Bauer 1642E-B, 63443 - 1 in. SDS-PLUS Variable-Speed Rotary Hammer Manual

Introduction

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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.

When unpacking, make sure that the product is intact and undamaged. If any parts are missing or broken, please call 1-888-866-5797 as soon as possible.

Read this material before using this product. Failure to do so can result in serious injury. SAVE THIS MANUAL.

WARNING SYMBOLS AND DEFINITIONS

	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.
	Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
	Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
	Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE CAUTION	Addresses practices not related to personal injury.

IMPORTANT SAFETY INFORMATION

General Power Tool Safety Warnings

Read all safety warnings and 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.
The term 'power tool' in the warnings refers to your battery-operated (cordless) power tool.

Work area safety

1. Keep work area clean and well lit.
   Cluttered or dark areas invite accidents.
2. 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.
3. Keep children and bystanders away while operating a power tool.
   Distractions can cause you to lose control.

Electrical safety

1. Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with grounded power tools.
   Unmodifies plugs and matching outlets will reduce risk of electric shock.
2. 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.
3. Do not expose power tools to rain or wet conditions.
   There is an increased risk of will increase the risk of electric shock.
4. 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.
5. 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.
6. If operating a power tool in a damp location is unavoidable, use a Ground Fault Circuit Interrupter (GFCI) protected supply.
   Use of a GFCI reduces the risk of electric shock.

Personal safety

1. 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.
2. Use personal protective 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.
3. Prevent unintentional starting. Ensure the trigger is in the off-position before connecting to power source, picking up or carrying the tool.
   Carrying power tools with your finger on the Trigger or energizing power tools that have the Trigger on invites accidents.
4. 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.
5. Do not overreach. Keep proper footing and balance at all times.
   This enables better control of the power tool in unexpected situations.
6. Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves away from moving parts.
   Loose clothes, jewelry or long hair can be caught in moving parts.
7. If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used.
   Use of these deveces can reduce dust‑related hazards.
8. Only use safety equipment that has been approved by an appropriate standards agency.
   Unapproved safety equipment may not provide adequate protection. Eye protection must be ANSI-approved and breathing protection must be NIOSH-approved for the specific hazards in the work area.

Power tool use and care

1. 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.
2. 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 repaired.
3. Disconnect 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.
4. 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.
5. 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.
6. Keep cutting tools sharp and clean.
   Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
7. 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.

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.

Rotary Hammer Safety Warnings

1. Wear ear protectors with rotary hammers.
   Exposure to noise can cause hearing loss.
2. Use auxiliary handles supplied with the tool.
   Loss of control can cause personal injury.
3. Hold power tools by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord.
   Cutting accessory contacting a "live" wire may make exposed metal parts of the power tool "live" and could give the operator an electric shock.
4. Let bit cool before touching, changing or adjusting it.
   Bits heat up dramatically while in use, and can burn you.
5. If the drill bit jams, release the trigger immediately; drill torque can cause injury or break bit.
6. Maintain labels and nameplates on the tool. These carry important safety information. If unreadable or missing, contact Harbor Freight Tools for a replacement.
7. Avoid unintentional starting. Prepare to begin work before turning on the tool.
8. 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.
9. When using a handheld power tool, maintain a firm grip on the tool with both hands to resist starting torque.
10. 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.
11. This product is not a toy. Keep it out of reach of children.
12. People with pacemakers should consult their physician(s) before use. Electromagnetic 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.

13. 
    Some dust created by power sanding, sawing, grinding, drilling, and other construction activities, contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Some examples of these chemicals 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.)

14. 
    The cord of this product contains lead and/or di (2-ethylhexyl) phthalate (DEHP), chemicals known to the State of California to cause cancer, and birth defects or other reproductive harm. Wash hands after handling. (California Health & Safety Code § 25249.5, et seq.)
15. 
    This product contains di (2-ethylhexyl) phthalate (DEHP), a chemical known to the State of California to cause cancer and birth defects or other reproductive harm. (California Health & Safety Code § 25249.5, et seq.)
16. 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.

Vibration Safety

This tool vibrates during use. Repeated or long-term exposure to vibration may cause temporary or permanent physical injury, particularly to the hands, arms and shoulders. To reduce the risk of vibration-related injury:

1. Anyone using vibrating tools regularly or for an extended period should first be examined by a doctor and then have regular medical check-ups to ensure medical problems are not being caused or worsened from use. Pregnant women or people who have impaired blood circulation to the hand, past hand injuries, nervous system disorders, diabetes, or Raynaud's Disease should not use this tool. If you feel any symptoms related to vibration (such as tingling, numbness, and white or blue fingers), seek medical advice as soon as possible.
2. Do not smoke during use. Nicotine reduces the blood supply to the hands and fingers, increasing the risk of vibration-related injury.
3. Wear suitable gloves to reduce the vibration effects on the user.
4. Use tools with the lowest vibration when there is a choice.
5. Include vibration-free periods each day of work.
6. Grip tool as lightly as possible (while still keeping safe control of it). Let the tool do the work.
7. To reduce vibration, maintain the tool as explained in this manual. If any abnormal vibration occurs, stop use immediately.

SAVE THESE INSTRUCTIONS.

Grounding

TO PREVENT ELECTRIC SHOCK AND DEATH FROM INCORRECT GROUNDING WIRE ONNECTION: 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. 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.)
3. 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 preceding illustration. (See 3-Prong Plug and Outlet.)

Double Insulated Tools: Tools with Two Prong Plugs

1. 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.
2. 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. Grounded tools require a three wire extension cord. Double Insulated tools can use either a two or three wire extension cord.
2. 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. 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.)
5. 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 suffix "W-A" ("W" in Canada) to indicate it is acceptable for outdoor use.
7. 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 electrician before using it.
8. Protect the extension cords from sharp objects, excessive heat, and damp or wet areas.

TABLE A: RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS* (120/240 VOLT)

Symbology

	Double Insulated
	Canadian Standards Association
	Underwriters Laboratories, Inc.
	Volts Alternating Current
	Amperes
n0 xxxx/min.	No Load Revolutions per Minute (RPM)
	marking concerning Risk of Eye Injury. Wear ANSI-approved safety goggles with side shields.
	Read the manual before set-up and/or use.
	marking concerning Risk of Hearing Loss. Wear hearing protection.
	marking concerning Risk of Fire. Do not cover ventilation ducts. Keep flammable objects away.
	marking concerning Risk of Electric Shock. Properly connect power cord to appropriate outlet.

Specifications

Setup - Before Use

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.

TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:
Turn the Power Switch of the tool off and unplug the tool from its electrical outlet before assembling or making any adjustments to the tool.

Note: For additional information regarding the parts listed in the following pages, refer to Parts List and Diagram.

Functions

Figure A

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.

Tool Set Up

TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION: Press and release the Trigger and unplug the tool from its electrical outlet before adjusting tool or installing accessories.

Adjusting the Auxiliary Handle

1. The Auxiliary Handle can be placed in a variety of positions.
2. To adjust the Auxiliary Handle, turn the Handle counterclockwise to loosen the band. Slide the Handle on or off the Rotary Hammer or to the desired position then turn the Handle clockwise to secure it in place.

Using the Depth Gauge

Figure B

1. The Depth Gauge can only be used if the Auxiliary Handle is in place and positioned on either side or the top of the Rotary Hammer. The body of the Hammer will interfere with the Depth Gauge if the Handle is in the bottom position.
2. Press and hold the Lock Button and slide the Depth Gauge through the Depth Gauge Slot on the Auxiliary Handle.
3. Position the Depth Gauge as needed, then release the Lock Button to secure the Depth Gauge in place.

Adjusting the Functions

Figure C

1. Adjust the Function Dial before using the Rotary Hammer. To adjust the Function Dial, press the Dial Release Button on the Function Dial handle and rotate the dial until it clicks in place at one of the three positions.

NOTICE: Move the Function Dial only when the Motor is stopped. Attempting to move the Function Dial while the Motor is engaged will result in abrupt Bit rotation and can cause property damage.

NOTICE: When moving the Function Dial, make sure the Dial clicks into the desired position. If not actively engaged, the Dial could slip out of position resulting in tool damage.

2. To Drill: Rotate the Function dial to the Drill setting. The Rotary Hammer will revolve when powered.
3. To Hammer/Drill: Rotate the Function Dial to the Hammer/Drill setting. The Rotary Hammer will revolve and hammer when powered.
4. To Chisel: Rotate the Function Dial to the Hammer setting. The Rotary Hammer will hammer when powered.

Changing Drill Bits

Wear heavy-duty work gloves to provide protection when inserting and removing drill bits. Drill bits become very hot during use. Do not remove drill bits until the bit has cooled. Do not strike stuck bits with a hammer.

1. Pull back on the Chuck and insert or remove the Drill Bit. If inserting the Drill Bit, make sure it slides all the way into the opening.
2. Release the Chuck.
3. Check that the Drill Bit is secured in place. It should not be able to be pulled out of the Chuck.
   Note: When drilling a hole larger than 1-1/4" diameter, use a Drill Bit with four cutting edges.

Work Piece and Work Area Set Up

1. Designate a work area that is clean and welllit. The work area must not allow access by children or pets to prevent distraction and injury.
2. Route the power cord along a safe route to reach the work area without creating a tripping hazard or exposing the power cord to possible damage. The power cord must reach the work area with enough extra length to allow free movement while working.
3. Secure loose work pieces using a vise or clamps (not included) to prevent movement while working.
4. There must not be objects, such as utility lines, nearby that will present a hazard while working.

General Operating Instructions

1. Install the Drill Bit.
2. Adjust the Auxiliary Handle and the Depth Gauge as needed.
3. Set the Function Dial to the desired setting.
4. Set the direction by pressing the Forward/Reverse Button on either side of the Rotary Hammer. The direction is indicated by the arrow on the button.
5. Plug in the Power Cord.

6. Turn on the Rotary Hammer:
   1. Squeeze and hold the Trigger. Release the Trigger to stop.
   2. Or, to run the Rotary Hammer continuously, squeeze and hold the Trigger, press the Trigger Lock, then release the Trigger. The Rotary Hammer will stay on until you squeeze and release the Trigger again.
7. Allow the Rotary Hammer to reach full speed before contacting the work surface.
8. When finished, to prevent accidents, turn off the tool and disconnect its power supply after use. Allow the bit to cool then remove it from the Chuck. Clean, then store the tool indoors out of children's reach.

Maintenance and Servicing

Procedures not specifically explained in this manual must be performed only by a qualified technician.

TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:
Press and release the Trigger and unplug the tool from its electrical outlet before performing any inspection, maintenance, or cleaning procedures.

TO PREVENT SERIOUS INJURY FROM TOOL FAILURE:
Do not use damaged equipment. If abnormal noise or vibration occurs, have the problem corrected before further use.

Cleaning, Maintenance, and Lubrication

1. BEFORE EACH USE, inspect the general condition of the tool. Check for loose hardware, misalignment or binding of moving parts, cracked or broken parts, damaged electrical wiring, and any other condition that may affect its safe operation.

2. AFTER USE, wipe external surfaces of the tool with clean cloth.
3. 
   If the supply cord of this power tool is damaged, it must be replaced only by a qualified service technician.

Troubleshooting

Problem	Possible Causes	Likely Solutions
Tool will not start.	Cord not connected. No power at outlet. Tool's thermal reset breaker tripped (if equipped). Internal damage or wear. (Carbon brushes or switch, for example.)	Check that cord is plugged in. Check power at outlet. If outlet is unpowered, turn off tool and check circuit breaker. If breaker is tripped, make sure circuit is right capacity for tool and circuit has no other loads. Turn off tool and allow to cool. Press reset button on tool. Have technician service tool.
Tool operates slowly.	Extension cord too long or cord diameter too small.	Eliminate use of extension cord. If an extension cord is needed, use one with the proper diameter for its length and load. See Extension Cords in Grounding section.
Performance decreases over time.	Accessory dull or damaged. Carbon brushes worn or damaged.	Keep cutting accessories sharp. Replace as needed. Have qualified technician replace brushes.
Excessive noise or rattling.	Internal damage or wear. (Carbon brushes or bearings, for example.)	Have technician service tool.
Overheating.	Forcing tool to work too fast. Accessory misaligned. Accessory dull or damaged. Blocked motor housing vents. Motor being strained by long or small diameter extension cord.	Allow tool to work at its own rate. Check and correct accessory alignment. Keep cutting accessories sharp. Replace as needed. Wear ANSI-approved safety goggles and NIOSH-approved dust mask/respirator while blowing dust out of motor using compressed air. Eliminate use of extension cord. If an extension cord is needed, use one with the proper diameter for its length and load. See Extension Cords in Grounding section.
Follow all safety precautions whenever diagnosing or servicing the tool. Disconnect power supply before service.

Visit our website at: http://www.harborfreight.com
Email our technical support at: productsupport@harborfreight.com

For technical questions, please call 1-888-866-5797.

Documents / Resources

References

• http://harborfreight.com

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