Harbor Freight Tools Impact Driver 92798 User Manual

CORDLESS IMPACT WRENCH  
1/2” DRIVE - 19.2 VOLT  
Model 92798  
OPERATING INSTRUCTIONS  
®
3491 Mission Oaks Blvd., Camarillo, CA 93011  
TO PREVENT SERIOUS INJURY,  
READ AND UNDERSTAND ALL WARNINGS  
AND INSTRUCTIONS BEFORE USE.  
Copyright©2005 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, please call 1-800-444-3353.  
 
which may ignite the dust or fumes.  
3.  
1.  
Keep bystanders, children, and visitors away while operating a power tool.  
Distractions can cause you to lose control. Protect others in the work area from  
debris such as chips and sparks. Provide barriers or shields as needed.  
ELECTRICAL SAFETY  
Grounded tools must be plugged into an outlet properly installed and  
grounded in accordance with all codes and ordinances. Never remove the  
grounding prong or modify the plug in any way. Do not use any adapter  
plugs. Check with a qualified electrician if you are in doubt as to whether  
the outlet is properly grounded. If the tools should electrically malfunction or  
break down, grounding provides a low resistance path to carry electricity away  
from the user.  
2.  
3.  
Double insulated tools are equipped with a polarized plug (one blade is  
wider than the other). This plug will fit in a polarized outlet only one way. If  
the plug does not fit fully in the outlet, reverse the plug. If it still does not  
fit, contact a qualified electrician to install a polarized outlet. Do not  
change the plug in any way. Double insulation  
eliminates the need for the  
three wire grounded power cord and grounded power supply system.  
Avoid body contact with grounded surfaces such as pipes, radiators,  
ranges, and refrigerators. There is an increased risk of electric shock if your  
body is grounded.  
4.  
5.  
Do not expose power tools to rain or wet conditions. Water entering a power  
tool will increase the risk of electric shock.  
Do not abuse the Power Cord. Never use the Power Cord to carry the tools  
or pull the Plug from an outlet. Keep the Power Cord away from heat, oil,  
sharp edges, or moving parts. Replace damaged Power Cords immedi-  
ately. Damaged Power Cords increase the risk of electric shock.  
6.  
1.  
When operating a power tool outside, use an outdoor extension cord  
marked “W-A” or “W”. These extension cords are rated for outdoor use, and  
reduce the risk of electric shock.  
PERSONAL SAFETY  
Stay alert. Watch what you are doing, and use common sense when oper-  
ating a power tool. Do not use a power tool while tired or under the influ-  
ence of drugs, alcohol, or medication. A moment of inattention while operat-  
ing power tools may result in serious personal injury.  
SKU 92798  
For technical questions, please call 1-800-444-3353.  
Page 3  
 
2.  
3.  
4.  
5.  
6.  
Dress properly. Do not wear loose clothing or jewelry. Contain long hair.  
Keep your hair, clothing, and gloves away from moving parts. Loose  
clothes, jewelry, or long hair can be caught in moving parts.  
Avoid accidental starting. Be sure the Power Switch is off before plugging  
in. Carrying power tools with your finger on the Power Switch, or plugging in  
power tools with the Power Switch on, invites accidents.  
Remove adjusting keys or wrenches before turning the power tool on. A  
wrench or a key that is left attached to a rotating part of the power tool may result  
in personal injury.  
Do not overreach. Keep proper footing and balance at all times. Proper  
footing and balance enables better control of the power tool in unexpected  
situations.  
Use safety equipment. Always wear eye ANSI-approved safety impact eye  
goggles. Dust mask, non-skid safety shoes, hard hat, or hearing protection  
must be used for appropriate conditions.  
TOOL USE AND CARE  
1.  
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.  
2.  
3.  
Do not force the tool. Use the correct tool for your application. The correct  
tool will do the job better and safer at the rate for which it is designed.  
Do not use the power tool if the Power Switch does not turn it on or off.  
Any tool that cannot be controlled with the Power Switch is dangerous and must  
be replaced.  
4.  
Disconnect the Power Cord Plug from the power source before making any  
adjustments, changing accessories, or storing the tool. Such preventive  
safety measures reduce the risk of starting the tool accidentally.  
5.  
6.  
Store idle tools out of reach of children and other untrained persons. Tools  
are dangerous in the hands of untrained users.  
Maintain tools with care. Keep tools clean and dry. Properly maintained  
tools with a sharp cutting edge are less likely to bind and are easier to control.  
Do not use a damaged tool. Tag damaged tools “Do not use” until repaired.  
SKU 92798  
For technical questions, please call 1-800-444-3353.  
Page 4  
 
7.  
8.  
Check for misalignment or binding of moving parts, breakage of parts, and  
any other condition that may affect the tool’s operation. If damaged, have  
the tool serviced before using. Many accidents are caused by poorly main-  
tained tools.  
Use only accessories that are recommended by the manufacturer for your  
model. Accessories that may be suitable for one tool may become hazardous  
when used on another tool.  
SERVICE  
1.  
2.  
Tool service must be performed only by qualified repair personnel. Service  
or maintenance performed by unqualified personnel could result in a risk of injury.  
When servicing a tool, use only identical replacement parts. Follow  
instructions in the “Inspection, Maintenance, And Cleaning” section of this  
manual. Use of unauthorized parts or failure to follow maintenance instructions  
may create a risk of electric shock or injury.  
SPECIFIC SAFETY RULES  
1.  
2.  
Maintain a safe working environment. Keep the work area well lit. Make sure  
there is adequate surrounding workspace. Always keep the work area free of  
obstructions, grease, oil, trash, and other debris. Do not use the Impact Wrench  
in areas near flammable chemicals, dusts, and vapors. Do not use this product  
in a damp or wet location.  
Maintain labels and nameplates on the Impact Wrench. These carry  
important information. If unreadable or missing, contact Harbor Freight Tools for  
a replacement.  
3.  
4.  
5.  
When using the Impact Wrench, always maintain a firm grip on the tool with  
both hands.  
Do not use the Impact Wrench or Charger (39) if it has been dropped, dam-  
aged, left outdoors, or immersed in liquid.  
Do not charge the Battery (37) when the temperature is below 50 degrees  
Fahrenheit or above 104 degrees Fahrenheit.  
6.  
7.  
Do not shake, drop, or strike the Battery (37).  
To avoid electrical shock, do not pull or carry the Charger (39) by its  
Power Cord or pull the Power Cord around sharp corners or edges. Do not  
SKU 92798  
For technical questions, please call 1-800-444-3353.  
Page 5  
 
unplug the Charger by pulling on the Power Cord. Keep the Power Cord  
away from heated surfaces.  
8.  
To avoid electrical shock, do not handle the Charger (39), its Power  
Cord Plug, or the Impact Wrench with wet hands.  
9.  
Keep the Handle of the Impact Wrench dry, clean, free from oil and  
grease.  
10.  
11.  
Avoid unintentional starting. Make sure you are prepared to begin work  
before turning on the Impact Wrench.  
Never leave the Charger (39) unattended when it is plugged into an  
electrical outlet. Make sure to unplug it from its electrical outlet before leaving.  
12.  
13.  
Always turn off the Impact Wrench and unplug the Charger (39) from  
its electrical outlet before changing accessories or performing any inspec-  
tion, maintenance, or cleaning procedures.  
Always switch to a fresh Battery (37) when tool performance begins to  
diminish. Severe heat is most destructive to a Battery. The more heat gener-  
ated, the faster the Battery loses power. A Battery that gets too hot can be per-  
manently damaged. Never over-discharge a Battery by using the tool even after  
tool performance is decreasing. Never attempt to discharge a tool’s Battery by  
continuing to pull the tool’s trigger. When tool performance begins to diminish,  
stop the tool, recharge the Battery, and use the fresh Battery for optimal perfor-  
mance.  
14.  
Battery (37) leakage may occur under extreme usage or temperature condi-  
tions. If Battery fluid comes in contact with skin, wash with soap and water and  
rinse with lemon juice and vinegar. If the fluid comes into contact with the eyes,  
flush with water for several minutes and contact a doctor immediately.  
15.  
16.  
Never burn the Battery, as it can explode in a fire. Do not charge the Impact  
Wrench with a leaking Battery. Contact local solid waste authorities for instruc-  
tions on correct disposal or recycling of the Battery.  
WARNING! People with pacemakers should consult their physician(s)  
before using this product. Operation of electrical equipment in close proximity to  
a heart pacemaker could cause interference or failure of the pacemaker.  
17.  
WARNING! The warnings, precautions, and instructions discussed in this  
manual cannot cover all possible conditions and situations that may occur. The  
operator must understand that common sense and caution are factors, which  
cannot be built into this product, but must be supplied by the operator.  
SKU 92798  
For technical questions, please call 1-800-444-3353.  
Page 6  
 
GROUNDING  
WARNING!  
Improperly connecting the grounding wire can result in the risk of electric  
shock. Check with a qualified electrician if you are in doubt as to whether the  
outlet is properly grounded. Do not modify the power cord plug provided with  
the tool. Never remove the grounding prong from the plug. Do not use the  
tool if the power cord or plug is damaged. If damaged, have it repaired by  
a service facility before use. If the plug will not fit the outlet, have a proper  
outlet installed by a qualified electrician.  
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  
Standard Association, and the National Electrical Code.  
Double insulated tools may be used in either of the 120 volt outlets shown in the  
following illustration. (See Figure A.)  
120 VOLT, GROUNDED,  
ELECTRICAL OUTLET.  
FIGURE A  
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  
SKU 92798  
For technical questions, please call 1-800-444-3353.  
Page 7  
 
serious drop in voltage, resulting in loss of power and possible tool damage.  
(See Figure B.)  
3.  
4.  
5.  
The smaller the gauge number of the wire, the greater the capacity of the cord.  
For example, a 14 gauge cord can carry a higher current than a 16 gauge cord.  
(See Figure B.)  
When using more than one extension cord to make up the total length, make  
sure each cord contains at least the minimum wire size required.  
(See Figure B.)  
If you are using one extension cord for more than one tool, add the nameplate  
amperes and use the sum to determine the required minimum cord size.  
(See Figure B.)  
6.  
7.  
If you are using an extension cord outdoors, make sure it is marked with the  
suffix “W-A” (“W” in Canada) to indicate it is acceptable for outdoor use.  
Make sure your extension cord is properly wired and in good electrical condition.  
Always replace a damaged extension cord or have it repaired by a qualified  
electrician before using it.  
8.  
Protect your extension cords from sharp objects, excessive heat, and damp or  
wet areas.  
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS*  
(120 VOLT)  
NAMEPLATE  
AMPERES  
EXTENSION CORD LENGTH  
(At Full Load)  
25  
FEET  
18  
18  
18  
18  
16  
14  
12  
50  
FEET  
18  
18  
18  
16  
14  
12  
10  
75  
FEET  
18  
18  
16  
14  
12  
10  
-
100  
FEET  
18  
16  
14  
12  
10  
-
150  
FEET  
0-2.0  
2.1-3.4  
16  
14  
12  
12  
-
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.  
FIGURE B  
SKU 92798  
For technical questions, please call 1-800-444-3353.  
Page 8  
 
SYMBOLOGY  
Double Insulated  
Canadian Standards  
Association  
Underwriters  
Laboratories, Inc.  
Volts Alternating Current  
V ~  
A
Amperes  
No Load Revolutions  
per Minute (RPM)  
no  
xxxx/min.  
FIGURE C  
PRODUCT FEATURES  
NOTE: For additional information regarding the parts listed in the following pages, refer  
to the Assembly Diagram on page 13.  
1.  
WARNING! Always make sure the Trigger (36) of the Impact Wrench is in  
its “OFF” position, the Battery (37) is removed from the Impact Wrench, and the  
Charger (39) is unplugged from its electrical outlet prior to making any adjust-  
ments to the tool. (See Figure D, next page.)  
2.  
3.  
Trigger (36): The Trigger is operated manually simply by squeezing the Trigger to  
turn on the Impact Wrench and releasing pressure on the Trigger to turn off the  
Impact Wrench. (See Figure D.)  
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.  
(See Figure D.)  
4.  
1/2” Drive Impact Head (7): The 1/2” Impact Head features a spring and ball to  
securely hold a socket. The Impact Head accepts all sizes of standard and metric  
sockets having a 1/2” drive. (See Figure D.)  
REV 03/05  
SKU 92798  
For technical questions, please call 1-800-444-3353.  
Page 9  
 
5.  
6.  
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. (See Figure D.)  
Charger (39): The Charger is powered by plugging its 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. (See Figure D.)  
IMPACT HEAD  
(7)  
BATTERY  
(37)  
FORWARD/REVERSE  
SWITCH  
TRIGGER  
(36)  
(32)  
TO 120 VOLT,  
GROUNDED,  
ELECTRICAL  
OUTLET.  
CHARGER  
(39)  
BATTERY  
(37)  
FIGURE D  
TO CHARGE THE IMPACT WRENCH  
1.  
2.  
3.  
NOTE: The Battery (37) requires charging. The first charge requires 1 hour  
charge time prior to using the Impact Wrench. (See Figure D.)  
The Battery (37) should only be recharged when the Impact Wrench begins to  
run slowly. (See Figure D.)  
When the Battery (37) requires recharging, a 1 hour charge allows the tool to  
operate at full power. Do not recharge the Battery longer than 1 hour, as damage  
to the Battery and/or Impact Wrench will occur. (See Figure D.)  
4.  
Make sure the Trigger (36) on the Impact Wrench is in its “OFF” position. Slide  
the Battery (37) off the handle of the Impact Wrench. Insert the Battery into the  
charging socket of the Charger (39). Then plug the Charger into the nearest 120  
volt, grounded, electrical outlet. (See Figure D.)  
SKU 92798  
For technical questions, please call 1-800-444-3353.  
Page 10  
 
5.  
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 Battery  
(37) for 1 hour. NOTE: When the Battery is fully charged the RED Charging  
Indicator Light will turn off, and the GREEN Charged Light will illuminate. Subse-  
quent charging can also be done in 1 hour. (See Figure D.)  
6.  
7.  
While charging, the Battery (37) and Charger (39) may become warm to the touch.  
This is normal, and does not indicate a problem. (See Figure D.)  
Once the Battery (37) is fully charged, disconnect the Charger (39) from the  
electrical outlet. Remove the Battery from the Charger, and insert the Battery  
into the handle of the Impact Wrench. (See Figure D.)  
8.  
NOTE: If charging more than one Battery (37), allow the Charger (39) to cool  
down before reusing. (See Figure D.)  
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 D.)  
2.  
3.  
Whenever possible, secure the workpiece in place, using a vise or clamps (not  
included).  
Insert the fully charged Battery (37) into the handle of the Impact Wrench.  
(See Figure D.)  
4.  
Use the Forward/Reverse Switch (32) to select the turning rotation of the Impact  
Wrench. (See Figure D.)  
5.  
6.  
Insert the socket onto the nut that is to be loosened/tightened.  
Make sure to 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. (See Figure D.)  
7.  
8.  
When finished, release the Trigger (36) to stop the Impact Wrench. Then, re-  
move the Battery (37) and socket from the tool. (See Figure D.)  
Make sure to store the Impact Wrench in a dry, clean location out of reach of  
children and other unauthorized people.  
REV 03/05  
SKU 92798  
For technical questions, please call 1-800-444-3353.  
Page 11  
 
INSPECTION, MAINTENANCE, AND CLEANING  
1.  
2.  
WARNING! Always let the Trigger (36) rest in its “OFF” position, remove  
the Battery (37) from the tool, and unplug the Charger (39) from its electrical  
outlet before performing any inspection, maintenance, or cleaning.  
Before each use: Inspect the general condition of the Impact Wrench. Check for  
misalignment or binding of moving parts, cracked or broken parts, leaking Battery,  
damaged Charger wiring, chipped or broken sockets, and any other condition that  
may affect its safe operation. If abnormal noise or vibration occurs, have the prob-  
lem corrected before further use.  
Do not use damaged equipment.  
3.  
4.  
Daily: With a clean cloth, remove all dirt, grease, and oil from the Impact Wrench.  
Do not immerse the Impact Wrench in any liquids.  
It may become necessary at sometime to replace or clean the two Carbon Brushes  
(29) when the Motor performance decreases, or stops working completely.  
To replace the Carbon Brushes: Remove the two Brush Holder Caps (28). Then,  
remove 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 and replacing used brushes, try to  
install them in the same holders and in the same direction they were removed. 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 when first used until they wear  
and conform to the Motor’s Rotor.  
5.  
CAUTION! All maintenance, service, or repairs not listed in this manual  
are only to be attempted by a qualified service technician.  
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.  
REV 04/06  
SKU 92798  
For technical questions, please call 1-800-444-3353.  
Page 12  
 
PARTS LIST & ASSEMBLY DIAGRAM  
Part #  
Description  
Stun Screw (1)  
Washer (1)  
Front Cover  
Oilite Bearing  
Rubber Washer  
Plate Washer  
Impact Head  
Impact Shaft  
Bearing (1)  
Torque Spring  
Buffer Pad  
Spring Pad  
Master Impact Driver  
Steel Ball  
Planetary Gear  
Straight Pin  
Bearing Pad  
Bearing (2)  
Part #  
21  
Description  
Bearing (3)  
Armature  
Plate  
Washer (2)  
Stator  
Oilite Bearing (2)  
Carbon Brush Shaft  
Brush Holder Cap  
Carbon Brush  
Brush Holder  
Connector  
Forward/Reverse Switch  
Right Body  
Left Body  
1
2
3
4
5
6
7
8
9
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
Carrying Strap  
Trigger  
Battery  
Stun Screw (2)  
Charger  
Inner Rim  
Rim Shaft  
NOTE:  
Some parts are listed and shown for illustration purposes only,  
and are not available individually as replacement parts.  
SKU 92798  
For technical questions, please call 1-800-444-3353.  
Page 13  
 

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