Milwaukee Power Tools Operators Manual

OPERATOR'S MANUAL
Cat. No.
0100-20, 0101-20, 0200-20, 0201-20,
0202-20, 0299-20, 0300-20, 0302-20
DRILLS
WARNING To reduce the risk of injury, user must read and understand operator's manual.
•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
jewelry. Keep your hair and clothing away from
moving parts. Loose clothes, jewelry 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.
•Do not let familiarity gained from frequent use
of tools allow you to become complacent and
ignore tool safety principles. A careless action can
cause severe injury within a fraction of a second.
GENERAL POWER TOOL
SAFETY WARNINGS
all safety warnings, instrucWARNING Read
tions, illustrations and specifica-
tions provided with this power tool. Failure to
follow all instructions listed below 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
mains-operated (corded) power tool or battery-operated (cordless) power tool.
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.
•Keep children and bystanders away while operatPOWER TOOL USE AND CARE
ing a power tool. Distractions can cause you to lose •Do not force the power tool. Use the correct power
control.
tool for your application. The correct power tool
will do the job better and safer at the rate for which
ELECTRICAL SAFETY
•Power tool plugs must match the outlet. Never it was designed.
modify the plug in any way. Do not use any •Do not use the power tool if the switch does not
adapter plugs with earthed (grounded) power turn it on and off. Any power tool that cannot be
tools. Unmodified plugs and matching outlets will controlled with the switch is dangerous and must be
repaired.
reduce risk of electric shock.
•Avoid body contact with earthed or grounded •Disconnect the plug from the power source and/
surfaces, such as pipes, radiators, ranges and or remove the battery pack, if detachable, from
refrigerators. There is an increased risk of electric the power tool before making any adjustments,
changing accessories, or storing power tools.
shock if your body is earthed or grounded.
•Do not expose power tools to rain or wet condi- Such preventive safety measures reduce the risk of
tions. Water entering a power tool will increase the starting the power tool accidentally.
•Store idle power tools out of the reach of children
risk of electric shock.
•Do not abuse the cord. Never use the cord for and do not allow persons unfamiliar with the
carrying, pulling or unplugging the power tool. power tool or these instructions to operate the
Keep cord away from heat, oil, sharp edges or power tool. Power tools are dangerous in the hands
moving parts. Damaged or entangled cords increase of untrained users.
•Maintain power tools and accessories. Check
the risk of electric shock.
•When operating a power tool outdoors, use an for misalignment or binding of moving parts,
extension cord suitable for outdoor use. Use of breakage of parts and any other condition that
a cord suitable for outdoor use reduces the risk of may affect the power tool’s operation. If damaged,
have the power tool repaired before use. Many
electric shock.
•If operating a power tool in a damp location is accidents are caused by poorly maintained power
unavoidable, use a ground fault circuit interrupter tools.
(GFCI) protected supply. Use of an GFCI reduces •Keep cutting tools sharp and clean. Properly
maintained cutting tools with sharp cutting edges
the risk of electric shock.
are less likely to bind and are easier to control.
PERSONAL SAFETY
•Use the power tool, accessories and tool bits
•Stay alert, watch what you are doing and use etc. in accordance with these instructions,
common sense when operating a power tool. Do taking into account the working conditions and
not use a power tool while you are tired or under the work to be performed. Use of the power tool
the influence of drugs, alcohol or medication. A for operations different from those intended could
moment of inattention while operating power tools result in a hazardous situation.
•Keep handles and grasping surfaces dry, clean
may result in serious personal injury.
•Use personal protective equipment. Always and free from oil and grease. Slippery handles and
wear eye protection. Protective equipment such grasping surfaces do not allow for safe handling and
as a dust mask, non-skid safety shoes, hard hat or control of the tool in unexpected situations.
hearing protection used for appropriate conditions
SERVICE
will reduce personal injuries.
•Prevent unintentional starting. Ensure the switch •Have your power tool serviced by a qualified
is in the off-position before connecting to power repair person using only identical replacement
source and/or battery pack, picking up or carrying parts. This will ensure that the safety of the power
the tool. Carrying power tools with your finger on tool is maintained.
SPECIFIC SAFETY RULES
the switch or energizing power tools that have the
switch on invites accidents.
FOR DRILLS
•Use auxiliary handle(s), if supplied with the tool.
Loss of control can cause personal injury.
2
•Hold power tool by insulated gripping surfaces,
when performing an operation where the cutting
accessory 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.
•Maintain labels and nameplates. These carry
important information. If unreadable or missing,
contact a MILWAUKEE service facility for a free
replacement.
•
dust created by power sanding,
WARNING Some
sawing, grinding, drilling, and other
construction activities contains chemicals known to
cause cancer, birth defects or other reproductive
harm. Some examples of these chemicals are:
•lead from lead-based paint
•crystalline silica from bricks and cement and other
masonry products, and
•arsenic and chromium from chemically-treated
lumber.
Your risk from these exposures varies, depending on
how often you do this type of work. To reduce your
exposure to these chemicals: work in a well ventilated
area, and work with approved safety equipment, such
as those dust masks that are specially designed to
filter out microscopic particles.
GROUNDING
connecting the groundWARNING Improperly
ing wire can result in the risk of
electric shock. Check with a qualified electrician
if you are in doubt as to whether the outlet is
properly grounded. Do not modify the plug provided with the tool. Never remove the grounding
prong from the plug. Do not use the tool if the
cord or plug is damaged. If damaged, have it
repaired by a MILWAUKEE service facility before
use. If the plug will not fit the outlet, have a
proper outlet installed by a qualified electrician.
Grounded Tools (Three-Prong Plugs)
Tools marked “Grounding Required” have a three
wire cord and three prong grounding plug. The plug
must be connected to a properly grounded outlet
(See Figure A). If the tool should electrically malfunction or break down, grounding provides a low
resistance path to carry electricity away from the
user, reducing the risk of electric shock.
The grounding prong in the plug is connected through
the green wire inside the cord to the grounding
system in the tool. The green wire in the cord must
be the only wire connected to the tool's grounding
system and must never be attached to an electrically
“live” terminal.
Your tool must be plugged into an appropriate outlet, properly installed and
grounded in accordance with all codes
and ordinances. The plug and outlet
Fig. A
should look like those in Figure A.
EXTENSION CORDS
Grounded tools require a three wire extension
cord. Double insulated tools can use either a two
or three wire extension cord. As the distance from
the supply outlet increases, you must use a heavier
gauge extension cord. Using extension cords with
inadequately sized wire causes a serious drop in
voltage, resulting in loss of power and possible tool
damage. Refer to the table shown to determine the
required minimum wire size.
The smaller the gauge number of the wire, the greater
the capacity of the cord. For example, a 14 gauge
cord can carry a higher current than a 16 gauge cord.
When using more than one extension cord to make
up the total length, be sure each cord contains at
least the minimum wire size required. If you are using
one extension cord for more than one tool, add the
nameplate amperes and use the sum to determine
the required minimum wire size.
Guidelines for Using Extension Cords
•If you are using an extension cord outdoors, be sure
it is marked with the suffix “W-A” (“W” in Canada)
to indicate that it is acceptable for outdoor use.
•Be sure your extension cord is properly wired
and in good electrical condition. Always replace a
damaged extension cord or have it repaired by a
qualified person before using it.
•Protect your extension cords from sharp objects,
excessive heat and damp or wet areas.
Recommended Minimum Wire Gauge
For Extension Cords*
Double Insulated Tools (Two-Prong Plugs)
Tools marked “Double Insulated” do not require
grounding. They have a special double insulation
system which satisfies OSHA requirements and
complies with the applicable standards
of Underwriters Laboratories, Inc., the
Canadian Standard Association and
the National Electrical Code. Double
Insulated tools may be used in either
of the 120 volt outlets shown in Figures Fig. B Fig. C
B and C.
SYMBOLOGY
Double Insulated
Volts
Alternating Current
Amps
No Load Revolutions per Minute (RPM)
C
Extension Cord Length
50'
75'
100'
150'
Nameplate Amps 25'
0 - 2.0
2.1 - 3.4
3.5 - 5.0
5.1 - 7.0
7.1 - 12.0
12.1 - 16.0
16.1 - 20.0
18
18
18
18
16
14
12
18
18
18
16
14
12
10
18
18
16
14
12
10
--
18
16
14
12
10
---
16
14
12
12
----
US
UL Listing for Canada and U.S.
Approval Mark for Mexico
* Based on limiting the line voltage drop to five volts at 150%
of the rated amperes.
3
SPECIFICATIONS
Cat. No....................................................... 0100-20
Volts..............................................................120 AC
Amps......................................................................7
No Load RPM............................................. 0 - 2500
Cat. No....................................................... 0101-20
Volts..............................................................120 AC
Amps......................................................................7
No Load RPM............................................. 0 - 4300
Cat. No....................................................... 0200-20
Volts..............................................................120 AC
Amps......................................................................7
No Load RPM............................................. 0 - 1200
Cat. No....................................................... 0201-20
Volts..............................................................120 AC
Amps......................................................................7
No Load RPM............................................. 0 - 2500
Cat. No....................................................... 0202-20
Volts..............................................................120 AC
Amps......................................................................7
No Load RPM............................................. 0 - 1200
Cat. No....................................................... 0299-20
Volts..............................................................120 AC
Amps......................................................................8
No Load RPM............................................... 0 - 850
Cat. No....................................................... 0300-20
Volts..............................................................120 AC
Amps......................................................................8
No Load RPM............................................... 0 - 850
Cat. No....................................................... 0302-20
Volts..............................................................120 AC
Amps......................................................................8
No Load RPM............................................... 0 - 850
1. To remove the Quik-Lok® Cord, turn the cord nut
1/4 turn to the left and pull it out.
2. To replace the Quik-Lok® Cord, align the connector
keyways and push the connector in as far as it will
go. Turn the cord nut 1/4 turn to the right to lock.
reduce the risk of injury, always
WARNING To
use a side handle when using this
tool. Always brace and hold securely.
Adjusting the Side Handle
(Cat. No. 0200-20, 0202-20, 0299-20,
0300-20, 0302-20)
Side handle
Gearcase
FUNCTIONAL DESCRIPTION
Locking
keys
2
3
1. Turn the side handle counterclockwise to loosen.
2. Slide the side handle assembly forward over the
chuck and rotate to the desired angle.
3. Slide the side handle back to the gearcase and
position the locking keys into the detents. The
locking keys help prevent the handle from slipping.
NOTE: The side handle ring must clear the chuck.
4. Turn the side handle clockwise to tighten.
NOTE: Always use the side handle for best control.
1
1. Chuck
7
2. Side handle
6
(0200-20, 0202-20,
0299-20, 0300-20, 0302-20 only)
3. Nameplate
4. Handle
5. Lock button
6. Trigger
7. Forward/Reverse switch
Detents
Side handle ring
Chuck Identification
5
Chuck Type
Drill Cat. No.
Keyed
0100-20
0101-20
0200-20
Double sleeve
Keyless
0201-20
Single sleeve
Keyless
0202-20
0302-20
4
ASSEMBLY
reduce the risk of injury, always
WARNING To
unplug tool before changing or
removing accessories. Only use accessories
specifically recommended for this tool. Others
may be hazardous.
Installing and Removing Bits
reduce the risk of injury, always
WARNING To
remove the chuck key from the
Removing and Replacing Quik-Lok® Cords
(Cat. No. 0100-20, 0101-20, 0202-20, 0302-20)
MILWAUKEE's exclusive Quik-Lok® Cords provide chuck after each use.
instant field replacement or substitution.
4
Keyed Chuck
Single Sleeve Keyless Chuck
These tools are equipped with a chuck tightened
using a key. Always unplug the tool before installing
or removing bits.
1. To open the chuck jaws, Tighten
place the chuck key in
one (1) of the three (3)
holes located on the
chuck. Turn the key
counterclockwise.
Loosen
Be sure the bit shank
and chuck jaws are
clean. Dirt particles
may prevent the bit
from lining up properly.
2. When using drill bits, insert the bit into the chuck.
Center the bit in the chuck jaws and lift it about
1/16" off of the bottom. Tighten the chuck jaws by
hand to align the bit.
When using screwdriver bits, insert the bit far
enough for the chuck jaws to grip the bit shank.
Tighten the chuck jaws by hand to align the bit.
3. To close the chuck jaws, place the chuck key in
each of the three holes in the chuck. Turn the
chuck key clockwise. Tighten securely.
4. To remove the bit, insert the chuck key into one
of the holes in the chuck. Turn the chuck key
counterclockwise.Be sure the bit shank and chuck
jaws are clean. Dirt particles may prevent the bit
from lining up properly.
reduce the risk of injury, do not
WARNING To
grasp the bit while the chuck is
rotating or while the bit is falling from the chuck.
These tools are equipped with a spindle-lock mechanism and a single-sleeve keyless chuck. Always
unplug the tool before inserting or removing bits.
1. To open the chuck jaws,
turn the chuck sleeve
counterclockwise.
Be sure the bit shank
Tighten
and chuck jaws are
clean. Dirt particles may
prevent the bit from lining up properly.
2. When using drill bits,
Loosen
insert the bit into the
chuck. Center the bit in
the chuck jaws and lift it
about 1/16" off of the
bottom. Tighten the
chuck jaws by hand to
align the bit.
When using screwdriver
bits, insert the bit far
enough for the chuck
jaws to grip the bit shank. Tighten the chuck jaws
by hand to align the bit.
To close
3. To close the chuck jaws,
turn the chuck sleeve
c l o c k w i s e . Ti g h t e n
securely. Several detents will be felt as the Sleeve
chuck sleeve is turned.
NOTE: If the spindle rotates when o
­ pening or closing the chuck jaws, grasp the chuck and slightly
rotate back and forth to engage the spindle-lock
mechanism.
Double Sleeve Keyless Chuck
The spindle will remain locked until the tool is
These tools are equipped with a hand tightening keyturned on. The spindle-lock mechanism will autoless chuck. Always unplug the tool before installing
matically disengage when the tool is turned on.
or removing bits.
4. To remove the bit, turn the chuck sleeve counter1. To open the chuck jaws,
clockwise to release the bit from the chuck jaws.
hold the collar and turn
reduce the risk of injury, always
WARNING To
the sleeve counterclockTighten
wear eye protection.
wise.
Chuck Removal
Be sure the bit shank
This tool is equipped with a threaded spindle to hold
and chuck jaws are
the chuck. Before removing the chuck, unplug the tool
clean. Dirt particles may
and open the chuck jaws. A left-handed thread screw
prevent the bit from linLoosen
is located inside the chuck to prevent the chuck from
ing up properly.
loosening when the tool is operated in reverse direc2. When using drill bits,
tion. Remove the screw by turning it clockwise. To
insert the bit into the
remove the chuck, hold
chuck. Center the bit in
the tool so that only the
the chuck jaws and lift it
side of the chuck rests
about 1/16" off of the
firmly and squarely on
bottom. Tighten the
a solid workbench. Inchuck jaws by hand to
sert the chuck key or a
align the bit.
chuck remover bar in
When using screwdriver
one of the keyholes.
bits, insert the bit far enough for the chuck jaws to Turn the chuck so the
grip the bit shank. Tighten the chuck jaws by hand key is at about a 30°
to align the bit.
angle to the bench top
3. To close the chuck jaws,
and strike the key
To close
hold the collar and turn
sharply with a hammer so the chuck turns in a counthe sleeve clockwise.
terclockwise direction (looking from the front of the
Tighten securely.
tool). This should loosen the chuck from the spindle
4. To remove the bit, hold
which has a right hand thread making it easy to remove
the chuck collar and turn
the chuck by hand.
Sleeve
Collar
the sleeve counterclockNOTE: When replacing the chuck, always replace
wise to release the bit from the chuck jaws.
the left hand thread screw in the chuck.
5
reduce the risk of injury, keep
OPERATION
WARNING To
hands and cord away from the bit
To reduce the risk of injury, always and all moving parts.
WARNING wear safety goggles or glasses
Starting, Stopping and Controlling Speed
with side shields.
1. To start the tool, pull the trigger.
Using Forward/Reverse Switch
2. To stop the tool, release the trigger.
1. For forward (clockwise)
3. To vary the drilling speed, simply increase or
rotation, push the fordecrease pressure on the trigger. The further the
ward/reverse switch to
trigger is pulled, the greater the speed.
Front of Tool
the left position as
Locking Trigger
shown.
2. For reverse (coun- Reverse
Forward The lock button holds the trigger in the ON position
for continuous full speed use.
terclockwise) rotation,
1. To lock the trigger, hold the lock button in while
push the forward/repulling the trigger. Release the trigger.
verse switch to the
2. To unlock the trigger, pull the trigger and release.
right position as shown.
The lock button will pop out.
Although an interlock
prevents reversing the
tool while the motor
is running, allow it to
come to a full stop beSwitch
Trigger
fore reversing.
APPLICATIONS
Cat. No.
0100-20
0101-20
0200-20
0201-20
0202-20
0299-20
0300-20
0302-20
No Load
RPM
0 - 2500
0 - 4300
0 - 1200
0 - 2500
0 - 1200
0 - 850
0 - 850
0 - 850
Flat Boring
Bits
Auger
Bits
Wood
Hole
Saws
1-1/2"
1-1/4"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
NR
NR
1"
7/8"
1"
1-1/2"
1-1/2"
1-1/2"
NR
NR
3-1/4"
2-1/4"
3-1/4"
3-5/8"
3-5/8"
3-5/8"
NR = Not recommended
Self-feed PathfinderTM
Bits
Bits
NR
NR
NR
NR
NR
2-9/16"
2-9/16"
2-9/16"
NR
NR
1-1/4"
1-1/4"
1-1/4"
1-1/4"
1-1/4"
1-1/4"
Wood/Steel
Twist
Bits
Steel
Hole
Saws
1/4"
1/4"
1/2"
1/2"
1/2"
3/4"
3/4"
3/4"
NR
NR
1-5/8"
NR
1-5/8"
2"
2"
2"
Drilling in Masonry
When drilling in masonry, use high speed carbidetipped bits. Drilling soft masonry materials such as
age, always check the work area for hidden pipes cinder block requires little pressure. Hard materials
like concrete require more pressure. A smooth, even
and wires before drilling.
flow of dust indicates the proper drilling rate. Do not
Selecting Bits
let the bit spin in the hole without cutting. Do not use
When selecting a bit, use the right type for your job. water to settle dust or to cool bit. Both actions will
For best performance, always use sharp bits.
damage the carbide.
To reduce the risk of explosion,
WARNING electric
shock and property dam-
Drilling
Drilling in Metal
1. Before drilling, be sure the workpiece is clamped
securely. Use backing material to prevent damage
to the workpiece during breakthrough.
2. When starting a hole, place the drill bit on the work
surface and apply firm pressure. Begin drilling at
a slow speed, gradually increasing the speed as
you drill.
3. Always apply pressure in line with the bit. Use
enough pressure to keep the drill biting, but do
not push hard enough to stall the motor.
4. Reduce pressure and ease the bit through the last
part of the hole. While the tool is still running, pull
the bit out of the hole to prevent jamming.
When drilling in metal, use high speed steel twist drills
or hole saws. Use slow speeds for hard metals and
high speeds for softer metals. Lubricate drill bits with
cutting oil when drilling in iron or steel. Use a coolant
when drilling in nonferrous metals such as copper,
brass or aluminum. Back the material to prevent
binding and distortion on breakthrough.
Driving Screws
When driving screws, use the proper screwdriver bit
for your job. After drilling pilot and shank holes, start
the screw slowly and increase the speed as driving
progresses. Set the screw by slowing to a stop. Do
not run screws down at excessive speeds. To remove
screws, reverse the motor.
Drilling in Wood, Composition Materials
and Plastic
When drilling in wood, composition materials and
plastic, start the drill slowly, gradually increasing
speed as you drill. When using twist drill bits, pull
the bit out of the hole frequently to clear chips from
the bit flutes. Use low speeds for plastics with a low
melting point.
6
Stalling
MAINTENANCE
reduce the risk of injury, always
WARNING To
unplug the tool before performing
If the tool seems as if it is about to stall, maintain a
firm grip and reduce pressure slightly to allow the
bit to regain speed. If the tool does stall, release
the trigger immediately. Reverse the motor, remove
the bit from the work and start again. Do not pull the
trigger on and off in an attempt to start a stalled drill.
This can damage the drill.
rotational force. To reduce the
WARNING High
risk of injury, always hold or brace
securely. Always use side handle on tools rated
1200 rpm or less.
any maintenance. Never disassemble the tool.
Contact a MILWAUKEE service facility for ALL
repairs.
Maintaining Tools
Keep your tool in good repair by adopting a regular
maintenance program. Inspect your tool for issues
such as undue noise, misalignment or binding of
moving parts, breakage of parts, or any other condition that may affect the tool operation. Return the tool
to a MILWAUKEE service facility for repair. After six
months to one year, depending on use, return the
tool to a MILWAUKEE service facility for inspection.
reduce the risk of personal inWARNING To
jury, electric shock and damage,
never immerse your tool in liquid or allow a liquid
to flow inside it.
Bit Binding
A high rotational force occurs when a bit binds. If
the bit binds, the tool will be forced in the opposite
direction of the bit rotation. Bits may bind if they are
misaligned or when they are breaking through a
hole. Wood boring bits can also bind if they run into
nails or knots. Be prepared for bit binding situations.
To reduce the chance of bit binding:
•Use sharp bits. Sharp bits are less likely to bind
when drilling.
•Use the proper bit for the job. There are bits that are
designed for specific purposes.
•Use caution when drilling pitchy, knotty, wet or
warped material or when drilling in material that may
contain nails.
Cleaning
Clean dust and debris from vents. Keep handles
clean, dry and free of oil or grease. Use only mild
soap and a damp cloth to clean, since certain cleaning agents and solvents are harmful to plastics and
other insulated parts. Some of these include gasoline,
turpentine, lacquer thinner, paint thinner, chlorinated
cleaning solvents, ammonia and household detergents containing ammonia. Never use flammable or
combustible solvents around tools.
Typical Bracing Methods
Forward rotation
Bracing
against the
floor
Repairs
For repairs, return the tool to the nearest service
center.
Reaction
Bracing
against your
leg
Reaction
Forward
rotation
Bracing against
a stud
Reaction
Reverse rotation
Reaction
Forward rotation
7
OPERATOR'S MANUAL
GENERAL POWER TOOL SAFETY WARNINGS
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. The term "power
tool" in the warnings refers to your mains-operated (corded) power tool or battery-operated
(cordless) power tool.
WORK AREA SAFETY
Cat. No.
0100-20
0101-20
0200-20
0201-20
0202-20
0299-20
0300-20
0302-20
•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.
•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 an GFCI
reduces the risk of electric shock.
PERSONAL SAFETY
HEAVY-DUTY DRILLS
TO REDUCE THE RISK OF INJURY, USER MUST READ AND UNDERSTAND OPERATOR'S
MANUAL.
•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 energising power tools
that have the switch on invites accidents.
•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.
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
•Use auxiliary handle(s), if supplied with the
tool. Loss of control can cause personal injury.
•Hold power tool by insulated gripping surfaces,
when performing an operation where the cutting
accessory 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.
•Maintain labels and nameplates. These carry
important information. If unreadable or missing,
contact a MILWAUKEE service facility for a free
replacement.
•WARNING Some dust created by power sanding,
sawing, grinding, drilling, and other construction
activities contains chemicals known to cause
cancer, birth defects or other reproductive harm.
Some examples of these chemicals are:
• lead from lead-based paint
• crystalline silica from bricks and cement and
other masonry products, and
• arsenic and chromium from chemically-treated
lumber.
Your risk from these exposures varies, depending
on how often you do this type of work. To reduce
your exposure to these chemicals: work in a well
ventilated area, and work with approved safety
equipment, such as those dust masks that are specially designed to filter out microscopic particles.
FUNCTIONAL DESCRIPTION
2
3
1
1. Chuck
6
5
2. Side handle
4
(0200-20, 0202-20,
0299-20, 0300-20, 0302-20 only)
3. Nameplate
4. Lock button
5. Trigger
6. Forward/Reverse switch
SYMBOLOGY
Double Insulated
Amps
Volts
SPECIFICATIONS
Cat. No. Volts AC
0100-20
120
0101-20
120
0200-20
120
0201-20
120
0202-20
120
0299-20
120
0300-20
120
0302-20
120
Amps
7
7
7
7
7
8
8
8
No Load RPM
0 - 2500
0 - 4000
0 - 1200
0 - 2500
0 - 1200
0 - 850
0 - 850
0 - 850
Alternating Current Only
No Load Revolutions
per Minute (RPM)
C
US
Underwriters Laboratories, Inc.
United States and Canada
Mexican Approvals Marking
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 plug
provided with the tool. Never remove the
grounding prong from the plug. Do not use
the tool if the cord or plug is damaged. If
damaged, have it repaired by a MILWAUKEE
service facility before use. If the plug will not
fit the outlet, have a proper outlet installed by
a qualified electrician.
Grounded Tools: Tools with Three Prong Plugs
Tools marked “Grounding Required” have a three
wire cord and three prong grounding plug. The
plug must be connected to a properly grounded
outlet (See Figure A). If the tool should electrically
malfunction or break down, grounding provides a
low resistance path to carry electricity away from
the user, reducing the risk of electric shock.
The grounding prong in the plug is connected
through the green wire inside the cord to the
grounding system in the tool. The green wire in the
cord must be the only wire connected to the tool's
grounding system and must never be attached to
an electrically “live” terminal.
Your tool must be plugged into
an appropriate outlet, properly
installed and grounded in accordance with all codes and ordinances.
The plug and outlet should look like
Fig. A
those in Figure A.
Double Insulated Tools:
Tools with Two Prong Plugs
Tools marked “Double Insulated” do not require
grounding. They have a special double insulation system which satisfies OSHA requirements
and complies with the applicable standards of
Underwriters Laboratories, Inc.,
the Canadian Standard Association and the National Electrical Code. Double Insulated
tools may be used in either of
the 120 volt outlets shown in
Fig. B Fig. C
Figures B and C.
EXTENSION CORDS
Grounded tools require a three wire extension
cord. Double insulated tools can use either a two
or three wire extension cord. As the distance from
the supply outlet increases, you must use a heavier
gauge extension cord. Using extension cords with
inadequately sized wire causes a serious drop in
voltage, resulting in loss of power and possible tool
damage. Refer to the table shown to determine the
required minimum wire size.
The smaller the gauge number of the wire, the
greater the capacity of the cord. For example, a 14
gauge cord can carry a higher current than a 16
gauge cord. When using more than one extension
cord to make up the total length, be sure each cord
contains at least the minimum wire size required.
If you are using one extension cord for more than
one tool, add the nameplate amperes and use the
sum to determine the required minimum wire size.
Guidelines for Using Extension Cords
• If you are using an extension cord outdoors, be
sure it is marked with the suffix “W-A” (“W” in
Canada) to indicate that it is acceptable for outdoor use.
• Be sure your extension cord is properly wired
and in good electrical condition. Always replace
a damaged extension cord or have it repaired by
a qualified person before using it.
• Protect your extension cords from sharp objects,
excessive heat and damp or wet areas.
Recommended Minimum Wire Gauge
For Extension Cords*
Extension Cord Length
Nameplate
Amperes
25'
50'
75'
100'
150'
0 - 2.0
2.1 - 3.4
3.5 - 5.0
5.1 - 7.0
7.1 - 12.0
12.1 - 16.0
16.1 - 20.0
18
18
18
18
16
14
12
18
18
18
16
14
12
10
18
18
16
14
12
10
18
16
14
12
10
16
14
12
12
* Based on limiting the line voltage drop to five volts at
150% of the rated amperes.
READ AND SAVE ALL
INSTRUCTIONS FOR FUTURE USE.
ASSEMBLY
Chuck Identification
WARNING To reduce the risk of injury,
Chuck Type
always unplug tool before changing or removing accessories. Only use accessories
specifically recommended for this tool. Others
may be hazardous.
Keyed
Removing and Replacing Quik-Lok® Cords
(Cat. No. 0100-20, 0101-20, 0202-20, 0302-20)
MILWAUKEE's exclusive Quik-Lok® Cords provide
instant field replacement or substitution.
Fig. 1
Drill Cat. No.
0100-20
0101-20
0200-20
Double sleeve
Keyless
0201-20
Single sleeve
Keyless
0202-20
0302-20
WARNING To reduce the risk of injury,
do not grasp the bit while the chuck is rotating or while the bit is falling from the chuck.
Double Sleeve Keyless Chuck
These tools are equipped with a hand tightening
keyless chuck. Always unplug the tool before installing or removing bits.
1. To open the chuck jaws, hold the collar and turn
the sleeve counterclockwise.
Single Sleeve Keyless Chuck
These tools are equipped with a spindle-lock mechanism and a single-sleeve keyless chuck. Always
unplug the tool before inserting or removing bits.
1. To open the chuck jaws, turn the chuck sleeve
counterclockwise.
Fig. 7
Fig. 4
Tighten
Loosen
Installing and Removing Bits
1. To remove the Quik-Lok® Cord, turn the cord nut
1/4 turn to the left and pull it out.
2. To replace the Quik-Lok® Cord, align the connector keyways and push the connector in as far as it
will go. Turn the cord nut 1/4 turn to the right to lock.
WARNING To reduce the risk of injury,
always use a side handle when using this tool.
Always brace and hold securely.
Adjusting the Side Handle (Cat. No. 0200-20,
0202-20, 0299-20, 0300-20, 0302-20)
Tighten
WARNING To reduce the risk of injury,
always remove the chuck key from the chuck
after each use.
Keyed Chuck
These tools are equipped with a chuck tightened
using a key. Always unplug the tool before installing
or removing bits.
1. To open the chuck jaws, place the chuck key
in one (1) of the three (3) holes located on the
chuck. Turn the key counterclockwise. Be sure
the bit shank and chuck jaws are clean. Dirt particles may prevent the bit from lining up properly.
Loosen
Be sure the bit shank and chuck jaws are clean. Dirt
particles may prevent the bit from lining up properly.
2. When using drill bits, insert the bit into the chuck.
Center the bit in the chuck jaws and lift it about
1/16" off of the bottom. Tighten the chuck jaws
by hand to align the bit.
Fig. 3
Tighten
Gearcase
Loosen
Fig. 8
Fig. 5
Fig. 2
Side handle
Be sure the bit shank and chuck jaws are clean. Dirt
particles may prevent the bit from lining up properly.
2. When using drill bits, insert the bit into the chuck.
Center the bit in the chuck jaws and lift it about
1/16" off of the bottom. Tighten the chuck jaws
by hand to align the bit.
When using screwdriver bits, insert the bit far
enough for the chuck jaws to grip the bit shank.
Tighten the chuck jaws by hand to align the bit.
3. To close the chuck jaws, hold the collar and turn
the sleeve clockwise. Tighten securely.
Fig. 6
When using screwdriver bits, insert the bit far
enough for the chuck jaws to grip the bit shank.
Tighten the chuck jaws by hand to align the bit.
3. To close the chuck jaws, turn the chuck sleeve
clockwise. Tighten securely. Several detents will
be felt as the chuck sleeve is turned.
Fig. 9
To close
To close
Sleeve
Locking
keys
Detents
Side handle ring
1. Turn the side handle counterclockwise to loosen.
2. Slide the side handle assembly forward over the
chuck and rotate to the desired angle.
3. Slide the side handle back to the gearcase and position the locking keys into the detents. The locking keys help prevent the handle from slipping.
NOTE: The side handle ring must clear the
chuck.
4. Turn the side handle clockwise to tighten.
NOTE: Always use the side handle for best control.
2. When using drill bits, insert the bit into the chuck.
Center the bit in the chuck jaws and lift it about
1/16" off of the bottom. Tighten the chuck jaws
by hand to align the bit.
When using screwdriver bits, insert the bit far
enough for the chuck jaws to grip the bit shank.
Tighten the chuck jaws by hand to align the bit.
3. To close the chuck jaws, place the chuck key in
each of the three holes in the chuck. Turn the
chuck key clockwise. Tighten securely.
4. To remove the bit, insert the chuck key into one
of the holes in the chuck. Turn the chuck key
counterclockwise.Be sure the bit shank and
chuck jaws are clean. Dirt particles may prevent
the bit from lining up properly.
Sleeve
Collar
4. To remove the bit, hold the chuck collar and turn
the sleeve counterclockwise to release the bit
from the chuck jaws.
NOTE: If the spindle rotates when opening or
closing the chuck jaws, grasp the chuck and
slightly rotate back and forth to engage the
spindle-lock mechanism.
The spindle will remain locked until the tool is
turned on. The spindle-lock mechanism will automatically disengage when the tool is turned on.
4. To remove the bit, turn the chuck sleeve counterclockwise to release the bit from the chuck jaws.
WARNING To reduce the risk of injury,
always wear eye protection.
Chuck Removal
This tool is equipped with a threaded spindle to hold
the chuck. Before removing the chuck, unplug the
tool and open the chuck jaws. A left-handed thread
screw is located inside the chuck to prevent the
chuck from loosening when the tool is operated in
reverse direction. Remove the screw by turning it
clockwise. To remove the chuck, hold the tool so that
only the side of the chuck rests firmly and squarely
on a solid workbench. Insert the chuck key or a chuck
remover bar in one of the keyholes. Turn the chuck
so the key is at about a 30° angle to the bench top
and strike the key
sharply with a ham- Fig. 10
mer so the chuck
turns in a counterclockwise direction
(looking from the
front of the tool). This
should loosen the
chuck from the spindle which has a right
hand thread making
it easy to remove the
chuck by hand.
NOTE: When replacing the chuck, always replace
the left hand thread screw in the chuck.
OPERATION
WARNING To reduce the risk of injury,
always unplug tool before attaching or removing accessories or making adjustments. Use
only specifically recommended accessories.
Others may be hazardous.
2. For reverse (counterclockwise) rotation, push
the forward/reverse switch to the right position
as shown. Although an interlock prevents reversing the tool while the motor is running, allow it to
come to a full stop before reversing.
WARNING To reduce the risk of injury,
keep hands and cord away from the bit and
all moving parts.
WARNING To reduce the risk of injury,
wear safety goggles or glasses with side
shields.
Using Forward/Reverse Switch
Fig. 11
Forward
Reverse
Switch
Trigger
1. For forward (clockwise) rotation, push the forward/reverse switch to the left position as shown.
Starting, Stopping and Controlling Speed
1. To start the tool, pull the trigger.
2. To stop the tool, release the trigger.
3. To vary the drilling speed, simply increase or
decrease pressure on the trigger. The further
the trigger is pulled, the greater the speed.
Locking Trigger
The lock button holds the trigger in the ON position
for continuous full speed use.
1. To lock the trigger, hold the lock button in while
pulling the trigger. Release the trigger.
2. To unlock the trigger, pull the trigger and release.
The lock button will pop out.
APPLICATIONS
Cat. No.
No Load
RPM
Flat Boring
Bits
Auger
Bits
Wood
Hole
Saws
0100-20
0101-20
0200-20
0201-20
0202-20
0299-20
0300-20
0302-20
0 - 2500
0 - 4000
0 - 1200
0 - 2500
0 - 1200
0 - 850
0 - 850
0 - 850
1-1/2"
1-1/4"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
NR
NR
1"
7/8"
1"
1-1/2"
1-1/2"
1-1/2"
NR
NR
3-1/4"
2-1/4"
3-1/4"
3-5/8"
3-5/8"
3-5/8"
NR = Not recommended
WARNING To reduce the risk of explosion, electric shock and property damage,
always check the work area for hidden pipes
and wires before drilling.
Self-feed PathfinderTM
Bits
Bits
NR
NR
NR
NR
NR
2-9/16"
2-9/16"
2-9/16"
NR
NR
1-1/4"
1-1/4"
1-1/4"
1-1/4"
1-1/4"
1-1/4"
Wood/Steel
Twist
Bits
Steel
Hole
Saws
1/4"
1/4"
1/2"
1/2"
1/2"
3/4"
3/4"
3/4"
NR
NR
1-5/8"
NR
1-5/8"
2"
2"
2"
Selecting Bits
When selecting a bit, use the right type for your
job. For best performance, always use sharp bits.
Drilling
1. Before drilling, be sure the workpiece is clamped
securely. Use backing material to prevent damage to the workpiece during breakthrough.
2. When starting a hole, place the drill bit on the
work surface and apply firm pressure. Begin
drilling at a slow speed, gradually increasing the
speed as you drill.
3. Always apply pressure in line with the bit. Use
enough pressure to keep the drill biting, but do
not push hard enough to stall the motor.
4. Reduce pressure and ease the bit through the
last part of the hole. While the tool is still running,
pull the bit out of the hole to prevent jamming.
bind if they run into nails or knots. Be prepared for
bit binding situations.
To reduce the chance of bit binding:
•Use sharp bits. Sharp bits are less likely to bind
when drilling.
•Use the proper bit for the job. There are bits that
are designed for specific purposes.
•Use caution when drilling pitchy, knotty, wet or
warped material or when drilling in material that
may contain nails.
Drilling in Wood, Composition Materials and
Plastic
When drilling in wood, composition materials and
plastic, start the drill slowly, gradually increasing
speed as you drill. When using twist drill bits, pull
the bit out of the hole frequently to clear chips from
the bit flutes. Use low speeds for plastics with a
low melting point.
Typical Bracing Methods
Drilling in Masonry
When drilling in masonry, use high speed carbidetipped bits. Drilling soft masonry materials such as
cinder block requires little pressure. Hard materials
like concrete require more pressure. A smooth,
even flow of dust indicates the proper drilling rate.
Do not let the bit spin in the hole without cutting.
Do not use water to settle dust or to cool bit. Both
actions will damage the carbide.
Drilling in Metal
When drilling in metal, use high speed steel twist
drills or hole saws. Use slow speeds for hard metals
and high speeds for softer metals. Lubricate drill
bits with cutting oil when drilling in iron or steel. Use
a coolant when drilling in nonferrous metals such
as copper, brass or aluminum. Back the material
to prevent binding and distortion on breakthrough.
Driving Screws
When driving screws, use the proper screwdriver
bit for your job. After drilling pilot and shank holes,
start the screw slowly and increase the speed as
driving progresses. Set the screw by slowing to a
stop. Do not run screws down at excessive speeds.
To remove screws, reverse the motor.
Stalling
If the tool seems as if it is about to stall, maintain a
firm grip and reduce pressure slightly to allow the
bit to regain speed. If the tool does stall, release
the trigger immediately. Reverse the motor, remove
the bit from the work and start again. Do not pull
the trigger on and off in an attempt to start a stalled
drill. This can damage the drill.
WARNING High rotational force. To
reduce the risk of injury, always hold or brace
securely. Always use side handle on tools
rated 1200 rpm or less.
Bit Binding
A high rotational force occurs when a bit binds. If
the bit binds, the tool will be forced in the opposite
direction of the bit rotation (See Fig. 12-14). Bits
may bind if they are misaligned or when they are
breaking through a hole. Wood boring bits can also
Fig. 12
Bracing
against the
floor
Forward rotation
Reaction
Fig. 13
Bracing
against your
leg
Reaction
Forward
rotation
Fig. 14
Bracing against
a stud
Reaction
Reverse rotation
Reaction
Forward rotation
ACCESSORIES
MAINTENANCE
WARNING To reduce the risk of injury,
always unplug the tool before attaching or
removing accessories. Use only specifically
recommended accessories. Others may be
hazardous.
WARNING To reduce the risk of injury,
always unplug your tool before performing
any maintenance. Never disassemble the tool
or try to do any rewiring on the tool’s electrical
system. Contact a MILWAUKEE service facility
for ALL repairs.
Maintaining Tools
Keep your tool in good repair by adopting a regular
maintenance program. Before use, examine the
general condition of your tool. Inspect guards,
switches, tool cord set and extension cord for
damage. Check for loose screws, misalignment,
binding of moving parts, improper mounting, broken parts and any other condition that may affect
its safe operation. If abnormal noise or vibration
occurs, turn the tool off immediately and have the
problem corrected before further use. Do not use a
damaged tool. Tag damaged tools “DO NOT USE”
until repaired (see “Repairs”).
Under normal conditions, relubrication is not necessary until the motor brushes need to be replaced.
After six months to one year, depending on use,
return your tool to the nearest MILWAUKEE service
facility for the following:
•Lubrication
•Brush inspection and replacement
•Mechanical inspection and cleaning (gears, spindles, bearings, housing, etc.)
•Electrical inspection (switch, cord, armature, etc.)
•Testing to assure proper mechanical and electrical
operation
WARNING To reduce the risk of injury,
electric shock and damage to the tool, never
immerse your tool in liquid or allow a liquid
to flow inside the tool.
Cleaning
Clean dust and debris from vents. Keep the tool
handles clean, dry and free of oil or grease. Use
only mild soap and a damp cloth to clean your
tool since certain cleaning agents and solvents
are harmful to plastics and other insulated parts.
Some of these include: gasoline, turpentine, lacquer
thinner, paint thinner, chlorinated cleaning solvents,
ammonia and household detergents containing
ammonia. Never use flammable or combustible
solvents around tools.
Repairs
If your tool is damaged, return the entire tool to the
nearest service center.
OPERATOR'S MANUAL
GENERAL POWER TOOL SAFETY WARNINGS
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. The term "power
tool" in the warnings refers to your mains-operated (corded) power tool or battery-operated
(cordless) power tool.
WORK AREA SAFETY
Catalog No.
0233-20
0234-6
0235-21
0244-1
•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.
•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 an GFCI
reduces the risk of electric shock.
PERSONAL SAFETY
HEAVY-DUTY MAGNUM DRILLS
TO REDUCE THE RISK OF INJURY, USER MUST READ AND UNDERSTAND OPERATOR'S
MANUAL.
•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 energising power tools
that have the switch on invites accidents.
•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.
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
•Use auxiliary handle(s), if supplied with the
tool. Loss of control can cause personal injury.
•Hold power tool by insulated gripping surfaces,
when performing an operation where the cutting
accessory 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.
•Maintain labels and nameplates. These carry
important information. If unreadable or missing,
contact a MILWAUKEE service facility for a free
replacement.
•WARNING Some dust created by power sanding,
sawing, grinding, drilling, and other construction
activities contains chemicals known to cause
cancer, birth defects or other reproductive harm.
Some examples of these chemicals are:
• lead from lead-based paint
• crystalline silica from bricks and cement and
other masonry products, and
• arsenic and chromium from chemically-treated
lumber.
Your risk from these exposures varies, depending
on how often you do this type of work. To reduce
your exposure to these chemicals: work in a well
ventilated area, and work with approved safety
equipment, such as those dust masks that are specially designed to filter out microscopic particles.
SPECIFICATIONS
Cat. No. Volts AC Amps
No Load RPM
0233-20
120
5.5
0-2800
0234-6
120
5.5
without RAD 0-950
RAD low 0-630
Rad high 0-1425
0235-21
120
5.5
0-950
0244-1
120
5.5
without RAD 0-700
RAD low 0-465
RAD high 0-1050
Right Angle Drive Unit Cat. No. 48-06-2871
FUNCTIONAL DESCRIPTION
2
3
1
READ AND SAVE ALL INSTRUCTIONS FOR FUTURE USE.
GROUNDING
SYMBOLOGY
Double Insulated
WARNING Improperly connecting the
Amps
Volts
Alternating Current Only
No Load Revolutions
per Minute (RPM)
C
US
Underwriters Laboratories, Inc.
United States and Canada
Mexican Approvals Marking
EXTENSION CORDS
Grounded tools require a three wire extension
cord. Double insulated tools can use either a two
or three wire extension cord. As the distance from
the supply outlet increases, you must use a heavier
gauge extension cord. Using extension cords with
inadequately sized wire causes a serious drop in
voltage, resulting in loss of power and possible tool
damage. Refer to the table shown to determine the
required minimum wire size.
The smaller the gauge number of the wire, the
greater the capacity of the cord. For example, a 14
gauge cord can carry a higher current than a 16
gauge cord. When using more than one extension
cord to make up the total length, be sure each cord
contains at least the minimum wire size required.
If you are using one extension cord for more than
one tool, add the nameplate amperes and use the
sum to determine the required minimum wire size.
Guidelines for Using Extension Cords
•If you are using an extension cord outdoors, be
sure it is marked with the suffix “W-A” (“W” in Canada) to indicate that it is acceptable for outdoor use.
•Be sure your extension cord is properly wired
and in good electrical condition. Always replace a
damaged extension cord or have it repaired by a
qualified person before using it.
•Protect your extension cords from sharp objects,
excessive heat and damp or wet areas.
Recommended Minimum Wire Gauge
For Extension Cords*
Extension Cord Length
1. Chuck
2. Side handle
3. Nameplate
4. Trigger
5. Forward/Reverse switch
5
4
Nameplate Amperes
25'
50'
75' 100' 150'
0 - 2.0
2.1 - 3.4
3.5 - 5.0
5.1 - 7.0
7.1 - 12.0
12.1 - 16.0
16.1 - 20.0
18
18
18
18
16
14
12
18
18
18
16
14
12
10
18
18
16
14
12
10
18
16
14
12
10
16
14
12
12
* Based on limiting the line voltage drop to five volts at
150% of the rated amperes.
grounding wire can result in the risk of electric shock. Check with a qualified electrician
if you are in doubt as to whether the outlet is
properly grounded. Do not modify the plug
provided with the tool. Never remove the
grounding prong from the plug. Do not use
the tool if the cord or plug is damaged. If
damaged, have it repaired by a MILWAUKEE
service facility before use. If the plug will not
fit the outlet, have a proper outlet installed by
a qualified electrician.
Grounded Tools: Tools with Three Prong Plugs
Tools marked “Grounding Required” have a three
wire cord and three prong grounding plug. The
plug must be connected to a properly grounded
outlet (See Figure A). If the tool should electrically
malfunction or break down, grounding provides a
low resistance path to carry electricity away from
the user, reducing the risk of electric shock.
The grounding prong in the plug is connected
through the green wire inside the cord to the
grounding system in the tool. The green wire in the
cord must be the only wire connected to the tool's
grounding system and must never be attached to
an electrically “live” terminal.
Your tool must be plugged into
an appropriate outlet, properly
installed and grounded in accordance with all codes and ordinances. The plug and outlet should look Fig. A
like those in Figure A.
Double Insulated Tools:
Tools with Two Prong Plugs
Tools marked “Double Insulated” do not require
grounding. They have a special double insulation system which satisfies OSHA requirements
and complies with the applicable standards of
Underwriters Laboratories, Inc.,
the Canadian Standard Association and the National Electrical Code. Double Insulated
tools may be used in either of
the 120 volt outlets shown in Fig. B Fig. C
Figures B and C.
ASSEMBLY
WARNING To reduce the risk of injury,
always unplug tool before changing or removing accessories. Only use accessories
specifically recommended for this tool. Others
may be hazardous.
Removing and Replacing Quik-Lok® Cords
MILWAUKEE's exclusive Quik-Lok® Cords provide
instant field replacement or substitution.
Fig. 1
1
2
3
4
1. To remove the Quik-Lok® Cord, turn the cord nut
1/4 turn to the left and pull it out.
2. To replace the Quik-Lok® Cord, align the connector keyways and push the connector in as far as it
will go. Turn the cord nut 1/4 turn to the right to lock.
Installing Side Handle
MILWAUKEE Magnum Drills are supplied with a
side handle that can be installed on either side of
the tool for right or left handed use. To install the
side handle, thread it into the socket on the desired
side of the tool and tighten it securely. Always use
the side handle for best control.
WARNING To prevent personal injury,
always remove the chuck key from the chuck
after each use.
Installing Bits into Keyed Chucks
(Cat. No. 0234-6, 0244-1)
Always unplug the tool before installing or removing bits.
1. Open the chuck jaws wide enough to insert the bit.
Be sure the bit shank and chuck jaws are clean.
Dirt particles may prevent the bit from lining up
properly.
2. When using drill bits, insert the bit into the chuck.
Center the bit in the chuck jaws and lift it about
1/16" off of the bottom. Tighten the chuck jaws by
hand to align the bit.
When using screwdriver bits, insert the bit far
enough for the chuck jaws to grip the bit shank.
Tighten the chuck jaws by hand to align the bit.
3. Place the chuck key in each of the three holes in
the chuck, turning it clockwise as shown. Tighten
securely.
Fig. 2
Tighten
Loosen
4. To remove the bit, insert the chuck key into one of
the holes in the chuck and turn it counterclockwise.
WARNING To reduce the risk of injury:
Do not grasp the bit while the chuck is rotat
ing or while the bit is falling from the chuck.
Release the trigger as soon as the ratcheting
stops to avoid throwing the bit.
Installing Bits into Keyless Chucks
(Cat. No. 0233-20)
These tools are equipped with a hand-tightening
keyless chuck. Always unplug the tool before installing or removing bits.
Fig. 3
Collar
Sleeve
Fig. 6
Removing the Chuck From RAD
The chuck can be removed from the Right Angle
Drive Unit in the same manner it is removed from
the drill; however, ALWAYS REMOVE RIGHT
ANGLE DRIVE FROM THE DRILL BEFORE ATTEMPTING TO LOOSEN Fig. 8
THE CHUCK. This will prevent damaging the drill's
gearing. Use the open
end wrench provided to
hold the Right Angle Drive
spindle before attempting
to loosen the chuck.
OPERATION
WARNING To reduce the risk of injury,
always unplug tool before attaching or removing accessories or making adjustments. Use
only specifically recommended accessories.
Others may be hazardous.
Fig. 4
WARNING To reduce the risk of injury,
wear safety goggles or glasses with side shields.
Using Forward/Reverse Switch
Attaching Right Angle Drive (RAD) to Drill
3. To close the chuck jaws, turn the chuck sleeve
in clockwise direction (Fig. 5). Tighten securely.
Several detents will be felt as the chuck sleeve
is turned.
Fig. 5
Fig. 7
Fig. 9
Forward
3
1
4
To close
2
5
Sleeve
Reverse
Trigger
WARNING To reduce the risk of injury,
keep hands and cord away from the bit and
all moving parts.
Starting, Stopping and Controlling Speed
1. To start the tool, pull the trigger.
2. To stop the tool, release the trigger.
3. To vary the drilling speed, simply increase or
decrease pressure on the trigger. The further
the trigger is pulled, the greater the speed.
Locking Trigger
The lock button holds the trigger in the ON position
for continuous full speed use.
Fig. 10
FWD.
K
Chuck Removal
This tool is equipped with a threaded spindle to hold
the chuck. Before removing the chuck, unplug the
tool and open the chuck jaws. A left-handed thread
screw is located inside the chuck to prevent the
chuck from loosening when the tool is operated
in reverse direction. Remove the screw by turning
it clockwise. To remove the chuck, hold the tool
so that only the side of the chuck rests firmly and
squarely on a solid workbench. Insert the chuck
key or a chuck remover bar in one of the keyholes.
Turn the chuck so the key is at about a 30° angle
to the bench top and strike the key sharply with a
hammer so the chuck turns in a counterclockwise
direction (looking from the front of the tool). This
should loosen the chuck from the spindle which
has a right hand thread making it easy to remove
the chuck by hand.
NOTE: When replacing the chuck, always replace
the left hand thread screw in the chuck.
1. For forward (clockwise) rotation, push the forward/reverse switch to FWD as shown.
2. For reverse (counterclockwise) rotation, push
the forward/reverse switch to REV as shown.
Although an interlock prevents reversing the tool
while the motor is running, allow it to come to a
full stop before reversing.
C
Installing Bits into Keyless Chucks
(Cat. No. 0235-21)
These tools are equipped with a spindle-lock mechanism and a single-sleeve keyless chuck. Always
unplug the tool before inserting or removing bits.
1. To open the chuck jaws, turn the chuck sleeve
in counterclockwise direction.
2. To install a bit, open the chuck jaws slightly wider
than the bit. Center the bit in the chuck jaws and
lift it about 1/16" off of the bottom. Align the bit
as shown (Fig. 4).
WARNING To reduce the risk of injury,
wear safety goggles or glasses with side
shields.
1. Remove the chuck from the drill following instructions (See “Removing the Chuck From the Drill”).
Slip the double hex coupling (1) over the hex on
the drill spindle.
Loosen the clamping screws on the clamping
sleeve (2) and slip the sleeve onto the drill collar.
2. Slide the Right Angle Drive head (4) into the other
side of the sleeve and turn the drive head slightly
in either direction so the hexagonal hole in the
coupling (1) engages the hexagonal portion of
the spindle (3).
NOTE: Attaching the drill chuck to the side
marked “LOW” reduces the speed by 1/3, or
33%. Attaching the drill chuck to the opposite
side increases the speed by 50%.
3. When assembled, turn the Right Angle Drive
head to the desired position and tighten the
clamping screws to secure the unit. Thread the
chuck onto the Right Angle Drive spindle (5).
INSTALL CHUCK LOCKING SCREW.
LO
1. To open the chuck jaws, turn the sleeve in the
counterclockwise direction.
When using drill bits, allow the bit to strike the
bottom of the chuck. Center the bit in the chuck
jaws and lift it about 1/16" off of the bottom.
When using screwdriver bits, insert the bit far
enough for the chuck jaws to grip the hex of the bit.
2. To close the chuck jaws, hold the collar while
turning the sleeve in the clockwise direction.
Tighten securely.
NOTE: If the spindle rotates when opening or closing
the chuck jaws, grasp the chuck and slightly rotate
back and forth to engage the spindle-lock mechanism.
The spindle will remain locked until the tool is turned
on. The spindle-lock mechanism will automatically
disengage when the tool is turned on.
Lock button
1. To lock the trigger, hold the lock button in while
pulling the trigger. Release the trigger.
2. To unlock the trigger, pull the trigger and release.
The lock button will pop out.
WARNING To reduce the risk of explosion, electric shock and property damage,
always check the work area for hidden pipes
and wires before drilling.
Drilling
1. Before drilling, be sure the workpiece is clamped
securely. Use backing material to prevent damage to the workpiece during breakthrough.
2. When starting a hole, place the drill bit on the
work surface and apply firm pressure. Begin
drilling at a slow speed, gradually increasing the
speed as you drill.
3. Always apply pressure in line with the bit. Use
enough pressure to keep the drill biting, but do
not push hard enough to stall the motor.
4. Reduce pressure and ease the bit through the
last part of the hole. While the tool is still running,
pull the bit out of the hole to prevent jamming.
Stalling
If the tool seems as if it is about to stall, maintain a
firm grip and reduce pressure slightly to allow the
bit to regain speed. If the tool does stall, release
the trigger immediately. Reverse the motor, remove
the bit from the work and start again. Do not pull
the trigger on and off in an attempt to start a stalled
drill. This can damage the drill.
MAINTENANCE
APPLICATIONS
CAPACITIES
Wood
Cat. No.
0233-20
0234-6
RAD low
RAD high
0235-21
0244-1
RAD low
RAD high
Flat Boring
Bits
1”
1-1/2”
1-1/2”
1-1/2”
1-1/2”
1-1/2”
1-1/2”
1-1/2”
Auger
Bits
N/R
1-1/2”
1-1/2”
1-1/8”
1-1/2”
1-1/2”
1-1/2”
1-1/2”
Ship Auger Bits
N/R
1-1/4”
1-1/2”
1”
1-1/4”
1-1/2”
1-1/2”
1-1/4”
Selecting Bits
When selecting a bit, use the right type for your
job. For best performance, always use sharp bits.
Drilling in Wood, Composition Materials and
Plastic
When drilling in wood, composition materials and
plastic, start the drill slowly, gradually increasing
speed as you drill. When using twist drill bits, pull
the bit out of the hole frequently to clear chips from
the bit flutes. Use low speeds for plastics with a
low melting point.
Selfeed
Bits
N/R
2”
2-1/4”
1-1/2”
2”
2-1/4”
2-9/16”
1-3/4”
Driving Screws
When driving screws, use the proper screwdriver
bit for your job. After drilling pilot and shank holes,
start the screw slowly and increase the speed as
driving progresses. Set the screw by slowing to a
stop. Do not run screws down at excessive speeds.
To remove screws, reverse the motor.
Steel
Twist
Hole
Drill
Saws
3/8”
1”
1/2”
2”
1/2”
2-1/8”
1/2”
1-1/2”
1/2”
2”
1/2”
2-1/4”
1/2”
2-1/4”
1/2”
1-3/4”
Masonry
CarbideTipped Bits
3/8”
1/2”
9/16”
7/16”
1/2”
9/16”
5/8”
1/2”
To reduce the chance of bit binding:
•Use sharp bits. Sharp bits are less likely to bind
when drilling.
•Use the proper bit for the job. There are bits that
are designed for specific purposes.
•Use caution when drilling pitchy, knotty, wet or
warped material or when drilling in material that
may contain nails.
Typical Bracing Methods
Forward rotation
Fig. 11
Drilling in Masonry
When drilling in masonry, use high speed carbidetipped bits. Drilling soft masonry materials such as
cinder block requires little pressure. Hard materials
like concrete require more pressure. A smooth,
even flow of dust indicates the proper drilling rate.
Do not let the bit spin in the hole without cutting.
Do not use water to settle dust or to cool bit. Both
actions will damage the carbide.
Drilling in Metal
When drilling in metal, use high speed steel twist
drills or hole saws. Use slow speeds for hard metals
and high speeds for softer metals. Lubricate drill
bits with cutting oil when drilling in iron or steel. Use
a coolant when drilling in nonferrous metals such
as copper, brass or aluminum. Back the material
to prevent binding and distortion on breakthrough.
Hole
Saws
1-3/4”
4”
4-1/2”
2-3/4”
4”
4-1/2”
5”
3-1/4”
Reaction
Bracing against the floor
Fig. 12
WARNING
Bracin against
Bracing
gainst
a stud
d
Reaction
R
i
Reverse
rotation
Replacing Brushes
MILWAUKEE Magnum Drills have an exclusive
Brush Cartridge System. The tool will not start when
the brushes are worn to 1/8", preventing expensive
damage to the armature. New brushes are provided
in the Cartridge for fast changes anywhere.
Fig. 14
Brush
holder
screw
Brush holder
Extra
brushes
Brushes
1. Unplug tool and rest it on its side with the cartridge facing up. Loosen the brush holder screw
in the cartridge and pull cartridge out.
Reaction
on
Forward rotation
WARNING Never use a different screw
as a brush holder screw.
Maintaining Tools
Keep your tool in good repair by adopting a regular
maintenance program. Before use, examine the
general condition of your tool. Inspect guards,
switches, tool cord set and extension cord for
damage. Check for loose screws, misalignment,
binding of moving parts, improper mounting, broken parts and any other condition that may affect
its safe operation. If abnormal noise or vibration
occurs, turn the tool off immediately and have the
problem corrected before further use. Do not use a
damaged tool. Tag damaged tools “DO NOT USE”
until repaired (see “Repairs”).
Under normal conditions, relubrication is not necessary until the motor brushes need to be replaced.
After six months to one year, depending on use,
return your tool to the nearest MILWAUKEE service
facility for the following:
•Lubrication
•Brush inspection and replacement
•Mechanical inspection and cleaning (gears, spindles, bearings, housing, etc.)
•Electrical inspection (switch, cord, armature, etc.)
•Testing to assure proper mechanical and electrical
operation
WARNING To reduce the risk of injury,
electric shock and damage to the tool, never
immerse your tool in liquid or allow a liquid
to flow inside the tool.
Cleaning
Clean dust and debris from vents. Keep the tool
handles clean, dry and free of oil or grease. Use
only mild soap and a damp cloth to clean your
tool since certain cleaning agents and solvents
are harmful to plastics and other insulated parts.
Some of these include: gasoline, turpentine, lacquer
thinner, paint thinner, chlorinated cleaning solvents,
ammonia and household detergents containing
ammonia. Never use flammable or combustible
solvents around tools.
Repairs
If your tool is damaged, return the entire tool to the
nearest service center.
Reaction
High rotational force. To
reduce the risk of injury, always hold or brace
securely. Always use side handle on tools
rated 1200 RPM or less.
Bit Binding
A high rotational force occurs when a bit binds. If
the bit binds, the tool will be forced in the opposite
direction of the bit rotation (See Fig. 11 - 13). Bits
may bind if they are misaligned or when they are
breaking through a hole. Wood boring bits can also
bind if they run into nails or knots. Be prepared for
bit binding situations.
always unplug your tool before performing
any maintenance. Never disassemble the tool
or try to do any rewiring on the tool’s electrical
system. Contact a MILWAUKEE service facility
for ALL repairs.
Fig. 15
Bracing
against
your leg
Forward
rotation
Fig. 13
WARNING To reduce the risk of injury,
2. Remove worn brushes. If the brushes should fall
into the tool, be sure to shake them out before
reinserting the cartridge. Discard BOTH brushes.
Brushes should always be replaced in sets.
3. A set of spare brushes is provided in the cartridge. Remove the brushes from storage compartment.
4. Position new brushes with the flat silver end facing into the brush holder. Push cartridge into the
tool and press evenly on top and bottom of the
cartridge to align terminals for proper connection.
5. Tighten the brush holder screw gently. If the head
of screw is damaged, use only MILWAUKEE
replacement parts.
ACCESSORIES
WARNING To reduce the risk of injury,
always unplug the tool before attaching or
removing accessories. Use only specifically
recommended accessories. Others may be
hazardous.
Rely only on high-grade power tools on our virtual shelves.