty will not apply to any product or part thereof if any part

from another manufacturer is installed therein or any repairs or alterations have been made or attempted by unauthorized persons;

h) This warranty will not apply to normal deterioration of the exterior

finish, such as, including but not limited to, scratches, dents, paint chips, or to any corrosion or discoloring by heat, abrasive and chemical cleaners; and

i) This warranty will not apply to component parts sold by and identified

as the product or company, which shall be covered under the product manufacturer’s warranty, if any.

Additional Limitations

This warranty applies only to the original purchaser, and cannot be transferred. Neither the retailer not the manufacturer shall be liable for any other expense, loss or damage, including, without limitation, but not limited to any indirect, incidental, consequential or exemplary damages arising in connection with the sale, use or inability to use this product.

Notice to Consumer

This warranty gives you specific legal rights, and you may have other rights, which may vary from province to province. The provisions contained in this warranty are not intended to limit, modify, take away from, disclaim or exclude any statutory warranties set forth in any applicable provincial or federal legislation.

Mastercraft is a superior line of products selected for their workmanship and materials. These products are designed to meet rigorous quality and performance standards, and are approved by our Quality Assurance laboratory.

TOLL-FREE HELPLINE: 1-800-689-9928

Page 2 of 2