Hole cutter Model 97194 Set up And Operating Instructions Diagrams within this manual may not be drawn proportionally. Due to continuing improvements, actual product may differ slightly from the product described herein. Distributed exclusively by Harbor Freight Tools. 3491 Mission Oaks Blvd., Camarillo, CA 93011 Visit our website at: http://www.harborfreight.com Read this material before using this product. Failure to do so can result in serious injury. Save this manual. Copyright 2007 by Harbor Freight Tools. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools. For technical questions or replacement parts, please call 1-800-444-335
Save This Manual Keep this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures. Write the product s serial number in the back of the manual near the assembly diagram (or month and year of purchase if product has no number). Keep this manual and the receipt in a safe and dry place for future reference. Important SAFETY Information In this manual, on the labeling, and all other information provided with this product: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Danger WARNING Caution Notice Caution DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE is used to address practices not related to personal injury. CAUTION, without the safety alert symbol, is used to address practices not related to personal injury. Page 2
General Safety Rules WARNING! Read all instructions Failure to follow all instructions listed below may result in electric shock, fire, and/or serious injury. SAVE THESE INSTRUCTIONS Work area safety a. b. c. Keep work area clean and well lit. Cluttered or dark areas invite accidents. Do not operate this product in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. This product can create sparks which may ignite the dust or fumes. Keep children and bystanders away while operating this product. Distractions can cause you to lose control. Personal safety a. b. c. d. e. f. g. Stay alert, watch what you are doing and use common sense when operating the Hole Cutter. Do not use a this product while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating this product may result in serious personal injury. Use safety 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. Avoid accidental starting. Ensure the power switch of the drill being used is in the off-position and that the drill is unplugged before attaching. Plugging in power tools that have the switch on invites accidents. Remove any adjusting key or wrench before turning the drill on. A wrench or a key left attached to a rotating part of the item may result in personal injury. Do not overreach. Keep proper footing and balance at all times. This enables better control of the Hole Cutter in unexpected situations. 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. If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of these devices can reduce dust-related hazards. Hole Cutter use and care a. Do not force the Hole Cutter. Use the correct Hole Cutter for your application. The correct Hole Cutter will do the job better and safer at the rate for which it was designed. Page 3
b. c. d. e. f. Disconnect the Hole Cutter from the drill before making any adjustments, changing Balance Bars, or storing. Such preventive safety measures reduce the risk of starting the Hole Cutter accidentally. Store this product out of the reach of children and do not allow persons unfamiliar with it, or these instructions, to operate. This product can be dangerous in the hands of untrained users. Maintain the Hole Cutter. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the product s operation. If damaged, have it repaired before use. Many accidents are caused by poorly maintained 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 Hole Cutter, accessories and tool bits etc., in accordance with these instructions and in the manner intended for the particular type of tool, taking into account the working conditions and the work to be performed. Use of the this tool for operations different from those intended could result in a hazardous situation. 4. Service a. Have your Hole Cutter serviced by a qualified repair person using only identical replacement parts. This will maintain the safety of the Hole Cutter. Vibration Hazard 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: 4. 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 medical or physical symptoms related to vibration (such as tingling, numbness, and white or blue fingers), seek medical advice as soon as possible. Do not smoke during use. Nicotine reduces the blood supply to the hands and fingers, increasing the risk of vibration-related injury. Wear suitable gloves to reduce the vibration effects on the user. Use tools with the lowest vibration when there is a choice between different processes. Page 4
.. 7. Include vibration-free periods each day of work. Grip tool as lightly as possible (while still keeping safe control of it). Let the tool do the work. To reduce vibration, maintain the tool as explained in this manual. If any abnormal vibration occurs, stop use immediately. Specific Safety Rules Maintain labels and nameplates on the tool. These carry important safety information. If unreadable or missing, contact Harbor Freight Tools for a replacement. Avoid unintentional starting. Prepare to begin work before turning on the drill. Maintain a firm grip on the drill Page
Specifications Maximum Speed 800 RPM (at smallest setting) Maximum Material Thickness 1 Hole Size Range 1-3/16 to 16-1/8 Shaft Diameter 7/8 Diameter Unpacking When unpacking, check to make sure that the item is intact and undamaged. If any parts are missing or broken, please call Harbor Freight Tools at the number shown on the cover of this manual as soon as possible. Set-up Instructions Read the entire Important Safety Information section at the beginning of this manual including all text under subheadings therein before set up or use of this product. WARNING Risk of accidental starting; resulting in serious personal injury. Turn the Power Switch of the drill to its OFF position, disconnect it from the power supply, and then disconnect the Hole Cutter before assembling or making any adjustments to the tool. 4. The Hole Cutter can be used to cut holes in wallboard, veneer, fiberglass, plywood, gypsum, plaster, fiber cement board, and aluminum up to 20 gauge. Determine the size of the hole to be cut. To cut through 2 material, measure carefully and cut from both sides. Use the 3mm Hex Wrench to loosen the Hex Screw that holds the Drill (23) in place and remove the Drill. See figure to the right. Holes in Adjusting Disk (6) for use with Adjustment Wrench Put the Adjustment Wrench (21) into any of the (21) holes in the Adjusting Disk (6), and move it in the direction indicated by the Open arrow on the bottom of the Fixed Disk (7). This will release the Rule (8), and allow it to be adjusted.. Adjust the Rule to the size of the hole being cut. Use the Adjustment Wrench to tighten the Adjusting Disk by turning it in the direction indicated by the Closed arrow. Hex Screw Drill (23) Page
. The correct Balance Bar will be determined according to the diameter of the hole being cut. The end of the Rule that the Balance Bar is connected to depends on the diameter of the cut. For small holes the Balance Bar will be mounted on the Rule near the Blade. For larger cuts the Balance Bar will be mounted on the other side of the Rule from the Blade. See Table 1 and 2 below. Table 1 (for smaller cuts) Table 2 (for larger cuts) Balance Bar Balance Bar Wrench (20) Blade (24) Drill (23) Wrench (20) Drill (23) Blade (24) Hole Size (for smaller cuts) 1-3/16 to 2-5/16 (30 to 60mm) H 2-5/16 to 3-1/2 (60 to 90mm) G 3-1/2 to 4-5/16 (90 to 110mm) F 4-5/16 to 5-1/8 (110 to 130mm) E 5-1/8 to 5-7/8 (130 to 150mm) D 5-7/8 to 6-11/16 (150 to 170mm) C 6-11/16 to 7-1/2 (170 to 190mm) B 7-1/2 to 8-1/4 (190 to 210mm) A Balance Bar Hole Size (for larger cuts) 8-1/4 to 9-1/16 (210 to 230mm) None 9-1/16 to 9-7/8 (230 to 250mm) A 9-7/8 to 10-5/8 (250 to 270mm) B 10-5/8 to 11-7/16 (270 to 290mm) 11-7/16 to 12-3/16 (290 to 310mm) 12-3/16 to 13 (310 to 330mm) E 13 to 13-3/4 (330 to 350mm) F 13-3/4 to 15 (350 to 380mm) G 15 to 16-1/8 (380 to 410mm) H C D Balance Bar 7. 8. 9. 10. 1 Use the Wrench (22) to secure the Balance Bar in the correct orientation. Put the Drill back in the center hole and secure with the hex screw. Make sure the hex screw fastens into the notch in the drill. Place the Cowl over the Upright Axle (5) so that it rests on the Adjusting Disk. Place the Spring over the Upright Axle so that it rests on the Cowl and secure in place with the Depth Adjustment Knob. The Knob is used to set the depth of the cut. Turn Knob clockwise to reduce the depth of the cut, or counter-clockwise to increase it. Only use a drill that can power the Hole Cutter at an appropriate speed, according to the chart on page 8. Page 7
Hole Diameter Power Drill Speed 1-3/16 to 1-7/8 (30 to 49mm) 800 RPM 2 to 2-3/4 (50 to 69mm) 600 RPM 2-3/4 to 3-1/2 (70 to 89mm) 400 RPM 3-1/2 to 4-5/8 (90 to 119mm) 200 RPM 4-11/16 to 16-1/8 (120 to 410mm) 100 RPM 1 Connect the Hole Cutter to a power drill that can accept a 7/8 diameter shaft, and has sufficient power to match the required RPM speed as listed above. 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. 4... 7. 8. Clear the area where the cut will be made of any dirt or debris. Inspect the work surface to check for any hidden utility lines or foreign objects (such as nails). The surface to be cut must be wood, plasterboard, sheet metal or fiber cement 1 thick or less. Assemble the Hole Cutter as instructed above and make sure all connections are secure. Follow all safety and use directions in the power drill manufacturer s manual. Do not connect the drill to its power source until after the Upright Axle has been seated firmly into the chuck of the drill. Make a hole in the center of the cut with an awl, and place the Upright Axle into the hole. Allow the Hole Cutter to come to full speed before applying it to the work surface. Make sure the Hole Cutter runs smoothly. If the unit is not properly balanced, the unit will rotate unsteadily. Using the minimum possible pressure to the tool, apply the Hole Cutter to the surface evenly and slowly cut the hole in the work surface. Do not force the tool, allow it to cut at its own pace. To prevent accidents, turn off the drill, disconnect power supply and disassemble after use. Clean, then store the tool indoors out of children s reach. Page 8
Maintenance And Servicing WARNING Risk of serious personal injury from accidental starting or electric shock. Turn the Power Switch of the drill to its OFF position, unplug it from the electrical outlet, and disconnect the Hole Cutter before performing any inspection, maintenance, or cleaning procedures on the Hole Cutter. Damaged equipment can fail, causing serious personal injury. Do not use damaged equipment. If abnormal noise or vibration occurs, have the problem corrected before further use. Cleaning, maintenance, and lubrication BEFORE EACH USE, inspect the general condition of the tool. Check for loose screws, misalignment or binding of moving parts, cracked or broken parts and any other condition that may affect its safe operation. Periodically, sharpen the Blade and Drill of the Hole Cutter with a file. After Use, clean external surfaces of the tool with clean, moist cloth. Lubricate the metal parts of the product with a light machine oil. Page 9
PLEASE READ THE FOLLOWING CAREFULLY The manufacturer and/or distributor has provided the parts list and assembly diagram in this manual as a reference tool only. Neither the manufacturer or distributor makes any representation or warranty of any kind to the buyer that he or she is qualified to make any repairs to the product, or that he or she is qualified to replace any parts of the product. In fact, the manufacturer and/or distributor expressly states that all repairs and parts replacements should be undertaken by certified and licensed technicians, and not by the buyer. The buyer assumes all risk and liability arising out of his or her repairs to the original product or replacement parts thereto, or arising out of his or her installation of replacement parts thereto. PARTS LIST Part Description Qty 1 Depth Adjustment Knob 1 2 Spring 1 3 Blade 1 4 Support Pad 1 5 Upright Axle 1 6 Adjusting Disk 1 7 Fixed Disk 1 8 Rule 1 9 6x12mm Screw 1 10 6x8mm Screw 1 11 3x12mm Hollow Pin 1 12 Balance Bar A 1 Part Description Qty 13 Balance Bar B 1 14 Balance Bar C 1 15 Balance Bar D 1 16 Balance Bar E 1 17 Balance Bar F 1 18 Balance Bar G 1 19 Balance Bar H 1 20 Wrench 1 21 Adjustment Wrench 1 22 3mm Hex Wrench 1 23 Drill 1 24 Cowl 2 Page 10
ASSEMBLY DIAGRAM 1 2 24 3 20 4 21 12 5 19 13 9 8 6 7 14 15 16 3 17 11 18 10 17 22 Record Product s Serial Number Here: Note: If product has no serial number, record month and year of purchase instead. Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. Page 11