Chicago Electric Impact Driver 96448 User Manual

19.2V 1/2” Cordless impaCt  
wrenCh  
model 96448  
set up and operating instruCtions  
Diagrams within this manual may not be drawn proportionally.  
Due to continuing improvements, actual product may differ slightly from the product described herein.  
®
distributed exclusively by harbor Freight tools  
3491 Mission Oaks Blvd., Camarillo, CA 93011  
Visit our website at: http://www.harborfreight.com  
read this material before using this product.  
Failure to do so can result in serious injury.  
saVe this manual.  
©
®
Copyright 2007 by Harbor Freight Tools . All rights reserved. No portion of this  
manual or any artwork contained herein may be reproduced in any shape or form  
without the express written consent of Harbor Freight Tools.  
For technical questions or replacement parts, please call 1-800-444-3353.  
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saVe this manual  
Keep this manual for the safety warnings and precautions, assembly, operating,  
inspection, maintenance and cleaning procedures. Write the product’s serial number  
in the back of the manual near the assembly diagram (or month and year of purchase if  
product has no number). Keep this manual and the receipt in a safe and dry place for  
future reference.  
important saFetY inFormation  
in this manual, on the labeling, and all other information  
provided with this product:  
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.  
danger indicates a hazardous situation  
which, if not avoided, will result in death or  
DANger  
serious injury.  
warning indicates a hazardous situation  
which, if not avoided, could result in death  
WArNINg  
or serious injury.  
Caution, used with the safety alert  
symbol, indicates a hazardous situation  
CAUTION  
which, if not avoided, could result in minor  
or moderate injury.  
notiCe is used to address practices not  
related to personal injury.  
Notice  
Caution, without the safety alert symbol,  
is used to address practices not related to  
CAUTION  
personal injury.  
SKU 96448  
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general saFetY rules  
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 battery-operated  
(cordless) power tool.  
saVe these instruCtions  
1.  
work area safety  
a. Keep work area clean and well lit. cluttered or dark areas invite accidents.  
b. Do not operate power tools in explosive atmospheres, such as in the pres-  
ence of flammable liquids, gases or dust. Power tools create sparks which  
may ignite the dust or fumes.  
c. keep children and bystanders away while operating a power tool. Dis-  
tractions can cause you to lose control.  
2.  
electrical safety  
a. 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. Unmodi-  
fied plugs and matching outlets will reduce risk of electric shock.  
b. Avoid body contact with earthed or grounded surfaces such as pipes, radia-  
tors, ranges and refrigerators. there is an increased risk of electric shock if  
your body is earthed or grounded.  
c. do not expose power tools to rain or wet conditions. Water entering a  
power tool will increase the risk of electric shock.  
d. do not abuse the cord. never use the cord for carrying, pulling or un-  
plugging the power tool. keep cord away from heat, oil, sharp edges or  
moving parts. Damaged or entangled cords increase the risk of electric  
shock.  
3.  
personal safety  
a. 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 influ-  
ence of drugs, alcohol or medication. A moment of inattention while operating  
power tools may result in serious personal injury.  
b. use safety equipment. always wear eye protection. Safety equipment  
such as dust mask, non-skid safety shoes, hard hat, or hearing protec-  
tion used for appropriate conditions will reduce personal injuries.  
c. remove any adjusting key or wrench before turning the power tool on. A  
wrench or a key left attached to a rotating part of the power tool may result in  
personal injury.  
SKU 96448  
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d. Do not overreach. Keep proper footing and balance at all times. this en-  
ables better control of the power tool in unexpected situations.  
e. Dress properly. Do not wear loose clothing or jewelry. Keep your hair, cloth-  
ing and gloves away from moving parts. Loose clothes, jewelry or long hair  
can be caught in moving parts.  
4.  
power tool use and care  
a. 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.  
b. Do not use the power tool if the Trigger does not turn it on and off. Any power  
tool that cannot be controlled with the trigger is dangerous and must be re-  
paired.  
c. disconnect the battery pack from the power tool before making any  
adjustments, changing accessories, or storing power tools. Such pre-  
ventive safety measures reduce the risk of starting the power tool acci-  
dentally.  
d. store idle power tools out of the reach of children and do not allow per-  
sons unfamiliar with the power tool or these instructions to operate the  
power tool. Power tools are dangerous in the hands of untrained users.  
e. Maintain power tools. Check for misalignment or binding of moving parts,  
breakage of parts and any other condition that may affect the power tools  
operation. If damaged, have the power tool repaired before use. Many ac-  
cidents are caused by poorly maintained power tools.  
f. Keep tools clean. Properly maintained tools are less likely to bind and are  
easier to control.  
g. Use the power tool, accessories and sockets 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.  
5.  
service  
a. Have your power tool serviced by a qualified repair person using only identi-  
cal replacement parts. this will ensure that the safety of the power tool is  
maintained.  
speCiFiC saFetY rules  
1.  
2.  
Maintain labels and nameplates on the tool. These carry important safety infor-  
mation. If unreadable or missing, contact Harbor Freight Tools for a replacement.  
Avoid unintentional starting. Prepare to begin work before turning on the tool.  
SKU 96448  
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3.  
4.  
5.  
6.  
Do not lay the tool down until it has come to a complete stop. Moving parts can  
grab the surface and pull the tool out of your control.  
When using a handheld power tool, maintain a firm grip on the tool with both  
hands to resist starting torque.  
Do not leave the tool unattended when it is plugged into an electrical outlet. Turn  
off the tool, and unplug it from its electrical outlet before leaving.  
Use clamps (not included) or other practical ways to secure and support the  
workpiece to a stable platform. Holding the work by hand or against your body is  
unstable and may lead to loss of control.  
7.  
The battery charger gets hot during use. The charger’s heat can build  
up to unsafe levels and create a fire hazard if it does not receive  
adequate ventilation, due to an electrical fault, or if it is used in a hot  
environment.  
Do not place the charger on a flammable surface. Do not obstruct any vents on  
the charger. especially avoid placing the charger on carpets and rugs; they  
are not only flammable, but they also obstruct vents under the charger.  
Place the charger on a stable, solid, nonflammable surface (such as a stable  
metal workbench or concrete floor) at least 1 foot away from all flammable ob-  
jects, such as drapes or walls. Keep a fire extinguisher and a smoke detector in  
the area. Frequently monitor the charger and battery during use.  
8.  
9.  
This product is not a toy. Keep it out of reach of children.  
People with pacemakers should consult their physician(s) before use. electro-  
magnetic fields in close proximity to heart pacemaker could cause pacemaker  
interference or pacemaker failure. In addition, people with pacemakers should:  
• Avoid operating alone.  
• Do not use with power switch locked on.  
• Properly maintain and inspect to avoid electrical shock.  
• Any power cord must be properly grounded. Ground Fault Circuit Interrupter  
(gFCI) should also be implemented – it prevents sustained electrical shock.  
10.  
Some dust created by power sanding, sawing, grinding, drilling, and other con-  
struction activities, contains chemicals known [to the State of California] to cause  
cancer, birth defects or other reproductive harm. Some examples of these chem-  
icals are: Lead from lead-based paints  
Crystalline silica from bricks and cement or other masonry products  
Arsenic and chromium from chemically treated lumber  
Your risk from these exposures varies, depending on how often you do this type  
of work. To reduce your exposure to these chemicals: work in a well ventilated  
area, and work with approved safety equipment, such as those dust masks that  
are specially designed to filter out microscopic particles. (California Health &  
Safety Code § 25249.5, et seq.)  
SKU 96448  
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11.  
12.  
Only use the included battery to power the Inpact Wrench. Never attempt to use  
a battery from any other powered tool in place of the battery for this tool.  
The warnings, precautions, and instructions discussed in this instruction manual  
cannot cover all possible conditions and situations that may occur. It must be  
understood by the operator that common sense and caution are factors which  
cannot be built into this product, but must be supplied by the operator.  
saVe these instruCtions.  
grounding  
improperly connecting the grounding wire can result in  
electric shock.  
WArNINg  
Check with a qualified electrician if you are in doubt as to  
whether the outlet is properly grounded. do not modify  
the power cord plug provided with the tool. never remove  
the grounding prong from the plug. do not use the tool if  
the power cord or plug is damaged. if damaged, have it  
repaired by a service facility before use. if the plug will not  
fit the outlet, have a proper outlet installed by a qualified  
electrician.  
grounded tools: tools with three prong plugs  
1.  
Tools marked with “Grounding Required” have a three wire cord and three prong  
grounding plug. The plug must be connected to a properly grounded outlet. If  
the tool should electrically malfunction or break down, grounding provides a low  
resistance path to carry electricity away from the user, reducing the risk of electric  
shock. (see 3-prong plug and outlet.)  
2.  
3.  
The grounding prong in the plug is connected through the green wire inside the  
cord to the grounding system in the tool. The green wire in the cord must be the  
only wire connected to the tool’s grounding system and must never be attached  
to an electrically “live” terminal. (see 3-prong plug and outlet.)  
The 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 the following illustration.  
(see 3-prong plug and outlet.)  
SKU 96448  
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outlets for 2-prong plug  
3-prong plug and outlet  
double insulated tools: tools with two prong plugs  
1.  
2.  
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 Stan-  
dard Association, and the National electrical Code.  
(see outlets for 2-prong plug.)  
Double insulated tools may be used in either of the 120 volt outlets shown in the  
preceding illustration. (see outlets for 2-prong plug.)  
extension Cords  
1.  
2.  
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.  
(see table a.)  
3.  
The smaller the gauge number of the wire, the greater the capacity of the cord.  
For example, a 14 gauge cord can carry a higher current than a 16 gauge cord.  
(see table a.)  
4.  
5.  
When using more than one extension cord to make up the total length, make  
sure each cord contains at least the minimum wire size required. (see table a.)  
If you are using one extension cord for more than one tool, add the nameplate  
amperes and use the sum to determine the required minimum cord size.  
(see table a.)  
6.  
If you are using an extension cord outdoors, make sure it is marked with the suf-  
fix “W-A” (“W” in Canada) to indicate it is acceptable for outdoor use.  
SKU 96448  
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7.  
8.  
Make sure the extension cord is properly wired and in good electrical condition.  
Always replace a damaged extension cord or have it repaired by a qualified elec-  
trician before using it.  
Protect the extension cords from sharp objects, excessive heat, and damp or wet  
areas.  
reCommended minimum wire gauge For eXtension Cords* (120/240 Volt)  
nameplate  
eXtension Cord length  
amperes  
(at full load)  
25 Feet  
50 Feet  
75 Feet  
100 Feet  
150 Feet  
0 – 2.0  
2.1 – 3.4  
18  
18  
18  
18  
18  
14  
12  
18  
18  
18  
16  
14  
12  
10  
18  
18  
16  
14  
12  
10  
-
18  
16  
14  
12  
10  
-
16  
14  
12  
12  
-
3.5 – 5.0  
5.1 – 7.0  
7.1 – 12.0  
12.1 – 16.0  
16.1 – 20.0  
taBle a  
-
-
-
* Based on limiting the line voltage drop to five volts at 150% of the rated amperes.  
symbology  
Double Insulated  
Volts Alternating Current  
Amperes  
V~  
a
Canadian Standards Association  
No Load revolutions per Minute  
(rPM)  
Underwriters Laboratories, Inc.  
n xxxx/min.  
0
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speCiFiCations  
Charger Input  
Charger Output  
Charge Time  
Speed  
120 V~, 60 Hz, 1.8 A  
7.2 - 24 V, 1.5 A  
1-3/4 - 2 Hours.  
0-2300 rPM  
Maximum Torque  
Battery Cell Type  
220 ft-lb  
NiCd, 1700 mAh, 1.2 V, Item 96756  
unpaCking  
When unpacking, check to make sure that the item is intact and undamaged. If  
any parts are missing or broken, please call Harbor Freight Tools at the number shown  
on the cover of this manual as soon as possible.  
list of contents  
description  
Qty  
Impact Wrench  
1
1
1
4
Charger  
Battery  
replacement Carbon Brush  
set up instruCtions  
read the entire important saFetY inFormation section at the  
beginning of this manual including all text under subheadings therein  
before set up or use of this product.  
risk of accidental starting; resulting in serious personal  
WArNINg  
injury. turn the Forward/reverse switch to the center, locked  
position and unplug the battery from the impact wrench  
before making any adjustments to the tool.  
note: For additional information regarding the parts listed in the following pages, refer  
to the Assembly Diagram near the end of this manual.  
tool Features  
1.  
Always make sure the Trigger (36) of the Impact Wrench is not depressed, the  
Forward/reverse Switch (32) is in the center, locked position, the Battery (37)  
is removed from the Impact Wrench, and the Charger (39) is unplugged from an  
electrical outlet prior to making any adjustments to the tool.  
reV 07l  
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trigger (36): Squeeze the Trigger to turn the Impact Wrench on and release pressure  
on the Trigger to turn the Impact Wrench off.  
Forward/reverse switch (32): The Forward/reverse Switch allows you to change  
the rotational direction of the Impact Wrench. For a clockwise rotation, move  
the Forward/reverse Button to the right. For a counterclockwise rotation, move  
the Forward/reverse Button to the left. To avoid damage to the Impact Wrench,  
always wait until the tool completely stops before changing rotational directions.  
1/2” drive impact head (7): The 1/2” Impact Head features a spring and ball to se-  
curely hold a socket.  
Battery (37): The power source for the Impact Wrench is a rechargeable, 19.2 VDC  
Battery. Make sure to follow all safety precautions when working with the Battery.  
Charger (39): The Charger is powered by plugging the Power Plug into a 120 volt,  
grounded, electrical outlet. NeVer attempt to power the Charger with any other  
electrical source other than a 120 volt, grounded electrical outlet.  
impact head  
(7)  
Battery (37)  
Forward/reverse  
switch (32)  
trigger (36)  
to 120 Volt,  
grounded,  
electrical  
outlet.  
Charger  
(39)  
Battery  
(37)  
Figure a  
Charging  
1.  
2.  
The Battery (37) must be charged between 1-3/4 to 2 hours, prior to the first use  
of the Impact Wrench.  
After first use, the Battery (37) should only be recharged when the performance  
of the Impact Wrench begins to diminish. Severe heat is destructive to batteries;  
the more heat generated, the faster the battery will lose power. A battery that  
gets too hot can be permanently damaged. Never discharge the battery by con-  
tinuing to pull the Trigger after the tool’s performance begins to diminish. Stop  
the tool, re-charge the battery, and use the fresh battery for optimal performance  
reV 07l, 08j  
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3.  
4.  
5.  
When the Battery requires recharging, a 1-3/4 hour charge allows the tool to op-  
erate at full power. Do not recharge the Battery longer than 2 hours, as damage  
to the Battery and/or Impact Wrench will occur.  
Slide the Battery off the handle of the Impact Wrench. Insert the Battery into  
the socket of the Charger (39). Then plug the Charger into the nearest 120 volt,  
grounded, electrical outlet.  
Verify that the reD Charging Indicator Light comes on. If it does not illuminate,  
check the power connection or try a different electrical outlet. Charge the Bat-  
tery for 1-3/4 hours. NOTe: When the Battery is fully charged the reD Charging  
Indicator Light will turn off, and the greeN Charged Light will illuminate.  
6.  
7.  
While charging, the Battery and Charger may become warm to the touch. This is  
normal and does not indicate a problem.  
Once the Battery is fully charged, disconnect the Charger from the electrical out-  
let. remove the Battery from the Charger, and insert the Battery into the handle  
of the Impact Wrench.  
note: Allow the battery to cool down before recharging it.  
note: To prevent accidents, turn off the tool and disconnect its power supply  
after use. Clean, then store the tool indoors out of children’s reach.  
operating instruCtions  
read the entire important saFetY inFormation section at the  
beginning of this manual including all text under subheadings therein  
before set up or use of this product.  
general operating instructions  
1.  
Before installing a socket, make sure the Battery (37) is removed from the Impact  
Wrench to avoid accidental starting. Then, firmly insert the Socket onto the 1/2”  
Impact Head (7) of the tool. (See Figure A.)  
2.  
3.  
4.  
Always fix the workpiece securely in place, using a vise or clamps (not included).  
Insert the fully charged Battery into the handle of the Impact Wrench.  
Use the Forward/reverse Switch (32) to select the turning rotation of the Impact  
Wrench.  
5.  
6.  
Insert the socket onto the nut that is to be loosened/tightened.  
Hold the Impact Wrench firmly with both hands, as torque from the Motor will  
cause the tool to twist. Then, squeeze the Trigger (36) to turn on the Impact  
Wrench.  
reV 07l  
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7.  
8.  
When finished, release the Trigger to stop the Impact Wrench. Then, remove the  
Battery and socket from the tool.  
Make sure to store the Impact Wrench in a dry, clean location out of reach of chil-  
dren and other unauthorized people.  
maintenanCe and serViCing  
risk of serious personal injury from accidental starting or  
electric shock. turn the Forward/reverse switch to the  
WArNINg  
center, locked position and disconnect the Battery before  
performing any inspection, maintenance, or cleaning  
procedures.  
damaged equipment can fail, causing serious personal  
injury. do not use damaged equipment. if abnormal noise or  
vibration occurs, have the problem corrected before further  
use.  
Cleaning and maintenance  
1.  
BeFore eaCh use, inspect the general condition of the tool. Check for loose  
screws, misalignment or binding of moving parts, cracked or broken parts, dam-  
aged electrical wiring, and any other condition that may affect its safe operation.  
2.  
3.  
aFter use, clean external surfaces of the tool with clean, moist cloth.  
warning! if the supply cord of this power tool is damaged, it must be  
replaced only by a qualified service technician.  
4.  
Dispose of the rechargeable NiCd battery according to State, Local and Federal  
regulations. Contact a local recycling center for disposal directions.  
replacing the Carbon Brushes  
1.  
2.  
3.  
It may become necessary at sometime to replace or clean the two Carbon Brush-  
es (29) when the Motor performance decreases, or stops working completely.  
remove the two Brush Holder Caps (28), then the two Carbon Brushes (29),  
keeping track of the orientation and location of each.  
If either Carbon Brush is worn more than halfway, replace both Carbon Brushes.  
If the Carbon Brushes are just dirty, however, they may be cleaned by rubbing  
them with a pencil eraser. If cleaning used brushes, try to install them in the  
same holders and orientation as when they were removed.  
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4.  
5.  
When installing the Carbon Brushes, make sure the carbon portion of the Carbon  
Brushes contact the Motor’s rotor and that the springs face away from the Motor.  
Also, make sure the springs operate freely.  
After replacement or cleaning, replace the two Brush Holder Caps.  
note: New Carbon Brushes tend to arc or spark until they wear and conform to the  
Motor’s rotor.  
troubleshooting  
problem  
possible Causes  
possible solutions  
Trigger Switch locked in  
place.  
1. Forward/reverse Switch is in  
1. Move button to the left or right for  
forward or reverse operation.  
center position.  
Impact Wrench operates 1. Battery weak.  
slowly or without force.  
1. recharge Battery completely.  
Impact Wrench does not  
turn on.  
1. Battery completely discharged. 1. recharge Battery completely.  
Battery will not hold  
charge.  
1. Battery dead. 1. replace with new Battery.  
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please read the Following CareFullY  
THe MANUFACTUrer AND/Or DISTrIBUTOr HAS PrOVIDeD THe PArTS LIST AND ASSeMBLY  
DIAgrAM IN THIS MANUAL AS A reFereNCe TOOL ONLY. NeITHer THe MANUFACTUrer Or  
DISTrIBUTOr MAKeS ANY rePreSeNTATION Or WArrANTY OF ANY KIND TO THe BUYer THAT  
He Or SHe IS qUALIFIeD TO MAKe ANY rePAIrS TO THe PrODUCT, Or THAT He Or SHe IS  
qUALIFIeD TO rePLACe ANY PArTS OF THe PrODUCT. IN FACT, THe MANUFACTUrer AND/Or  
DISTrIBUTOr exPreSSLY STATeS THAT ALL rePAIrS AND PArTS rePLACeMeNTS SHOULD  
Be UNDerTAKeN BY CerTIFIeD AND LICeNSeD TeCHNICIANS, AND NOT BY THe BUYer. THe  
BUYer ASSUMeS ALL rISK AND LIABILITY ArISINg OUT OF HIS Or Her rePAIrS TO THe  
OrIgINAL PrODUCT Or rePLACeMeNT PArTS THereTO, Or ArISINg OUT OF HIS Or Her  
INSTALLATION OF rePLACeMeNT PArTS THereTO.  
parts list  
part  
1
description  
part  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
description  
Screw (1)  
Washer (1)  
Front Cover  
Bearing  
Bearing (3)  
Armature  
Plate  
2
3
4
Washer (2)  
Stator  
5
rubber Washer  
Plate Washer  
Impact Head  
Impact Shaft  
Bearing (1)  
6
Bearing (2)  
7
Carbon Brush Shaft  
Brush Holder Cap  
Carbon Brush  
Brush Holder  
Connector  
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
Torque Spring  
Buffer Pad  
Spring Pad  
Forward/reverse Switch  
right Body  
Master Impact Driver  
Steel Ball  
Left Body  
Planetary gear  
Straight Pin  
Bearing Pad  
Bearing (2)  
Carrying Strap  
Trigger  
Battery  
Screw (2)  
Inner rim  
Charger (not shown)  
rim Shaft  
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assemBlY diagram  
38  
record products serial number here:  
note: If product has no serial number, record month and year of purchase instead.  
note: Some parts are listed and shown for illustration purposes only, and are not avail-  
able individually as replacement parts.  
SKU 96448  
For technical questions, please call 1-800-444-3353.  
Page 16  
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limited 90 daY warrantY  
Harbor Freight Tools Co. makes every effort to assure that its products meet high  
quality and durability standards, and warrants to the original purchaser that this prod-  
uct is free from defects in materials and workmanship for the period of 90 days from  
the date of purchase. This warranty does not apply to damage due directly or indirectly,  
to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities,  
criminal activity, improper installation, normal wear and tear, or to lack of maintenance.  
We shall in no event be liable for death, injuries to persons or property, or for incidental,  
contingent, special or consequential damages arising from the use of our product. Some  
states do not allow the exclusion or limitation of incidental or consequential damages, so  
the above limitation of exclusion may not apply to you. THIS WArrANTY IS exPreSS-  
LY IN LIeU OF ALL OTHer WArrANTIeS, exPreSS Or IMPLIeD, INCLUDINg THe  
WArrANTIeS OF MerCHANTABILITY AND FITNeSS.  
To take advantage of this warranty, the product or part must be returned to us  
with transportation charges prepaid. Proof of purchase date and an explanation of the  
complaint must accompany the merchandise. If our inspection verifies the defect, we  
will either repair or replace the product at our election or we may elect to refund the  
purchase price if we cannot readily and quickly provide you with a replacement. We will  
return repaired products at our expense, but if we determine there is no defect, or that  
the defect resulted from causes not within the scope of our warranty, then you must  
bear the cost of returning the product.  
This warranty gives you specific legal rights and you may also have other rights  
which vary from state to state.  
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353  
SKU 96448  
For technical questions, please call 1-800-444-3353.  
Page 17  
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