Drill Master 67042 Installation manual

18 VOLT CUTOUT TOOL
67042
SET UP AND OPERATING INSTRUCTIONS
NOTE: BATTERY PACK (67029) SOLD SEPARATELY.
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©2009 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. Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein. Tools required for
assembly and service may not be included.
For technical questions or replacement parts, please call 1-800-444-3353.

SKU 67042 For technical questions, please call 1-800-444-3353. Page 2
SAVE THIS MANUAL
Keep this manual for the safety warn-
ings and precautions, assembly, operat-
ing, 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 provid-
ed 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 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.
General Power Tool Safety
Warnings
WARNING Read all safety
warnings and instructions.
Failure to follow the warnings and
instructions may result in electric
shock, re 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 safety1.
Keep work area clean and well lit.a.
Cluttered or dark areas invite acci-
dents.
Do not operate power tools in ex-b.
plosive atmospheres, such as in
the presence of ammable liquids,
gases or dust. Power tools create
sparks which may ignite the dust or
fumes.
Keep children and bystandersc.
away while operating a power
tool. Distractions can cause you to
lose control.
Electrical safety2.
Do not expose power tools to rain
or wet conditions. Water entering

SKU 67042 For technical questions, please call 1-800-444-3353. Page 3
a power tool will increase the risk of
electric shock.
Personal safety3.
Stay alert, watch what you area.
doing and use common sense
when operating a power tool. Do
not use a power tool while you
are tired or under the inuence of
drugs, alcohol or medication. A
moment of inattention while operat-
ing power tools may result in serious
personal injury.
Use personal protective equip-b.
ment. Always wear eye protec-
tion. Safety 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.c.
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 nger
on the switch or energizing power
tools that have the switch on invites
accidents.
Remove any adjusting key ord.
wrench before turning the power
tool on. A wrench or a key left at-
tached to a rotating part of the power
tool may result in personal injury.
Do not overreach. Keep propere.
footing and balance at all times.
This enables better control of the
power tool in unexpected situations.
Dress properly. Do not wearf.
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 theg.
connection of dust extraction and
collection facilities, ensure these
are connected and properly used.
Use of these devices can reduce
dust-related hazards.
Only use safety equipment thath.
has been approved by an appro-
priate standards agency. Unap-
proved safety equipment may not
provide adequate protection. Eye
protection must be ANSI-approved
and breathing protection must be
NIOSH-approved for the specic
hazards in the work area.
Power tool use and care4.
Do not force the power tool. Usea.
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 theb.
switch does not turn it on and off.
Any power tool that cannot be con-
trolled with the switch is dangerous
and must be repaired.
Disconnect the battery pack fromc.
the power tool before making any
adjustments, changing accesso-
ries, or storing power tools. Such
preventive safety measures reduce
the risk of starting the power tool ac-
cidentally.
Store idle power tools out of thed.
reach of children and do not allow
persons unfamiliar with the power
tool or these instructions to oper-
ate the power tool. Power tools are
dangerous in the hands of untrained
users.

SKU 67042 For technical questions, please call 1-800-444-3353. Page 4
Maintain power tools. Check fore.
misalignment or binding of mov-
ing parts, breakage of parts and
any other condition that may af-
fect the power tool’s operation. If
damaged, have the power tool re-
paired before use. Many accidents
are caused by poorly maintained
power tools.
Keep cutting tools sharp andf.
clean. Properly maintained cutting
tools with sharp cutting edges are
less likely to bind and are easier to
control.
Use the power tool, accessoriesg.
and tool bits etc. in accordance
with these instructions, taking
into account the working condi-
tions and the work to be per-
formed. Use of the power tool
for operations different from those
intended could result in a hazardous
situation.
Battery tool use and care5.
Recharge only with the chargera.
specied by the manufacturer. A
charger that is suitable for one type
of battery pack may create a risk of
re when used with another battery
pack.
Use power tools only with speci-b.
cally designated battery packs.
Use of any other battery packs may
create a risk of injury and re.
When battery pack is not in use,c.
keep it away from other metal ob-
jects, like paper clips, coins, keys,
nails, screws or other small metal
objects, that can make a connec-
tion from one terminal to another.
Shorting the battery terminals to-
gether may cause burns or a re.
Under abusive conditions, liquidd.
may be ejected from the battery;
avoid contact. If contact acciden-
tally occurs, ush with water. If
liquid contacts eyes, additionally
seek medical help. Liquid ejected
from the battery may cause irritation
or burns.
Service6.
Have your power tool serviced bya.
a qualied repair person using
only identical replacement parts.
This will ensure that the safety of the
power tool is maintained.
Cutout Tool Safety Warnings
Hold power tool by insulated grip-1.
ping surfaces when performing an
operation where cutting tool may
contact hidden wiring. Contact with
a ″live″ wire will make exposed metal
parts of the tool ″live″ and shock the
operator.
Use clamps or another practical2.
way to secure and support the
work piece to a stable platform.
Holding the work by hand or against
your body leaves it unstable and may
lead to loss of control.
3. Before cutting into a wall,
turn off all power in
circuits with wiring within
that wall, and know the
location of - and stay well clear of -
all utility lines (wiring, gas pipes,
water pipes, etc.).
Only use bits rated to at least the4.
maximum speed indicated in the
specication chart.
Use the depth gauge at all times.5.
The depth gauge is a working plat-

SKU 67042 For technical questions, please call 1-800-444-3353. Page 5
form for the tool, and is required for
stable, controlled operation.
Do not use a normal drill bit in this6.
cutout tool. Only cutout tool bits
designed specically for sideways
cutting should be used.
Bit is extremely hot after use.7. Al-
low bit to cool completely before
touching it.
Do not start tool while bit is touch-8.
ing workpiece. Allow bit to come up
to full speed before contacting work-
piece.
Maintain labels and nameplates on9.
the tool. These carry important safety
information. If unreadable or miss-
ing, contact Harbor Freight Tools for a
replacement.
Avoid unintentional starting. Prepare10.
to begin work before turning on the
tool.
Do not lay the tool down until it has11.
come to a complete stop. Moving
parts can grab the surface and pull
the tool out of your control.
When using a handheld power tool,12.

both hands to resist starting torque.
Do not leave the tool unattended13.
while the battery is attached. Turn off
(0 position) the tool and disconnect
the battery before leaving.
14. The battery charger gets
hot during use. The
charger’s heat can build
up to unsafe levels and

receive adequate ventilation, due to
an electrical fault, or if it is used in a
hot environment.
-
mable surface. Do not obstruct any
vents on the charger. Especially
avoid placing the charger on car-
pets and rugs; they are not only
ammable, but they also obstruct
vents under the charger.
Place the charger on a stable, solid,

stable metal workbench or concrete



smoke detector in the area. Fre-
quently monitor the charger and
battery while charging.
This product is not a toy. Keep it out15.
of reach of children.
People with pacemakers should16.
consult their physician(s) before use.
-
imity to heart pacemaker could cause
pacemaker interference or pacemak-
er failure. In addition, people with
pacemakers should:


avoid electrical shock.
WARNING: Some dust created by17.
power sanding, sawing, grinding, drill-
ing, and other construction activities,
contains chemicals known [to the
State of California] to cause cancer,
birth defects or other reproductive
harm. Some examples of these
chemicals are:

-
ment or other masonry products
-
cally treated lumber
Your risk from these exposures var-

SKU 67042 For technical questions, please call 1-800-444-3353. Page 6
ies, 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

particles. (California Health & Safety
Code § 25249.5, et seq.)
The warnings, precautions, and in-18.
structions discussed in this instruction
manual cannot cover all possible con-
ditions 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. Re-
peated or long-term exposure to
vibration may cause temporary or

to the hands, arms and shoulders. To
reduce the risk of vibration-related

Anyone using vibrating tools regu-1.
larly or for an extended period should

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
-
vous system disorders, diabetes, or
Raynaud’s Disease should not use
this tool. If you feel any symptoms
related to vibration (such as tingling,

seek medical advice as soon as pos-
sible.
Do not smoke during use. Nico-2.
tine reduces the blood supply to the


Wear suitable gloves to reduce the3.
vibration effects on the user.
Use tools with the lowest vibration4.
when there is a choice.
Include vibration-free periods each5.
day of work.
Grip tool as lightly as possible (while6.

the tool do the work.
To reduce vibration, maintain the tool7.
as explained in this manual. If any
abnormal vibration occurs, stop use
immediately.
SAVE THESE
INSTRUCTIONS.
Extension Cords
Note: Extension cords must not be used
with this item’s charger.
Symbology
Double Insulated
Canadian Standards Association

V~ Volts Alternating Current
AAmperes
n0xxxx/min. 
(RPM)

SKU 67042 For technical questions, please call 1-800-444-3353. Page 7
SPECIFICATIONS
Battery 18 V, NiCd
SKU 67029, Sold Separately
Charger SKU 67031, Sold Separately
Cut Depth 1 1/2” Maximum
Speed 
 1/8” & 1/4”
UNPACKING
When unpacking, make sure that the
item is intact and undamaged. If any parts
are missing or broken, please call Harbor
Freight Tools at 1-800-444-3353 as soon
as possible.
FUNCTIONS
Circle
Cutting
Attachment
Battery
Pack
Handle
Power
Switch
Lock
Lever
Motor
Housing
Bit
Base
Plate
ASSEMBLY
Note: For additional information regarding
the parts listed in the following pages,
refer to the Assembly Diagram near
the end of this manual.
WARNING: TO PREVENT SERIOUS
INJURY AND LOSS OF CONTROL:
Properly secure the Base Plate (15)
before use.
1.
loose position and slide the Base
Plate Support (17) over the end of
the tool with the bracket on the Base
Plate Support (17) extending away
from the handle.
Lock
Lever
(tight
position)
Base Plate
Support
Lock
Screw
Base
Plate
Figure A
2. 
to the tight position.
Slide the Base Plate (15) into place3.
on the Base Plate Support (17) and



SKU 67042 For technical questions, please call 1-800-444-3353. Page 8
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:
Turn the tool off (0 position)
and remove Battery Pack
before Tool Set Up.
CUTOUT BIT REPLACEMENT:1.
TO PREVENT
INJURY AND
BURNS:
Allow Cutout Bit to cool
completely and wear heavy-
duty work gloves before
touching the Cutout Bit.
The Cutout Bit gets very hot
during operation.
(Base Plate
and Base Plate
Support removed
for clarity)
Collet Nut Collet
Spindle
Lock
a. 
loosening the Collet Nut, turning it
counterclockwise.
Remove the Cutout Bit.b.
c.
The Collet MUST match the shaft
size. The Collet can be replaced if
the Collet Nut is removed.
Inspect the new Cutout Bit. It mustd.
be undamaged, unbent, designed for
use on cutout tools (not a drill bit),
and designed to rotate in the same
direction as the arrow next to the

Insert the new Cutout Bit fully intoe.
the Collet. Tighten the Collet Nut
securely.
BASE PLATE (15) ADJUSTMENT:2.

Plate (15) to desired height and

CIRCLE CUTTING GUIDE (14)3.
SETUP:
Remove the Bit.a.
Circle
Guide
Bracket
Disk
Nut
Circle Size
Knob
Circle
Cutting
Guide
Ball
Knob
Figure B
b. Place Circle Guide Bracket (16) into
Base Plate (15) with the threaded
portion facing downward. Turn it so

Place Circle Cutting Guide (14) overc.
the threaded portion of the Circle

SKU 67042 For technical questions, please call 1-800-444-3353. Page 9
Guide Bracket (16) and secure it in
place with the Disk Nut (13).
Reinstall the Bit, and secure ind.
place.
e.

indicated on scale, and tighten it.
Work Piece and Work Area Set Up
TO PREVENT
SERIOUS INJURY
AND DEATH:
Before cutting into a wall,
turn off all power in circuits
with wiring within that wall,
know the location of all
utility lines (wiring, gas
pipes, water pipes, etc.), and
stay well clear of all utility
lines.
Designate a work area that is clean1.
and well-lit. The work area must not
allow access by children or pets to

Secure loose work pieces using a2.
vise or clamps (not included) to pre-
vent movement while working.
Charging Instructions
The Charger (SKU 67031) and Bat-1.
tery Pack (SKU 67029) are sold
separately. Please refer to the 67031
Charger manual for important safety
warnings and proper instructions on
charging the battery pack.
WARNING! Do NOT use a different2.
Charger or Battery Pack to power
this tool.
General Operating Instructions
WARNING!1. TO PREVENT
SERIOUS INJURY,
BEFORE OPERATION:
Remove Battery Pack.a.
Inspect workpiece to ensure theb.
cutting area is free of foreign ob-
jects and utility lines.
Make sure that the Base Plate isc.
in place and in proper working
order.
Tighten all knobs/bolts securely.d.
Tighten Collet Nut.e.
Switch tool off (0 position).2.
Install fully charged Battery Pack3.
(67029, sold separately) into base at
back of handle.
Hold the tool with one hand on the4.
handle and the other hand on the mo-
tor housing.
Position the bit near, but not touching,5.
the work surface.

SKU 67042 For technical questions, please call 1-800-444-3353. Page 10
CIRCLE CUTTING GUIDE USE:6A.
Drill a hole where the center of thea.
circle will be.
Ball
Knob
Circle Size
Knob
Handle
Bit
Note: Numbers shown on scale
represent hole diameter of the hole
to be cut.
b.

Hold the Ball Knob with one handc.
and hold the Handle with the other
hand.
Turn the switch on (I position) andd.
allow the tool to come up to full
speed.
Slowly insert the tip of the Circlee.

previously.
f.
work surface.
Turn the tool around slowly until itg.
has made one full revolution.
NORMAL USE:6B.
Turn the switch on (I position) anda.
allow the tool to come up to full
speed.
Slowly insert the bit into the workb.

against the work surface.
Slowly complete the cut. Allow thec.
tool to do the work.
7.
Bit from the work surface, turn off (0
position) the tool, and wait until the
Bit stops.
To prevent accidents, disconnect the8.
battery and set the tool down away

After tool bit cools, clean the tool,
then store it indoors out of children’s
reach.

SKU 67042 For technical questions, please call 1-800-444-3353. Page 11
MAINTENANCE AND
SERVICING
Procedures not specically
explained in this manual
must be performed only by a
qualied technician.
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
OPERATION:
Turn the Power Switch of the
tool off (0 position) and
remove Battery Pack 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 and Maintenance
BEFORE EACH USE,1. inspect the
general condition of the tool. Check
for loose screws, misalignment or
binding of moving parts, cracked or
broken parts, damaged electrical wir-
ing, and any other condition that may
affect its safe operation.
AFTER USE,2. wipe external surfaces
of the tool with clean cloth.
Troubleshooting
Problem Possible Causes Likely Solutions
Tool will not start. Battery Pack not properly1.
connected or charged.
Internal damage or wear.2.
(Carbon brushes or switch, for
example.)
Connect fully-charged Battery Pack1.
completely.
Have technician service tool.2.
Performance
decreases over time.
Bit dull or damaged.1.
Carbon brushes worn or2.
damaged.
Keep Bit sharp. Replace as needed.1.
2.
brushes.
Excessive noise or
rattling.
Bent Bit.1.
Internal damage or wear.2.
(Carbon brushes or bearings, for
example.)
Inspect and replace as needed.1.
Have technician service tool.2.
Overheating. Forcing tool to work too fast.1.
Bit dull or damaged.2.
Blocked motor housing vents.3.
Allow tool to work at its own rate.1.
Keep Bit sharp. Replace as needed.2.
Wear ANSI-approved safety goggles and3.
NIOSH-approved dust mask/respirator
while blowing dust out of motor using
compressed air.
Follow all safety precautions whenever diagnosing or servicing the
tool. Disconnect power supply before service.

SKU 67042 For technical questions, please call 1-800-444-3353. Page 12
Part Description Qty.
1 Screw ST3.9x16 8
2a  1
2b Right Housing 1
3 Button Spring 1
4 1
5 Shaft Sleeve 1
6 Pin 1
7 Washer 1
8 Ball Knob 1
9 1
10  1
11 Flange Bolt 1
12 Square Nut 1
13 Disk Nut 1
14 Circle Cutting Guide 1
15 Base Plate 1
16 Circle Guide Bracket 1
17 Base Plate Support 1
18  1
Part Description Qty.
19 Pin 1
20  1
21 Collet Nut 1
22a 1/4" Collet 1
22b 1/8” Collet 1
23 Retaining Ring Ø11 1
24 Bearing Sleeve 1
25 Bearing 6205 RS 1
26 Motor Shaft 1
27 Fan 1
28 Retaining Ring Ø10 1
29 Shock Absorber 2
30 Motor 1
31 Switch Button 1
32 Switch 1
33 Terminal Bracket 1
34 Terminal 2
35 E-Clip 1
PLEASE READ THE FOLLOWING CAREFULLY


DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT







PARTS LIST
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 avail-
able individually as replacement parts.

SKU 67042 For technical questions, please call 1-800-444-3353. Page 13
ASSEMBLY DIAGRAM
22a/22b
2b
2a

SKU 67042 For technical questions, please call 1-800-444-3353. Page 14
LIMITED 90 DAY WARRANTY
Harbor Freight Tools Co. makes every effort to assure that its products meet high
quality and durability standards, and warrants to the original purchaser that this prod-
uct is free from defects in materials and workmanship for the period of 90 days from
the date of purchase. This warranty does not apply to damage due directly or indirectly,
to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities,
criminal activity, improper installation, normal wear and tear, or to lack of maintenance.

contingent, special or consequential damages arising from the use of our product. Some
states do not allow the exclusion or limitation of incidental or consequential damages, so
the above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESS-


To take advantage of this warranty, the product or part must be returned to us with
transportation charges prepaid. Proof of purchase date and an explanation of the com-
-
ther repair or replace the product at our election or we may elect to refund the purchase
price if we cannot readily and quickly provide you with a replacement. We will return re-
paired products at our expense, but if we determine there is no defect, or that the defect
resulted from causes not within the scope of our warranty, then you must bear the cost
of returning the product.

which vary from state to state.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • [phone]