Drill Master 91938 Owner's Manual & Safety Instructions

Cut-Off Wheel sold separately.

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REV 14i

Owner’s Manual & Safety Instructions

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.

When unpacking, make sure that the product is intact

and undamaged. If any parts are missing or broken,

please call 1-888-866-5797 as soon as possible.

Copyright© 2004 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.

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

Page 2 For technical questions, please call 1-888-866-5797. Item 91938

SAFETY OPERATION MAINTENANCESETUP

Table of Contents

Safety ......................................................... 2

Specifications ............................................. 7

Setup .......................................................... 7

Operation .................................................... 8

Maintenance .............................................. 12

Parts List and Diagram .............................. 14

Warranty .................................................... 16

WARNING SYMBOLS AND DEFINITIONS

This is the safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all safety messages that

follow this symbol to avoid possible injury or death.

Indicates a hazardous situation which, if not avoided,

will result in death or serious injury.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate injury.

Addresses practices not related to personal injury.

IMPORTANT SAFETY INFORMATION

General Tool Safety Warnings

WARNING Read all safety warnings and instructions.

Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

Save all warnings and instructions for future reference.

1. KEEP GUARDS IN PLACE and in working order.

2. REMOVE ADJUSTING KEYS AND
WRENCHES. Form habit of checking to
see that keys and adjusting wrenches are
removed from tool before turning it on.

3. KEEP WORK AREA CLEAN.
Cluttered areas and benches invite accidents.

4. DON’T USE IN DANGEROUS ENVIRONMENT.
Don’t use power tools in damp or wet locations, or
expose them to rain. Keep work area well lighted.

5. KEEP CHILDREN AWAY. All visitors should
be kept safe distance from work area.

6. MAKE WORKSHOP KID PROOF with padlocks,
master switches, or by removing starter keys.

7. DON’T FORCE TOOL. It will do the job better
and safer at the rate for which it was designed.

8. USE RIGHT TOOL. Don’t force tool or attachment
to do a job for which it was not designed.

Page 3For technical questions, please call 1-888-866-5797.Item 91938

SAFETYOPERATIONMAINTENANCE SETUP

TABLE A: RECOMMENDED MINIMUM WIRE

GAUGE FOR EXTENSION CORDS

(120 VOLT)

NAMEPLATE

AMPERES

(at full load)

EXTENSION CORD

LENGTH

25′ 50′ 100′ 150′

0 – 6 18 16 16 14

6.1 – 10 18 16 14 12

10.1 – 12 16 16 14 12

12.1 – 16 14 12 Do not use.

9. USE PROPER EXTENSION CORD. Make sure
your extension cord is in good condition. When
using an extension cord, be sure to use one heavy
enough to carry the current your product will
draw. An undersized cord will cause a drop in line
voltage resulting in loss of power and overheating.
Table A shows the correct size to use depending
on cord length and nameplate ampere rating.
If in doubt, use the next heavier gauge. The smaller
the gauge number, the heavier the cord.

10. WEAR PROPER APPAREL. Do not wear loose
clothing, gloves, neckties, rings, bracelets, or other
jewelry which may get caught in moving parts.
Nonslip footwear is recommended.
Wear protective hair covering to contain long hair.

11. ALWAYS USE SAFETY GLASSES. Also use
face or dust mask if cutting operation is dusty.
Everyday eyeglasses only have impact resistant
lenses, they are NOT safety glasses.

12. SECURE WORK. Use vise to hold work when
practical. It’s safer than using your hand
and it frees both hands to operate tool.

13. DON’T OVERREACH.
Keep proper footing and balance at all times.

14. MAINTAIN TOOLS WITH CARE. Keep
tools sharp and clean for best and safest
performance. Follow instructions for
lubricating and changing accessories.

15. DISCONNECT TOOLS before servicing;
when changing accessories, such as
blades, bits, cutters, and the like.

16. REDUCE THE RISK OF UNINTENTIONAL
STARTING. Make sure switch is in
off position before plugging in.

17. USE RECOMMENDED ACCESSORIES.
Consult the owner’s manual for recommended
accessories. The use of improper accessories
may cause risk of injury to persons.

18. NEVER STAND ON TOOL.
Serious injury could occur if the tool is tipped or
if the cutting tool is unintentionally contacted.

19. CHECK DAMAGED PARTS. Before further use
of the tool, a guard or other part that is damaged
should be carefully checked to determine that
it will operate properly and perform its intended
function – check for alignment of moving parts,
binding of moving parts, breakage of parts,
mounting, and any other conditions that may
affect its operation. A guard or other part that is
damaged should be properly repaired or replaced.

20. NEVER LEAVE TOOL RUNNING
UNATTENDED. TURN POWER OFF. Don’t
leave tool until it comes to a complete stop.

General Tool Safety Warnings (cont.)

Page 4 For technical questions, please call 1-888-866-5797. Item 91938

SAFETY OPERATION MAINTENANCESETUP

Grounding Instructions

TO PREVENT ELECTRIC SHOCK AND DEATH FROM INCORRECT GROUNDING WIRE
CONNECTION
READ AND FOLLOW THESE INSTRUCTIONS:

110-120 VAC Grounded Tools: Tools with Three Prong Plugs

1. In the event of a malfunction or breakdown,
grounding provides a path of least resistance for
electric current to reduce the risk of electric shock.
This tool is equipped with an electric cord having an
equipment-grounding conductor and a grounding
plug. The plug must be plugged into a matching
outlet that is properly installed and grounded in
accordance with all local codes and ordinances.

2. Do not modify the plug provided – if it will
not fit the outlet, have the proper outlet
installed by a qualified electrician.

3. Improper connection of the equipment-grounding
conductor can result in a risk of electric shock.
The conductor with insulation having an outer
surface that is green with or without yellow
stripes is the equipment-grounding conductor. If
repair or replacement of the electric cord or plug
is necessary, do not connect the equipment­grounding conductor to a live terminal.

4. Check with a qualified electrician or service
personnel if the grounding instructions are
not completely understood, or if in doubt as
to whether the tool is properly grounded.

5. Use only 3-wire extension cords that
have 3-prong grounding plugs and 3-pole
receptacles that accept the tool’s plug.

6. Repair or replace damaged or
worn cord immediately.

125 VAC 3-Prong Plug and Outlet

(for up to 125 VAC and up to 15 A)

Grounding

Pin

7. This tool is intended for use on a circuit that has
an outlet that looks like the one illustrated above in
125 VAC 3-Prong Plug and Outlet. The tool has
a grounding plug that looks like the plug illustrated
above in 125 VAC 3-Prong Plug and Outlet.

8. The outlet must be properly installed and grounded
in accordance with all codes and ordinances.

9. Do not use an adapter to connect
this tool to a different outlet.

Page 5For technical questions, please call 1-888-866-5797.Item 91938

SAFETYOPERATIONMAINTENANCE SETUP

Cut-Off Saw Safety Warnings

For Your Own Safety Read Instruction
Manual Before Operating Cut-Off Saw

1. Check Swing Guard (53) for proper closing before
each use. Do not operate the Saw if the Swing
Guard does not move freely and close instantly.
Never clamp or tie the Swing Guard into the open
position. If the saw is accidently dropped, the Swing
Guard may be bent. Raise the Swing Guard and
make sure it moves freely and does not touch the
Cut-Off Wheel or another part, in all depths of cut.

2. The Swing Guard should be retracted manually
only for special cuts such as “Pocket Cuts” and
“Compound Cuts.” Raise the Swing Guard only
enough to begin the cut. As soon as the cut-off
wheel enters the material, the Swing Guard must
be released. For all other sawing, the Swing Guard
should be allowed to operate automatically.

3. The Saw is not to be used for any cutting in the
locked down position. The Saw should be locked
down position only for carrying and storage.

4. Always use cut‑off wheels with a 14″ diameter,

1″ arbor hole, and rated at a minimum of 3,500 RPM.

Cut-off wheels that do not match the mounting
hardware of the Saw or that are rated at less than
the Saw’s maximum RPM may fly off the Saw or
may run eccentrically, causing loss of control.

5. Never use damaged or incorrect cut-off wheel
washers or bolts. The cut-off wheel’s washers and
bolts were specially designed for your Saw, for
optimum performance and safety of operation.

6. Do not use the cut-off wheel (sold separately)
to cut aluminum, copper, brass, or other
non-ferrous metals. The cut-off wheel is
designed to cut only ferrous (iron containing)
metals such as steel alloys and cast iron.
If using other cut-off wheels, only use them on
materials that the manufacturer recommends.

7. Before using the Cut-Off Saw, make sure
the cut-off wheel is properly mounted on the
saw spindle. Make sure the cut-off wheel
is balanced and is not broken or bent.

8. Wear eye protection.

9. Use grinding wheel suitable for
speed of cut-off wheel.

10. Replace cracked wheel immediately.

11. Do not overtighten wheel nut.

12. Use only flanges furnished with the Cut-Off saw.

13. Frequently clean grinding dust
from beneath Cut-Off saw.

14. Wear a full face shield over ANSI-approved
safety goggles during use.

15. DO NOT OPERATE WITH ANY GUARD

DISABLED, DAMAGED, OR REMOVED. Moving
guards must move freely and close instantly.

16. The use of accessories or attachments not
recommended by the manufacturer may
result in a risk of injury to persons.

17. When servicing use only identical replacement parts.

18. Only use safety equipment that has been approved
by an appropriate standards agency. Unapproved
safety equipment may not provide adequate
protection. Eye protection must be ANSI-approved
and breathing protection must be NIOSH-approved
for the specific hazards in the work area.

19. Industrial applications must follow OSHA guidelines.

20. Maintain labels and nameplates on the tool.
These carry important safety information.
If unreadable or missing, contact
Harbor Freight Tools for a replacement.

21. Avoid unintentional starting.
Prepare to begin work before turning on the tool.

22. People with pacemakers should consult their
physician(s) before use. Electromagnetic fields in
close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure.

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

• Lead from lead-based paints

• Crystalline silica from bricks and cement or other
masonry products

• Arsenic and chromium from chemically
treated lumber
Your risk from these exposures varies, depending
on how often you do this type of work. To reduce
your exposure to these chemicals: work in a well
ventilated area, and work with approved safety
equipment, such as those dust masks that are
specially designed to filter out microscopic particles.
(California Health & Safety Code § 25249.5, et seq.)

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

25. The warnings, precautions, and instructions
discussed in this instruction manual cannot
cover all possible conditions and situations
that may occur. It must be understood by the
operator that common sense and caution are
factors which cannot be built into this product,
but must be supplied by the operator.