Milwaukee 0302-20, 0299-20, 0201-20, 0101-20, 0200-20 User Manual
...
OPERATOR'S MANUAL
MANUEL de L'UTILISATEUR
MANUAL del OPERADOR
Catalog No.
No de Cat.
Catálogo No.
0100-20 0202-20
0101-20 0299-20
0200-20 0300-20
0201-20 0302-20
HEAVY-DUTY DRILLS
EXTRA ROBUSTES PERCEUSES
TALADROS PARA SERVICIO PESADO
TO REDUCE THE RISK OF INJURY, USER MUST READ AND UNDERSTAND
OPERATOR'S MANUAL.
AFIN DE RÉDUIRE LE RISQUE DE BLESSURES, L'UTILISATEUR DOIT LIRE ET
BIEN COMPRENDRE LE MANUEL DE L'UTILISATEUR.
PARA REDUCIR EL RIESGO DE LESIONES, EL USUARIO DEBE LEER Y
ENTENDER EL MANUAL DEL OPERADOR.
GENERAL SAFETY RULES-FOR ALL POWER TOOLS
WARNING!
READ ALL INSTRUCTIONS
Failure to follow all instructions listed below may result in electric shock, fire
and/or serious injury. The term "power tool" in all of the warnings listed
below refers to your mains-operated (corded) power tool or batteryopearted (cordless) power tool.
SAVE THESE INSTRUCTIONS
WORK AREA SAFETY
1. Keep work area clean and well lit.
Cluttered or dark areas invite accidents.
2. Do not operate power tools in ex-
plosive atmospheres, such as in
the presence of flammable liquids, gases, or dust. Power tools
create sparks which may ignite the dust
or fumes.
3. Keep children and bystanders
away while operating a power tool.
Distractions can cause you to lose
control.
ELECTRICAL SAFETY
4. Power tool plugs must match the
outlet. Never modify the plug in any
way. Do not use any adapter plugs
with earthed (grounded) power
tools. Unmodified plugs and matching
outlets will reduce risk of electric shock.
5. Avoid body contact with earthed
or grounded surfaces such as
pipes, radiators, ranges and refrigerators. There is an increased
risk of electric shock if your body is
earthed or grounded.
6. Do not expose power tools to rain
or wet conditions. Water entering a
power tool will increase the risk of
electric shock.
7. Do not abuse the cord. Never use
the cord for carrying, pulling, or
unplugging the power tool. Keep
cord away from heat, oil, sharp
edges, or moving parts. Damaged
or entangled cords increase the risk of
electric shock.
8. When operating a power tool out-
doors, use an extension cord suitable for outdoor use. Use of a cord
suitable for outdoor use reduces 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 you are 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. Use safety equipment. Always
wear eye protection. Safety equipment such as dust mask, non-skid
safety shoes, hard hat, or hearing protection used for appropriate conditions
will reduce personal injuries.
11. Avoid accidental starting. Ensure
the switch is in the off-position
before plugging in. Carrying tools
with your finger on the switch or plugging in power tools that have the
switch on invites accidents.
12. Remove any adjusting key or
wrench before turning the power
tool on. A wrench or a key left at-
tached to a rotating part of the power
tool may result in personal injury.
13. Do not overreach. Keep proper
footing and balance at all times.
This enables better control of the
power tool in unexpected situations.
14. Dress properly. Do not wear loose
clothing or jewellery. Keep your
hair, clothing and gloves away from
moving parts. Loose clothes,
jewellery, or long hair can be caught in
moving parts.
15. If devices are provided for the
connection of dust extraction and
collection facilities, ensure these
are connected and properly used.
Use of these devices can reduce dustrelated hazards.
POWER TOOL USE AND CARE
16. Do not force the power tool. Use
the correct power tool for your application. The correct power tool will
do the job better and safer at the rate
for which it was designed.
17. Do not use the power tool if the
switch does not turn it on and off.
Any power tool that cannot be controlled with the switch is dangerous
and must be repaired.
18. Disconnect the plug from the
power source and/or the battery
pack from the power tool before
making any adjustments, changing accessories, or storing power
tools. Such preventive safety mea-
sures reduce the risk of starting the
tool accidentally.
19. Store idle power tools out of the
reach of children and do not allow persons unfamiliar with the
power tools or these instructions
to operate power tools. Power
tools are dangerous in the hands of
untrained users.
20. Maintain power tools. Check for
misalignment or binding of moving parts, breakage of parts and
any other condition that may affect the power tool's operation. If
damaged, have the power tool
repaired before use. Many acci-
dents are caused by poorly maintained
power tools.
21. Keep cutting tools sharp and
clean. Properly maintained cutting
tools with sharp cutting edges are less
likely to bind and are easier to control.
22. Use the power tool, accessories
and tool bits etc., in accordance
with these instructions and in the
manner intended for the particular type of power tool, taking into
account the working conditions
and the work to be performed. Use
of the power tool for operations different from those intended could result in
a hazardous situation.
SERVICE
23. Have your power tool serviced by
a qualified repair person using
only identical replacement parts.
This will ensure that the safety of the
power tool is maintained.
32
SPECIFIC SAFETY RULES
GROUNDING
1. Hold power tools by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord. Contact
with a live wire will make exposed metal parts of the tool live and shock the operator.
2. Use auxiliary handles supplied with the tool. Loss of control can cause personal
injury.
3. Wear ear protectors with impact drills. Exposure to noise can cause hearing loss.
4. Maintain labels and nameplates. These carry important information. If
unreadable or missing, contact a MILWAUKEE service facility for a free replacement.
5. WARNING! Some dust created by power sanding, sawing, grinding, drilling, and other
construction activities contains chemicals known to cause cancer, birth defects or
other reproductive harm. Some examples of these chemicals are:
lead from lead-based paint
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 those dust masks that are specifically
designed to filter out microscopic particles.
Symbology
Double Insulated
Catalog
No.
Specifications
Volts
Amps
AC
No Load
RPM
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 plug provided
with the tool. Never remove the
grounding prong from the plug.
Do not use the tool if the cord or
plug is damaged. If damaged,
have it repaired by a MILWAUKEE
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
Tools marked Grounding Required have
a three wire cord and three prong grounding plug. The plug must be connected to a
properly grounded outlet (See Figure A). 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.
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.
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.
Double Insulated Tools:
Tools with Two Prong Plugs
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.
Double Insulated tools may be used in either of the 120 volt outlets shown in
Figures B and C.
Canadian Standards
Association
Underwriters
Laboratories, Inc.
Volts Alternating Current
No Load Revolutions
per Minute (RPM)
Amperes
Mexican Approvals Marking
0100-20
0101-20
0200-20
0201-20
0202-20
0299-20
0300-20
0302-20
120
120
120
120
120
120
120
120
7
7
7
7
7
8
8
8
0 - 2500
0 - 4000
0 - 1200
0 - 2500
0 - 1200
0 - 850
0 - 850
0 - 850
Fig. A
Fig. B
54
Fig. C
EXTENSION CORDS
FUNCTIONAL DESCRIPTION
Grounded tools require a three wire extension cord. Double insulated tools can
use either a two or three wire extension
cord. 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. Refer
to the table shown to determine the required minimum wire size.
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. When
using more than one extension cord to make
up the total length, be sure each cord contains at least the minimum wire size required. 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 wire size.
Guidelines for Using Extension Cords
If you are using an extension cord out-
doors, be sure it is marked with the
suffix W-A (W in Canada) to indicate that it is acceptable for outdoor
use.
Be sure your extension cord is prop-
erly wired and in good electrical
condition. Always replace a damaged
extension cord or have it repaired by a
qualified person before using it.
Protect your extension cords from
sharp objects, excessive heat and
damp or wet areas.
Recommended Minimum Wire
Gauge for Extension Cords*
Nameplate
Amperes
0 - 2.0
2.1 - 3.4
3.5 - 5.0
5.1 - 7.0
7.1 - 12.0
12.1 - 16.0
16.1 - 20.0
* Based on limiting the line voltage drop to
five volts at 150% of the rated amperes.
Extension Cord Length
25'
18
18
18
18
16
14
12
50'
18
18
18
16
14
12
10
75'
18
18
16
14
12
10
100'
18
16
14
12
10
150'
16
14
12
12
2
3
1
1. Chuck
2. Side handle*
3. Nameplate
4. Lock button
5. Trigger
6. Forward/Reverse switch
* Cat. Nos. 0200-20, 0202-20, 0299-20, 0300-20,
0302-20 only
4
6
5
READ AND SAVE ALL INSTRUCTIONS FOR FUTURE USE.
76
TOOL ASSEMBLY
CHUCK IDENTIFICATION
WARNING!
To reduce the risk of injury,
always unplug tool before attaching or removing accessories
or making adjustments. Use only
specifically recommended accessories. Others may be hazardous.
Removing and Replacing Quik-Lok
Cords (Fig. 1) (Cat. No. 0100-20,
0101-20, 0202-20, 0302-20
MILWAUKEE's exclusive Quik-Lok® Cords
provide instant field replacement or
substitution.
Fig. 1
1. To remove the Quik-Lok® Cord, turn the
cord nut 1/4 turn to the left and pull it
out.
2. To replace the Quik-Lok® Cord, align the
connector keyways and push the connector in as far as it will go. Turn the
cord nut 1/4 turn to the right to lock.
WARNING!
To reduce the risk of injury, always use a side handle when using this tool. Always brace and
hold securely.
Adjusting the Side Handle (Fig. 2)
(Cat. No. 0200-20, 0202-20, 0299-20,
®
0300-20, 0302-20)
Fig. 2
Side handle
Gearcase
Detents
Locking keys
1. Turn the side handle counterclockwise
to loosen.
2. Slide the side handle assembly forward
over the chuck and rotate to the desired angle.
3. Slide the side handle back to the
gearcase and position the locking keys
into the detents. The locking keys help
prevent the handle from slipping.
NOTE: The side handle ring must clear
the chuck.
4. Turn the side handle clockwise to
tighten.
NOTE: Always use the side handle for
best control.
Side handle ring
Chuck Type
Keyed
Double sleeve
Keyless
Single sleeve
Keyless
Installing and Removing Bits
WARNING!
To reduce the risk of injury, always remove the chuck key from
the chuck after each use.
Keyed Chuck (Fig. 3)
These tools are equipped with a chuck tightened using a key. Always unplug the tool
before installing or removing bits.
1. To open the chuck jaws, place the
chuck key in one (1) of the three (3)
holes located on the chuck. Turn the
key counterclockwise (Fig. 3).
Fig. 3
Be sure the bit shank and chuck jaws
are clean. Dirt particles may prevent
the bit from lining up properly.
2. When using drill bits, insert the bit into
the chuck. Center the bit in the chuck
jaws and lift it about 1/16" off of the
bottom. Tighten the chuck jaws by hand
to align the bit.
Loosen
Tighten
Drill Cat. No.
0100-20
0101-20
0200-20
0299-20
0300-20
0201-20
0202-20
0302-20
When using screwdriver bits, insert the
bit far enough for the chuck jaws to
grip the bit shank. Tighten the chuck
jaws by hand to align the bit.
3. To close the chuck jaws, place the
chuck key in each of the three holes in
the chuck. Turn the chuck key clockwise (Fig. 3). Tighten securely.
4. To remove the bit, insert the chuck key
into one of the holes in the chuck. Turn
the chuck key counterclockwise.
WARNING!
To reduce the risk of injury, do not
grasp the bit while the chuck is
rotating or while the bit is falling
from the chuck.
Double Sleeve Keyless
Chuck (Fig. 4, 5, & 6)
These tools are equipped with a hand tightening keyless chuck. Always unplug the
tool before installing or removing bits.
1. To open the chuck jaws, hold the collar
and turn the sleeve counterclockwise
(Fig. 4).
Fig. 4
Tighten
Loosen
98
Be sure the bit shank and chuck jaws
are clean. Dirt particles may prevent
the bit from lining up properly.
2. When using drill bits, insert the bit into
the chuck. Center the bit in the chuck
jaws and lift it about 1/16" off of the
bottom. Tighten the chuck jaws by hand
to align the bit (Fig. 5).
Fig. 5
When using screwdriver bits, insert the
bit far enough for the chuck jaws to
grip the bit shank. Tighten the chuck
jaws by hand to align the bit.
3. To close the chuck jaws, hold the collar
and turn the sleeve clockwise
(Fig. 6). Tighten securely.
Fig. 6
Collar
To close
Sleeve
Be sure the bit shank and chuck jaws
are clean. Dirt particles may prevent
the bit from lining up properly.
2. When using drill bits, insert the bit into
the chuck. Center the bit in the chuck
jaws and lift it about 1/16" off of the
bottom. Tighten the chuck jaws by hand
to align the bit (Fig. 8).
Fig. 8
When using screwdriver bits, insert the
bit far enough for the chuck jaws to
grip the bit shank. Tighten the chuck
jaws by hand to align the bit.
3. To close the chuck jaws, turn the chuck
sleeve clockwise (Fig. 9). Tighten securely. Several detents will be felt as
the chuck sleeve is turned.
Fig. 9
To close
WARNING!
To reduce the risk of injury,
always wear eye protection.
Chuck Removal (Fig. 7)
This tool is equipped with a threaded spindle
to hold the chuck. Before removing the
chuck, unplug the tool and open the chuck
jaws. A left-handed thread screw is located inside the chuck to prevent the chuck
from loosening when the tool is operated
in reverse direction. Remove the screw by
turning it clockwise. To remove the chuck,
hold the tool so that only the side of the
chuck rests firmly and squarely on a solid
workbench. Insert the chuck key or a chuck
remover bar in one of the keyholes. Turn
the chuck so the key is at about a 30° angle
to the bench top and strike the key sharply
with a hammer so the chuck turns in a
counterclockwise direction (looking from
the front of the tool). This should loosen
the chuck from the spindle which has a
right hand thread making it easy to remove
the chuck by hand.
NOTE: When replacing the chuck, always
replace the left hand thread screw in the
chuck.
Fig. 7
4. To remove the bit, hold the chuck collar
and turn the sleeve counterclockwise
to release the bit from the chuck jaws.
Single Sleeve Keyless Chuck
(Fig. 7, 8, & 9)
These tools are equipped with a spindlelock mechanism and a single-sleeve keyless chuck. Always unplug the tool before
inserting or removing bits.
1. To open the chuck jaws, turn the chuck
sleeve counterclockwise (Fig. 7).
Fig. 7
Tighten
Loosen
Sleeve
NOTE: If the spindle rotates when
opening or closing the chuck jaws,
grasp the chuck and slightly rotate back
and forth to engage the spindle-lock
mechanism.
The spindle will remain locked until the
tool is turned on. The spindle-lock
mechanism will automatically disengage when the tool is turned on.
4. To remove the bit, turn the chuck sleeve
counterclockwise to release the bit
from the chuck jaws.
1110
OPERATION
APPLICATIONS
WARNING!
To reduce the risk of injury, wear
safety goggles or glasses with
side shields. Unplug the tool
before changing accessories or
making adjustments.
Using Forward/Reverse Switch
(Fig. 10)
Fig. 10
Switch
1. For forward (clockwise) rotation, push
the forward/reverse switch to the left
position as shown.
2. For reverse (counterclockwise) rotation, push the forward/reverse switch
to the right position as shown. Although
an interlock prevents reversing the tool
while the motor is running, allow it to
come to a full stop before reversing.
Forward
Reverse
Trigger
WARNING!
To reduce the risk of injury, keep
hands and cord away from the bit
and all moving parts.
Starting, Stopping and Controlling
Speed
1. To start the tool, pull the trigger.
2. To stop the tool, release the trigger.
3. To vary the drilling speed, simply increase or decrease pressure on the
trigger. The further the trigger is pulled,
the greater the speed.
Locking Trigger (Fig. 11)
The lock button holds the trigger in the ON
position for continuous full speed use.
Fig. 11
Lock
button
1. To lock the trigger, hold the lock button
in while pulling the trigger. Release the
trigger.
2. To unlock the trigger, pull the trigger
and release. The lock button will pop
out.
Cat.
No Load
No.
0100-20
0101-20
0200-20
0201-20
0202-20
0299-20
0300-20
0302-20
NR = Not recommended
0 - 2500
0 - 4000
0 - 1200
0 - 2500
0 - 1200
0 - 850
0 - 850
0 - 850
Flat Boring
RPM
Bits
1-1/2"
1-1/4"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
Auger
Bits
NR
NR
1"
7/8"
1"
1-1/2"
1-1/2"
1-1/2"
WARNING!
To reduce the risk of explosion,
electric shock and property
damage, always check the work
area for hidden pipes and wires
before drilling.
Selecting Bits
When selecting a bit, use the right type for
your job. For best performance, always
use sharp bits.
Drilling
1. Before drilling, be sure the workpiece
is clamped securely. Use backing material to prevent damage to the workpiece during breakthrough.
2. When starting a hole, place the drill bit
on the work surface and apply firm
pressure. Begin drilling at a slow speed,
gradually increasing the speed as you
drill.
3. Always apply pressure in line with the
bit. Use enough pressure to keep the
drill biting, but do not push hard enough
to stall the motor.
4. Reduce pressure and ease the bit
through the last part of the hole. While
the tool is still running, pull the bit out of
the hole to prevent jamming.
Wood
NR
NR
NR
NR
NR
Path-
finder
1-1/4"
1-1/4"
1-1/4"
1-1/4"
1-1/4"
1-1/4"
Hole
Saws
3-1/4"
2-1/4"
3-1/4"
3-5/8"
3-5/8"
3-5/8"
Selffeed
Bits
NR
NR
2-9/16"
2-9/16"
2-9/16"
Drilling in Wood, Composition
Materials and Plastic
When drilling in wood, composition materials and plastic, start the drill slowly, gradually increasing speed as you drill. When
using twist drill bits, pull the bit out of the
hole frequently to clear chips from the bit
flutes. Use low speeds for plastics with a
low melting point.
Drilling in Masonry
When drilling in masonry, use high speed
carbide-tipped bits. Drilling soft masonry
materials such as cinder block requires little
pressure. Hard materials like concrete require more pressure. A smooth, even flow
of dust indicates the proper drilling rate.
Do not let the bit spin in the hole without
cutting. Do not use water to settle dust or
to cool bit. Both actions will damage the
carbide.
Drilling in Metal
When drilling in metal, use high speed steel
twist drills or hole saws. Use slow speeds
for hard metals and high speeds for softer
metals. Lubricate drill bits with cutting oil
when drilling in iron or steel. Use a coolant
when drilling in nonferrous metals such as
copper, brass or aluminum. Back the material to prevent binding and distortion on
breakthrough.
Bits
NR
NR
Wood/Steel
TM
Twist
Bits
1/4"
1/4"
1/2"
1/2"
1/2"
3/4"
3/4"
3/4"
Steel
Hole
Saws
NR
NR
1-5/8"
NR
1-5/8"
2"
2"
2"
1312
Driving Screws
When driving screws, use the proper
screwdriver bit for your job. After drilling
pilot and shank holes, start the screw
slowly and increase the speed as driving
progresses. Set the screw by slowing to
a stop. Do not run screws down at excessive speeds. To remove screws, reverse
the motor.
Stalling
If the tool seems as if it is about to stall,
maintain a firm grip and reduce pressure
slightly to allow the bit to regain speed. If
the tool does stall, release the trigger immediately. Reverse the motor, remove the
bit from the work and start again. Do not
pull the trigger on and off in an attempt to
start a stalled drill. This can damage the
drill.
WARNING!
High rotational force. To reduce
the risk of injury, always hold or
brace securely. Always use side
handle on tools rated 1200 rpm or
less.
Bit Binding
A high rotational force occurs when a bit
binds. If the bit binds, the tool will be forced
in the opposite direction of the bit rotation
(See Fig. 12-14). Bits may bind if they are
misaligned or when they are breaking
through a hole. Wood boring bits can also
bind if they run into nails or knots. Be prepared for bit binding situations.
To reduce the chance of bit binding:
Use sharp bits. Sharp bits are less likely
to bind when drilling.
Use the proper bit for the job. There are
bits that are designed for specific
purposes.
Use caution when drilling pitchy, knotty,
wet or warped material or when drilling in material that may contain nails.
Typical Bracing Methods
Fig. 12
Reaction
Bracing against the floor
Fig. 13
Forward
rotation
Bracing against your leg
Fig. 14
Reverse rotation
Bracing against a stud
Forward rotation
Reaction
Forward rotation
Reaction
MAINTENANCE
WARNING!
To reduce the risk of injury,
always unplug your tool before
performing any maintenance.
Never disassemble the tool or try
to do any rewiring on the tool's
electrical system. Contact a
MILWAUKEE service facility for
ALL repairs.
Maintaining Tools
Keep your tool in good repair by adopting a
regular maintenance program. Before use,
examine the general condition of your tool.
Inspect guards, switches, tool cord set and
extension cord for damage. Check for
loose screws, misalignment, binding of
moving parts, improper mounting, broken
parts and any other condition that may affect its safe operation. If abnormal noise
or vibration occurs, turn the tool off immediately and have the problem corrected
before further use. Do not use a damaged
tool. Tag damaged tools DO NOT USE until
repaired (see Repairs).
Under normal conditions, relubrication is
not necessary until the motor brushes
need to be replaced. After six months to
one year, depending on use, return your
tool to the nearest MILWAUKEE service
facility for the following:
Lubrication
Brush inspection and replacement
Mechanical inspection and cleaning
(gears, spindles, bearings, housing,
etc.)
Electrical inspection (switch, cord,
armature, etc.)
Testing to assure proper mechanical
and electrical operation
WARNING!
To reduce the risk of injury,
electric shock and damage to the
tool, never immerse your tool in
liquid or allow a liquid to flow
inside the tool.
Cleaning
Clean dust and debris from vents. Keep
the tool handles clean, dry and free of oil
or grease. Use only mild soap and a damp
cloth to clean your tool since certain cleaning agents and solvents are harmful to plastics and other insulated parts. Some of
these include: gasoline, turpentine, lacquer
thinner, paint thinner, chlorinated cleaning
solvents, ammonia and household detergents containing ammonia. Never use flammable or combustible solvents around
tools.
Repairs
If your tool is damaged, return the entire
tool to the nearest service center.
1514
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