instruction manual impact driver - power tools plus 54-2735... · 2016-01-04 · instruction manual...

INSTRUCTION MANUAL

IMPACT DRIVER054-2735-2

If any parts are missing or damaged, or if you have any questions, please call our toll-free helpline at 1-800-689-9928.

Read and understand this instruction manual thoroughly before using the product. It contains important information for your safety as well as operating and maintenance advice.

Keep this instruction manual for future use. Should this product be passed on to a third party, then this instruction manual must be included.

TECHNICAL SPECIFICATIONS 4

SAFETY GUIDELINES 5–12

KEY PARTS DIAGRAM 13

ACCESSORIES 14

OPERATING INSTRUCTIONS 15–19

MAINTENANCE 20–21

EXPLODED VIEW 22

PARTS LIST 23

WARRANTY 24–25

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This symbol designates that this tool is listed by with both Canadian and U.S. requirements by Underwriters Laboratories.

61TNE213739JD2178U

IMPACT DRIVER 054-2735-2 IMPACT DRIVER 054-2735-2

Rating 120 V, 60 Hz, AC

Amperes 3.5 AMP

Impact speed 0–3,200 BPM

Torque 1400 in/lbs

Hex drive 1/4” Quick release

Weight 4 lb 7 oz (2.0 kg)

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4General safety warnings

WARNING: Before using this tool or any of its accessories, read this manual and follow all Safety Rules and Operating Instructions. The important precautions, safeguards and instructions appearing in this manual are not meant to cover all possible situations. It must be understood that common sense and caution are factors which cannot be built into the product.

This instruction manual includes the following:

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

EYE, EAR & LUNG PROTECTION

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.

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

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

SAVE THESE INSTRUCTIONS FOR REFERENCE

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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 lumberThe 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.

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 120 V AC operation. It must be connected to a 120 V AC, 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.

Power tool safety

WARNING: Read all safety warnings and all instructions. Failure to follow the

warnings and instructions may result in electric shock, fire and/or serious injury.

Save all warnings and instructions for future reference.

Work area safety

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

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


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Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

Electrical safety

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.

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.

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 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.

When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.

If operating a power tool in a damp location is unavoidable, use a ground fault circuit interrupter (GFCI) protected supply. Use of a ground fault circuit interrupter (GFCI) reduces the risk of electric shock.

Personal safety

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.

Use personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.

Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.


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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.

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

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.

If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards.

Power tool use and care

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.

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.

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 measures reduce the risk of starting the power tool accidentally.

Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.

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 accidents are caused by poorly maintained power tools.

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

Use the power tool, accessories and tool bits etc. in accordance with these instructions, 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.


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Hold power tool by insulated gripping surfaces, because the blade may contact its own cord. Cutting a “live” wire may make exposed metal parts of the tool “live” and could give the operator an electric shock.

Service

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.

Specific safety rules

WARNING: Know your impact driver. Read the Owner’s Manual carefully. 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.

Always use hearing protection when operating the impact driver.

Use only impact sockets and accessories that are designed for use with an impact driver. Do not use chrome plated sockets and accessories. Chrome plated sockets and accessories are designed for hand use only and MUST NOT be used with an impact driver. They may shatter and possibly cause serious injury.

Before each use, check the impact sockets and accessories for excessive wear or cracks. Worn or damaged sockets or accessories may shatter and possibly cause serious injury. Worn accessories may allow the socket to come off during operation of the impact driver.

After installing any accessory in the hex drive, pull outward on the accessory to ensure it is properly installed and cannot be pulled out of the hex drive.

Never use the impact driver as a torque wrench. Always use a torque wrench to adjust the fastener to the specified torque.


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Extension cord safety

WARNING: Keep the extension cord clear of the working area. Position the cord so it will not get caught on the workpiece, tools or any other obstructions while you are working with the power tool.

Make sure any extension cord used with this tool is in good condition. When using an extension cord, be sure to use one of heavy enough gauge to carry the current the tool will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating.

The table below shows the correct size to use according to cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number the heavier the cord.

Be sure your extension cord is properly wired and in good condition. Always replace a damaged extension cord or have it repaired by a qualified electrician before using it. Protect your extension cord from sharp objects, excessive heat and damp or wet areas.

Use a separate electrical circuit for your power tools. This circuit must not be less than 14 gauge wire and should be protected with either a 15 A time delayed fuse or circuit breaker. Before connecting the power tool to the power source, make sure the switch is in the OFF position and the power source is the same as indicated on the nameplate. Running at lower voltage will damage the motor.


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Keep the impact driver handle and body clean and free of oil and grease. Always use a clean dry cloth when cleaning. Do not use solvents, brake fluid, gasoline or other petroleum products to clean the tool. They will damage the tool.

Do not wear neckties or loose clothing.

When wearing gloves, they must be tight fitting and slip resistant type. Leather gloves offer the best protection.

Always use two hands when operating the impact driver. Use one hand on the handle and the other on the front of the tool body.

Never place your hand so it is touching the socket or accessory when the tool is turned ON. Your hand could be seriously injured.

Always remove the plug from the power source before installing or removing any socket or accessory.

Be ready for components to shift when removing any fastener. The speed of the fastener removal could cause unexpected shifting of the components.


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MINIMUM GAUGE (AWG) EXTENSION CORDS (120 V use only) Amperage rating Total length

More than

Not more than

25' (7.5 m)

50' (15 m)

100' (30 m)

150' (45 m)

0 6 18 16 16 14 6 10 18 16 14 12 10 12 16 16 14 12 12 16 14 12 Not Applicable

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... 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

0 ………….. Off position

……. Directional arrow ……... Warning symbol ……. Wear your safety glasses ……... Wear hearing protection

Symbols

V …............ VoltsA ………... AmperesHz ……… HertzW ………. WattskW ........... Kilowatts

........ MicrofaradsL ………... LitresKg ……… KilogramsH ………... HoursN/cm2 ....... Newtons per square centimetrePa ……… PascalsBPM ….. Beats per minuteMin ……. MinutesS ………... Seconds

or AC …... Alternating current

.. Three-phase alternating current

.. Three-phase alternating current with neutral

...... Read all safety warnings and instructions

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No. Description No. Description

1 Air vents 4 Forward/reverse button

2 Handle 5 1/4” hex drive

3 Variable speed trigger switch

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15Installing screwdriver bits or nut drivers

WARNING: Use only screwdriver bits that are designed for use with an impact driver. Do not use chrome plated sockets and accessories. Chrome plated sockets and accessories are designed for hand use only and MUST NOT be used with an impact driver. They may shatter and possibly cause serious injury.

WARNING: Always remove the plug from the power source before changing any sockets, bits or accessories. You may injure your hand if the tool is started accidentally.

1. To install a screwdriver bit, pull outward on the hex drive sleeve (1) (Fig. 1). While holding the hex drive sleeve out, insert the bit (2) fully into the hex drive and then release the outer sleeve.

2. When the hex drive sleeve is released, pull outward on the bit to ensure the retaining balls inside the hex drive are engaged with the groove in the bit (3) to prevent the bit from sliding out of the hex drive.

3. To remove the bit, pull outward on the hex drive sleeve and pull the bit out of the hex drive.

WARNING: Never use a screwdriver bit or nut driver that does NOT have the locking groove. These accessories will not be adequately held in the hex drive and could come loose and possibly injure the operator.

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SIllustration Description Size Qty

1/4” hex drive nut driver

3/16”, 1/4”, 9/32”, 5/16”, 11/32”, 3/8”

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Screwdriver bit R1, R2, R3 3

Screwdriver bit PZ1, PZ2, PZ3 3

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Tightening & removing fasteners

The most common uses for the impact driver are to drive or remove screws and to tighten or loosen small nuts.

The principles for operating the impact driver are the same for most applications. For illustrative purposes, driving a wood screw is shown. OP

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Forward/reverse button

This impact driver is equipped with a forward/reverse button (1) (Fig. 2).

1. To operate the impact driver in the forward direction, press the forward/reverse button to the LEFT for driving screws or tightening nuts.

2. To operate the impact driver in the reverse direction, press the forward/reverse button to the RIGHT for removing screws or removing nuts. NOTE: Never press the forward/reverse button while the tool it turned ON. Damage to the tool will result.

Variable speed trigger switch

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

1. To start tool, gently squeeze the trigger switch (2) (Fig. 3). NOTE: The tool will turn at its slowest speed when the trigger switch is depressed slightly. The tool will turn at its fastest speed when the trigger switch is fully depressed.

2. To stop the tool, release the trigger switch.


fig. 2

fig. 3

For safety reasons, the operator must read the sections of this Owner’s Manual entitled “GENERAL SAFETY WARNINGS”, “POWER TOOL SAFETY”, “SPECIFIC SAFETY RULES”, “EXTENSION CORD SAFETY” and “SYMBOLS” before using this impact driver.

Verify the following every time the impact driver is used:

1. Safety glasses and hearing protection are being worn.

2. Screwdriver bit or nut driver is “impact driver” rated.

3. Screwdriver bit or nut driver s in good condition.

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

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screw being driven.

2. Insert the bit into the hex drive (Fig. 1).

3. Set the forward/reverse button to the LEFT for driving screws (Fig. 2).

4. Insert the screwdriver bit (1) fully into the screw head (3) (Fig. 6).

5. While holding the impact driver firmly against the screw with both hands and the bit aligned with the screw, squeeze the trig-ger switch and drive the screw.

6. When the screw is driven to the correct depth, release the switch and the impact driver will stop.

NOTE: As the screw is driven into the wood, the torque required to completely drive the screw into the wood will increase. The impact function will allow you to continue driving the screw until it is fully nested in the countersunk area.

7. Release the trigger as soon as the screw is driven to the desired depth. Failure to release the trigger at this point will result in an overdriven screw and possibly twist the head off the screw.

8. To remove screws, follow the same general procedure as for driving screws.

9. Push the forward/reverse button to the RIGHT for removing screws.

10. Insert the bit fully into the screw head.

11. Hold the impact driver and bit firmly against the screw head and squeeze the trigger switch.

NOTE: The impact action will allow you to remove tight screws.


Preparing screw holes

It is important to prepare screw holes before attempting to fasten two pieces of wood together. Proper preparation will make screws drive easier and prevent misaligned components, stripped screw heads, splitting and separating of wood components.

1. Clamp components that are to be screwed together in their desired position (Fig. 4).

2. Drill a pilot hole (1) through the outer piece (2) and into the inner piece (3). Drill hole 2/3 the diameter of the smooth portion of the screw shank. NOTE: If the wood is soft, drill the hole 2/3 the length of the screw. If the wood is hard, drill the hole the full length of the screw.

3. Remove the clamp from the two pieces to be screwed together.

4. Enlarge the hole (1) in the outer piece (2) so it is the same size as the smooth portion of the screw shank (Fig. 5).

5. If using a flat head screw, counter-sink the hole (4) so the head of the screw will be flush with the surface when fully driven into place.

Driving screws

When driving screws, care must be taken to use a bit that correctly fits the head of the screw being driven. Be sure to use the largest bit size that will properly fit into the head of the screw. The bit must also be in good condition and not worn so it will drive screws without slipping out of the screw head.

Always hold the impact driver with two hands when driving and removing screws to provide the best possible control over the tool.

fig. 4

fig. 5

fig. 6

Replacing carbon motor brushes

The carbon motor brushes will wear down and require replacing. The time intervals between replacements will vary depending upon the torques being achieved and the hours of use. It is recommended that the brushes be checked after each 10 hours of use. When the length of the carbon brush reaches 1/4” (6.35 mm), the brushes should be replaced.

WARNING: Unplug the tool from the power source.

1. Use a 3/16” (4 mm) slot screwdriver and remove one brush cap (1) (Fig. 7). Turn the brush cap counter clockwise to remove it from the motor housing.

2. Pull the spring & brush assembly (2) from the brush holder (3) in the motor housing (4).

3. Insert the new spring & brush assembly into the motor housing.

4. Compress the spring into the brush holder and thread the brush cap back into the motor housing. NOTE: Make sure the brush cap threads are not cross-threaded. Do NOT over tighten.

5. Repeat steps 1 to 4 and replace the second carbon brush located on the opposite side of the motor housing.

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General

WARNING: When servicing, use only identical replacement parts. 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 at any time 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 as well as 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 high-grade lubricant for the life of the unit under normal conditions. Therefore, no further lubrication is required.

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WARNING: When servicing, use only Mastercraft® replacement parts. The use of any other parts may create a safety hazard or cause damage to the impact driver.

Any attempt to repair or replace electrical parts on this impact driver 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 Qty

21 4110050003 Pin 3

22 2030020229 Washer N0.4 1

23 4010010084 Bearing 6002-2RS 1

24 2010090067 Inner gear ring 1

25 3150070079 Gear box 1

26 4010010054 Bearing 6000-2RS 1

27 1010180009 Rotor 1

28 3150140006 Carbon brush cap 2

29 3150060015 Brush holder 2

30 1230010030 Carbon brush 2

31 2030070027 Brush holder support 1

32 4010010053 Bearing 607-2RS 1

33 1020180008 Stator 1

34 3011180004 Enclosure 1

35 3120030017 Direction setting button 1

36 1061010002 Switch 1

37 4030010106 Screw ST3.9X19 8

38 4030010098 Screw ST3.9X13 2

39 3140010004 Cord guard 1

40 1190030012 UL plug cord 1

Key # Part # Part Name Qty

1 2050080131 Fixing ring 1

2 2030020001 Washer No.1 1

3 2050060004 Bushing spring 1

4 2040170001 Bushing 1

5 4080030001 Ball 3.5 1

6 3140100006 Casting rubber cover 1

7 2020050059 Aluminum casting 1

8 4030010114 ST3.9X25 4

9 4040030001 Spring washer 4 4

10 3140020017 “O” ring 1

11 2010080012 Shaft bushing 1

12 2030020034 Washer No.2 1

13 2040050115 Outer shaft 1

14 4080070001 Steel ball 5.5 2

15 2040200002 Torsion slot 1

16 4080040001 Steel ball 4 21

17 2030020035 Washer No.3 1

18 2050060178 Torsion spring 1

19 2040050022 Inner shaft 1

20 2010010027 Planetary gear 3

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This Mastercraft® product is guaranteed for a period of three 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 case, which are guaranteed for a period of two 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 one 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 if 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 and that are expected to become inoperative or unusable after a reasonable period of use;

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

YEARANS3

LIMITED WARRANTY†

DE GARANTIE LIMITÉE†


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, including, but not limited to, scratches, dents, paint chips, or to any corrosion or discolouring by heat, abrasive and chemical cleaners; and i. This warranty will not apply to component parts sold by and identified as the product of another company, which shall be covered under that product manufacturer’s warranty, if any.

Additional LimitationsThis warranty applies only to the original purchaser, and cannot be transferred. Neither the retailer nor 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 ConsumerThis 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

Rev 2.5 19/08/2013

WAR

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instruction manual impact driver - power tools plus 54-2735... · 2016-01-04 · instruction manual...

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